FEATURES High efficiency: 92% @ 12V/8A Size: 58.4mmx22.8mmx8.4mm (2.30”x0.90”x0.33”) (Without heat-spreader) 58.4mmx22.8mmx12.7mm (2.30”x0.90”x0.50”) (With heat-spreader) Standard footprint Industry standard pin out Fixed frequency operation Input UVLO, Output OCP, OVP, OTP 2250V isolation Basic insulation No minimum load required ISO 9001, TL 9000, ISO 14001, QS 9000, OHSAS 18001 certified manufacturing facility Delphi Series E48SC12008, Eighth Brick Family DC/DC Power Modules: 48V in, 12V/8A out The Delphi Series E48SC12008, Eighth Brick, 48V input, single output, isolated DC/DC converter is the latest offering from a world leader in UL/CUL 60950-1 (US & Canada) Recognized OPTIONS Negative/Positive on/off logic SMT or through-hole version power systems technology and manufacturing -- Delta Electronics, Inc. This product family provides up to 96 watts, improved and very cost effective power solution of industry standard footprint and pinout. With creative design technology and optimization of component placement, these converters possess outstanding electrical and thermal performances, as well as extremely high reliability under highly stressful operating conditions. All models are fully protected from abnormal input/output voltage, current, and temperature conditions. The Delphi Series converters meet all safety requirements with basic insulation. DATASHEET DS_ E48SC12008_03192012 APPLICATIONS Telecom / Datacom Wireless Networks Optical Network Equipment Server and Data Storage Industrial / Testing Equipment LUO LUOTECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS E48SC12008 (Standard) Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Transient 100ms Operating Ambient Temperature -40 Storage Temperature -55 Input/Output Isolation Voltage INPUT CHARACTERISTICS Operating Input Voltage 36 Input Under-Voltage Lockout Turn-On Voltage Threshold 33 Turn-Off Voltage Threshold 31 Lockout Hysteresis Voltage 1 Maximum Input Current 100% Load, 36Vin No-Load Input Current Off Converter Input Current 2 Inrush Current(I t) Input Reflected-Ripple Current P-P thru 12µH inductor, 5Hz to 20MHz Input Voltage Ripple Rejection 120 Hz OUTPUT CHARACTERISTICS Output Voltage Set Point Vin=48V, Io=Io.max, Tc=25°C 11.88 Output Voltage Regulation Over Load Io=Io,min to Io,max Over Line Vin= 36V to 75V Over Temperature Tc= -40°C to 85°C Total Output Voltage Range Over sample load, line and temperature 11.76 Output Voltage Ripple and Noise 5Hz to 20MHz bandwidth Peak-to-Peak Full Load, 1µF ceramic, 10µF tantalum RMS Full Load, 1µF ceramic, 10µF tantalum Operating Output Current Range 0 Output DC Current-Limit Inception Output Voltage 10% Low 110 DYNAMIC CHARACTERISTICS Output Voltage Current Transient 48V, 10µF Tan & 1µF Ceramic load cap, 0.1A/µs Positive Step Change in Output Current 25% Io.max to 50% Io.max Negative Step Change in Output Current 50% Io.max to 25% Io.max Settling Time (within 1% Vout nominal) Turn-On Transient Start-Up Time, From On/Off Control Start-Up Time, From Input Maximum Output Capacitance Full load; 5% overshoot of Vout at startup EFFICIENCY 100% Load 48Vin 60% Load 48Vin ISOLATION CHARACTERISTICS Input to Output Isolation Resistance 10 Isolation Capacitance FEATURE CHARACTERISTICS Switching Frequency ON/OFF Control, Negative Remote On/Off logic Logic Low (Module On) Von/off at Ion/off=1.0mA -0.7 Logic High (Module Off) Von/off at Ion/off=0.0 µA 3.5 ON/OFF Control, Positive Remote On/Off logic Logic Low (Module Off) Von/off at Ion/off=1.0mA -0.7 Logic High (Module On) Von/off at Ion/off=0.0 µA 3.5 ON/OFF Current (for both remote on/off logic) Ion/off at Von/off=0.0V Leakage Current (for both remote on/off logic) Logic High, Von/off=12V Pout ≦ max rated power Output Voltage Trim Range -10% Pout ≦ max rated power Output Voltage Remote Sense Range Output Over-Voltage Protection Over full temperature range 13.8 GENERAL SPECIFICATIONS MTBF Io=80% of Io, max; 300LFM @25C Weight Without heat-spreader Weight With heat-spreader Over-Temperature Shutdown Refer to Figure 19 for Hot spot 1 location ( Without heat spreader, Hot spot 1) (48Vin,80% Io, 200LFM,Airflow from Vin+ to Vin-) Over-Temperature Shutdown Refer to Figure 19 for NTC resistor location ( Without heat spreader, NTC Resistor) Over-Temperature Shutdown Refer to Figure 21 for Hot spot 2 location (With heat spreader, Hot spot 2) (48Vin,80% Io, 200LFM,Airflow from Vin+ to Vin-) Note: Please attach thermocouple on NTC resistor to test OTP function, the hot spots’ temperature is just for reference. DS_E48SC12008_03192012 Typ. 34 32 2 Max. Units 80 100 85 125 2250 Vdc Vdc °C °C Vdc 75 Vdc 35 33 3 3.5 Vdc Vdc Vdc A mA mA 2 As mA dB 80 10 1 20 60 12.00 12.12 Vdc ±3 ±3 ±15 ±15 ±100 12.25 mV mV mV V 40 15 120 25 8 140 mV mV A % 200 200 200 40 40 mV mV µs 80 80 2000 92.0 90.5 % % 2250 Vdc MΩ pF 400 kHz 0.8 12 V V 0.8 12 1 50 10% 10 16.8 V V mA µA % % V 1000 350 15.0 ms ms µF 2.2 21.4 33.5 M hours grams grams 127 °C 123 °C 118 °C 2 ELECTRICAL CHARACTERISTICS CURVES Figure 1: Efficiency vs. load current for 8A, minimum, nominal, and maximum input voltage at 25°C Figure 2: Power dissipation vs. load current for 8A, minimum, nominal, and maximum input voltage at 25°C. Figure 3: Typical full load input characteristics at room temperature DS_E48SC12008_03192012 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Logic Figure 4: Turn-on transient at full rated load current (CC Mode load) (10ms/div). Vin=48V.Top Trace: Vout, 5V/div; Bottom Trace: ON/OFF input, 5V/div DS_E48SC12008_03192012 Figure 5: Turn-on transient at zero load current (10ms/div). Vin=48V.Top Trace: Vout, 5V/div; Bottom Trace: ON/OFF input, 5V/div 4 ELECTRICAL CHARACTERISTICS CURVES Figure 6: Output voltage response to step-change in load current (50%-25%-50% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF, tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (200mV/div, 200us/div), Bottom Trace: I out (2A/div). Scope measurement should be made using a BNC cable (length shorter than 20 inches). Position the load between 51 mm to 76 mm (2 inches to 3 inches) from the module Figure 7: Output voltage response to step-change in load current (50%-25%-50% of Io, max; di/dt = 2.5A/µs). Load cap: 10µF, tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (200mV/div, 200us/div), Bottom Trace: I out (2A/div). Scope measurement should be made using a BNC cable (length shorter than 20 inches). Position the load between 51 mm to 76 mm (2 inches to 3 inches) from the module Figure 8: Test set-up diagram showing measurement points for Input Terminal Ripple Current and Input Reflected Ripple Current. Note: Measured input reflected-ripple current with a simulated source Inductance (LTEST) of 12μH. Capacitor Cs offset possible battery impedance. Measure current as shown above DS_E48SC12008_03192012 5 ELECTRICAL CHARACTERISTICS CURVES Figure 9: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 12µH source impedance and 33µF electrolytic capacitor (100mA/div,1us/div) Copper Figure 10: Input reflected ripple current, is, through a 12µH source inductor at nominal input voltage and rated load current (20mA/div,1us/div) Strip Vo(+) 10u 1u SCOPE RESISTIVE LOAD Vo(-) Figure 11: Output voltage noise and ripple measurement test setup DS_E48SC12008_03192012 6 ELECTRICAL CHARACTERISTICS CURVES 13.0 12.0 11.0 OUTPUT VOLTAGE(V) 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 0 Figure 12: Output voltage ripple at nominal input voltage and rated load current (Io=8A)(20mV/div,1us/div) Load capacitance: 1µF ceramic capacitor and 10µF tantalum capacitor. Bandwidth: 20 MHz. Scope measurements should be made using a BNC cable (length shorter than 20 inches). Position the load between 51 mm to 76 mm (2 inches to 3 inches) from the module DS_E48SC12008_03192012 1 2 3 4 5 6 7 8 OUTPUT CURRENT(A) 9 10 11 12 Figure 13: Output voltage vs. load current showing typical current limit curves and converter shutdown points 7 DESIGN CONSIDERATIONS Input Source Impedance The impedance of the input source connecting to the DC/DC power modules will interact with the modules and affect the stability. A low ac-impedance input source is recommended. If the source inductance is more than a few μH, we advise adding a 10 to 100 μF electrolytic capacitor (ESR < 0.7 Ω at 100 kHz) mounted close to the input of the module to improve the stability. Layout and EMC Considerations Delta’s DC/DC power modules are designed to operate in a wide variety of systems and applications. For design assistance with EMC compliance and related PWB layout issues, please contact Delta’s technical support team. An external input filter module is available