HA1SV12004 50W DC/DC Power Modules FEATURES High efficiency : 86% @110Vin full load Size:61.0mm*57.9mm*12.7mm(2.4’’ *2.28’’ *0.5’’) Industry standard pin out and footprint Fixed frequency operation Input UVP/ OVP Hiccup output over current protection (OCP) Hiccup output over voltage protection (OVP) Output current limited protection(OCL) Auto recovery OTP Monotonic startup into normal 3000V isolation and reinforce insulation No minimum load required ISO 9001, TL 9000, ISO 14001, QS9000, OHSAS18001 certified manufacturing facility Delphi Series HA1SV12, half Brick Family DC/DC Power Modules: 53~154V in, 12V/4.2A out, 50W EN61373，EN50155 EN60950-1 APPLICATIONS Railway /Transportation system The Delphi Module HA1SV12004PRFA, half brick, 53~154V input, single output, isolated DC/DC converter is the latest offering from a world leader in power system and technology and manufacturing ― Delta Electronics, Inc. This product provides up to 100 watts power in an industry standard footprint and pin out. 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. The HA1SV12004PRFA offers more than 79% high efficiency at 2A load in all input voltage range. DATASHEET DS_HA1SV12004_01282015 E-mail: [email protected] http://www.deltaww.com/dcdc P1 TECHNICAL SPECIFICATIONS PARAMETER 1.ABSOLUTE MAXIMUM RATINGS 1.1 Input Voltage 1.2 Input surge withstand 1.3 Operating Ambient Temperature 1.4 Storage Temperature 1.5 Input/Output Isolation Voltage 2. INPUT CHARACTERISTICS 2.1 Operating Input Voltage 2.2 Input Under-Voltage Lockout 2.2.1 Turn-On Voltage Threshold 2.2.2 Turn-Off Voltage Threshold 2.3 Input Over-Voltage Lockout 2.3.1 Turn-On Voltage Threshold 2.3.2 Turn-Off Voltage Threshold 2.4 Operating input current 2.5 Maximum Input Current 2.6 No-Load Input Current 2.7 Off Converter Input Current 2.8 Input Reflected-Ripple Current（pk-pk） 3. OUTPUT CHARACTERISTICS 3.1 Output Voltage Set Point 3.1.1 Load regulation 3.1.2 Line regulation 3.1.3 Temperature regulation 3.2 Output Voltage Ripple and Noise 3.2.1 Peak-to-Peak 3.2.2 rms 3.3 Operating Output Current Range 3.4 Output DC Current-Limit Inception 4. DYNAMIC CHARACTERISTICS 4.1 Output Voltage Current Transient 4.1.1 Positive Step Change in Output Current 4.1.2 Negative Step Change in Output Current 4.2 Turn-On Transient 4.2.1 Start-Up Time, From On/Off Control 4.2.2 Start-Up Time, from Vin=53V to 90%Vo.set 4.2.3 Rise time(Vout from 10% to 90%) 4.3 Maximum output capacitor 5. EFFICIENCY 5.1 100% Load 5.2 60% Load 6. ISOLATION CHARACTERISTICS 6.1 Input to Output 6.2 Input to base 6.3 Output to base 6.4 Isolation Resistance 7. FEATURE CHARACTERISTICS 7.1 Switching Frequency 7.2 ON/OFF Control, Negative Remote On/Off logic 7.2.1 Logic High (Module On) 7.2.2 Logic Low (Module Off) 7.3 Output Voltage Trim Range 7.4 Output Over-Voltage Protection 8. GENERAL SPECIFICATIONS 8.1 Weight 8.2 Over-Temperature Shutdown ( NTC resistor ) 8.3 MTBF NOTES and CONDITIONS EN50155 <100ms HA1SV12004PRFA Min. Typ. Max. Units 53 110 154 250 100 125 3000 Vdc Vdc °C °C Vdc 53 110 154 Vdc 49 46 51 48 53 50 Vdc Vdc 154 158 158 162 162 166 Vdc Vdc 1.1 18.3 17.1 35 1.2 30 30 A mA mA mA 12 ±0.05 ±0.01 ±0.004 12.2 ±0.2 ±0.2 ±0.007 Vdc % % %/℃ 40 6 4.9 60 15 4.2 5.4 mV mV A A 200 200 400 400 mV mV 50 55 25 100 80 50 ms ms ms -40 -55 reinforce Full Load, 53Vin Vin=110V, Io=0A Vin=110V Vin=110V, Io=full load，Cin=150uF/400V Vin=110V, Io=0, Tc=25°C Vin=110V, Io=Io min to Io max Vin=53V to160V, Io=full load Vin=110V, Tc= min to max case temperatrue 5Hz to 20MHz bandwidth Full Load, Full Load, 11.8 0 4.4 110V, 0.1A/µs 50% Io.max to 75% 75% Io.max to 50% Vin=110V Capacitor:680uF/25V(RUBYCON) ( P/N: 140146810408)*1 Vin=110V Vin=110V 680 µF 86 83.5 % % 3000 1500 500 Over full temp range; % of nominal Vout With heat spreader Refer to Figure 18 for NTC resistor location 3 0 -10 110 10 Vrms Vrms Vrms MΩ 300 kHz 120 80 118 1,302,169 5 1 10 130 V V % % grams °C hours (TA=25°C, Natural convection, Vin=110Vdc, nominal Vout unless otherwise noted; DS_HA1SV12004_01282015 E-mail: [email protected] http://www.deltaww.com/dcdc P2 ELECTRICAL CHARACTERISTICS CURVES 100. 00% 10. 0 90. 00% 8. 0 70. 00% 60. 00% 50. 00% 110V 40. 00% 53V 30. 00% 154V 20. 00% power l oss ef f i ci ency 80. 00% 6. 0 53V 110V 4. 0 154V 2. 0 10. 00% 0. 00% 0 1 2 3 4 5 Out put cur r ent ( A) 0. 0 0 1 2 3 4 5 Out put cur r ent ( A) Figure 1: Efficiency vs. load current for 53，110and 154V input voltage at 25°C. Figure 2: Power dissipation vs. load current fr 53,110and 154V input voltage at 25°C. Figure 3: Turn-on transient at zero load current) (10ms/div). Top Trace: Vout; 5V/div; Bottom Trace: ON/OFF input: 2V/div. Figure 4: Turn-on transient at full load current (10ms/div). Top Trace: Vout: 5V/div; Bottom Trace: ON/OFF input: 2V/div. Figure 5: Turn-on transient at zero load current (10ms/div). Top Trace: Vout; 5V/div; Bottom Trace: input voltage: 50V/div. Figure 6: Turn-on transient at full load current (10ms/div). Top Trace: Vout; 1V/div; Bottom Trace: input voltage: 50V/div. DS_HA1SV12004_01282015 E-mail: [email protected] http://www.deltaww.com/dcdc P3 ELECTRICAL CHARACTERISTICS CURVES Figure 7: Output voltage response to step-change in load current (50%-75%-50% of full load; di/dt = 0.1A/µs). Bottom Trace: Vout;50mV/div; Time: 1ms/div Figure 8: Output voltage response to step-change in load current (50%-75%-50% of full load; di/dt = 2.5A/µs). Bottom Trace: Vout;50mV/div; Time: 1