for easier EMC compliance design. Application notes to assist designers in addressing these issues are pending release. Schematic and components list Cin is 100uF low ESR Aluminum cap; Cx is 2.2uF ceramic cap; CY1,CY2 are 22nF ceramic caps; L1 is common-mode inductor,L1=1.32mH; end-user’s safety agency standard, i.e., UL60950-1, CSA C22.2 NO. 60950-1 2nd and IEC 60950-1 2nd : 2005 and EN 60950-1 2nd: 2006+A11+A1: 2010, if the system in which the power module is to be used must meet safety agency requirements. Basic insulation based on 75 Vdc input is provided between the input and output of the module for the purpose of applying insulation requirements when the input to this DC-to-DC converter is identified as TNV-2 or SELV. An additional evaluation is needed if the source is other than TNV-2 or SELV. When the input source is SELV circuit, the power module meets SELV (safety extra-low voltage) requirements. If the input source is a hazardous voltage which is greater than 60 Vdc and less than or equal to 75 Vdc, for the module’s output to meet SELV requirements, all of the following must be met: The input source must be insulated from the ac mains by reinforced or double insulation. The input terminals of the module are not operator accessible. A SELV reliability test is conducted on the system where the module is used, in combination with the module, to ensure that under a single fault, hazardous voltage does not appear at the module’s output. When installed into a Class II equipment (without grounding), spacing consideration should be given to the end-use installation, as the spacing between the module and mounting surface have not been evaluated. Test result: Vin=48V, Io=8A, The power module has extra-low voltage (ELV) outputs when all inputs are ELV. dBμV 80.0 Limits 55022MQP 55022MAV 70.0 60.0 50.0 40.0 Transducer LISNPUL Traces PK+ AV 30.0 This power module is not internally fused. To achieve optimum safety and system protection, an input line fuse is highly recommended. The safety agencies require a fuse with 10A maximum rating to be installed in the ungrounded lead. A lower rated fuse can be used based on the maximum inrush transient energy and maximum input current. Soldering and Cleaning Considerations 20.0 10.0 0.0 150 kHz 1 MHz 10 MHz 30 MHz Green line is quasi peak mode, blue line is average mode. Safety Considerations The power module must be installed in compliance with the spacing and separation requirements of the DS_E48SC12008_03192012 Post solder cleaning is usually the final board assembly process before the board or system undergoes electrical testing. Inadequate cleaning and/or drying may lower the reliability of a power module and severely affect the finished circuit board assembly test. Adequate cleaning and/or drying is especially important for un-encapsulated and/or open frame type power modules. For assistance on appropriate soldering and cleaning procedures, please contact Delta’s technical support team. 8 FEATURES DESCRIPTIONS Vi(+) Vo(+) Over-Current Protection Sense(+) The modules include an internal output over-current protection circuit, which will endure current limiting for an unlimited duration during output overload. If the output current exceeds the OCP set point, the modules will automatically shut down (hiccup mode). The modules will try to restart after shutdown. If the overload condition still exists, the module will shut down again. This restart trial will continue until the overload condition is corrected. Over-Voltage Protection The modules include an internal output over-voltage protection circuit, which monitors the voltage on the output terminals. If this voltage exceeds the over-voltage set point, the module will shut down (hiccup mode)。 The modules will try to restart after shutdown. If the over voltage condition still exists, the module will shut down again. This restart trial will continue until the over voltage condition is corrected. Over-Temperature Protection ON/OFF Sense(-) Vi(-) Vo(-) Figure 14: Remote on/off implementation Remote Sense Remote sense compensates for voltage drops on the output by sensing the actual output voltage at the point of load. The voltage between the remote sense pins and the output terminals must not exceed the output voltage sense range given here: [Vo(+) – Vo(–)] – [SENSE(+) – SENSE(–)] ≤ 10% × Vout This limit includes any increase in voltage due to remote sense compensation and output voltage set point adjustment (trim). The over-temperature protection consists of circuitry that provides protection from thermal damage. If the temperature exceeds the over-temperature threshold the module will shut down. The module will restart if the temperature is within specification. Vi(+) Vo(+) Sense(+) Remote On/Off Sense(-) Vi(-) Vo(-) The remote on/off feature on the module can be either negative or positive logic. Negative logic turns the module on during a logic low and off during a logic high. Positive logic turns the modules on during a logic high and off during a logic low. Figure 15: Effective circuit configuration for remote sense operation Remote on/off can be controlled by an external switch between the on/off terminal and the Vi(-) terminal. The switch can be an open collector or open drain. If the remote sense feature is not used to regulate the output at the point of load, please connect SENSE(+) to Vo(+) and SENSE(–) to Vo(–) at the module. For negative logic if the remote on/off feature is not used, please short the on/off pin to Vi(-). For positive logic if the remote on/off feature is not used, please leave the on/off pin to floating. The output voltage can be increased by both the remote sense and the trim; however, the maximum increase is the larger of either the remote sense or the trim, not the sum of both. Contact Resistance Contact and Distribution Losses When using remote sense and trim, the output voltage of the module is usually increased, which increases the power output of the module with the same output current. Care should be taken to ensure that the maximum output power does not exceed the maximum rated power. DS_E48SC12008_03192012 9 FEATURES DESCRIPTIONS (CON.) Output Voltage Adjustment (TRIM) To increase or decrease the output voltage set point, the modules may be connected with an external resistor between the TRIM pin and either the SENSE(+) or SENSE(-). The TRIM pin should be left open if this feature is not used. Figure 17: Circuit configuration for trim-up (increase output voltage) Figure 16: Circuit configuration for trim-down (decrease output voltage) If the external resistor is connected between the TRIM and SENSE (-) pins, the output voltage set point decreases (Fig. 16). The external resistor value required to obtain a percentage of output voltage change △% is defined as: Rtrim down Rtrim up 5.11Vo (100 ) 511 10.2K 1.225 Ex. When Trim-up +10%(12V×1.1=13.2V) Rtrim up 5.11 12 (100 10 ) 511 10.2 489.329K 1.225 10 10 511 10.2K Ex. When Trim-down -10%(12V×0.9=10.8V) Rtrim down If the external resistor is connected between the TRIM and SENSE (+) the output voltage set point increases (Fig. 17). The external resistor value required to obtain a percentage output voltage change △% is defined as: 511 10.2 40.9K 10 The output voltage can be increased by both the remote sense and the trim, however the maximum increase is the larger of either the remote sense or the trim, not the sum of both. When using remote sense and trim, the output voltage of the module is usually increased, which increase the output power of the module with the same output current. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. DS_E48SC12008_03192012 10 THERMAL CONSIDERATIONS Thermal management is an important part of the system design. To ensure proper, reliable operation, sufficient cooling of the power module is needed over the entire temperature range of the module. Convection cooling is usually the dominant mode of heat transfer. Hence, the choice of equipment to characterize the thermal performance of the power module is a wind tunnel. Thermal Testing Setup Delta’s DC/DC power modules are characterized in heated vertical wind tunnels that simulate the thermal environments encountered in most electronics equipment. This type of equipment commonly uses vertically mounted circuit cards in cabinet racks in which the power modules are mounted. The following figure shows the wind tunnel characterization setup. The power module is mounted on a test PWB and is vertically positioned within the wind tunnel. The space between the neighboring PWB and the top of the power module is constantly kept at 6.35mm (0.25’’). PWB FANCING PWB MODULE 50.8(2.00") AIR VELOCITY AND AMBIENT TEMPERATURE SURED BELOW THE MODULE AIR FLOW Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) Figure 18: Wind tunnel test setup Thermal Derating Heat can be removed by increasing airflow over the module. To enhance system reliability; the power module should always be operated below the maximum operating temperature. If the temperature exceeds the maximum module temperature, reliability of the unit may be affected. DS_E48SC12008_03192012 11 THERMAL CURVES (WITHOUT HEAT SPREADER) NTC RESISTOR THERMAL CURVES (WITH HEAT SPREADER) AIRFLOW AIRFLOW HOT SPOT 1 HOT SPOT 2 Figure 19: * Hot spot 1& NTC resistor temperature measured Figure 21: * Hot spot 2 temperature measured point points Output Current (A) 9.0 E48SC12008(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation) Output Current (A) 9.0 E48SC12008(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation; With Heatspreader) 8.0 8.0 7.0 7.0 Natural Convection 6.0 Natural Convection 6.0 100LFM 100LFM 5.0 200LFM 5.0 200LFM 300LFM 300LFM 4.0 500LFM 500LFM 3.0 400LFM 4.0 400LFM 3.0 600LFM 2.0 2.0 1.0 1.0 0.0 0.0 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 20: Output current vs. ambient temperature and air velocity @Vin=48V(Transverse Orientation, airflow from Vin+ to Vin-,without heat spreader) DS_E48SC12008_03192012 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 22: Output current vs. ambient temperature and air velocity @Vin=48V (Transverse Orientation, airflow from Vin+ to Vin-,with heat spreader) 12 PICK AND PLACE LOCATION(SMD) RECOMMENDED PAD LAYOUT (SMD) SURFACE-MOUNT TAPE & REEL DS_E48SC12008_03192012 13 LEADED (Sn/Pb) PROCESS RECOMMEND TEMPERATURE PROFILE(SMD) Note: The temperature refers to the pin of E48SC, measured on the pin +Vout joint. LEAD FREE (SAC) PROCESS RECOMMEND TEMPERATURE PROFILE(SMD) Temp. Peak Temp. 240 ~ 245 ℃ 217℃ Ramp down max. 4℃/sec. 200℃ 150℃ Preheat time 100~140 sec. Time Limited 90 sec. above 217℃ Ramp up max. 3℃/sec. 25℃ Time Note: The temperature refers to the pin of E48SC, measured on the pin +Vout joint. DS_E48SC12008_03192012 14 MECHANICAL DRAWING Surface-mount module Through-hole module All pins are copper alloy with tin plated over Nickel under plating. DS_E48SC12008_03192012 15 MECHANICAL DRAWING(WITH HEAT-SPREADER) * For modules with through-hole pins and the optional heatspreader, they are intended for wave soldering assembly onto system boards; please do not subject such modules through reflow temperature profile. All pins are copper alloy with tin plated over Nickel under plating. DS_E48SC12008_03192012 16 PART NUMBERING SYSTEM E 48 S Type of Input Number of Product Voltage Outputs E- Eighth Brick 48 36~75V S- Single C 120 08 N R Product Series Output Voltage Output Current ON/OFF Logic Pin Length/Type 120 - 12V 08 -8A N - Negative K – 0.110’’ F- RoHS 6/6 A- Standard Functions P - Positive N - 0.145” (Lead Free) H - with Heatspreader C- Improved E48SR series F A Option Code R - 0.170” Space - C - 0.181” RoHS 5/6 S - 0.189” T - 0.220” L - 0.248” M - SMD pin MODEL LIST MODEL NAME E48SC12008NRFH E48SC12008NRFA INPUT 36V -75V 36V -75V OUTPUT 3.5A 3.5A 12V 12V EFF @ 100% LOAD 8A 8A 92% 92% Default remote on/off logic is negative and pin length is 0.145” For different remote on/off logic and pin length, please refer to part numbering system above or contact your local sales office. CONTACT: www.deltaww.com/dcdc USA: Telephone: East Coast: 978-656-3993 West Coast: 510-668-5100 Fax: (978) 656 3964 Email: [email protected] Europe: Telephone: +31-20-655-0967 Fax: +31-20-655-0999 Email: [email protected] Asia & the rest of world: Telephone: +886 3 4526107 Ext.6220~6224 Fax: +886 3 4513485 Email: [email protected] WARRANTY Delta offers a two (2) year limited warranty. Complete warranty information is listed on our web site or is available upon request from Delta. Information furnished by Delta is believed to be accurate and reliable. However, no responsibility is assumed by Delta for its use, nor for any infringements of patents or other rights of third parties, which may result from its use. No license is granted by implication or otherwise under any patent or patent rights of Delta. Delta reserves the right to revise these specifications at any time, without notice. DS_E48SC12008_03192012 17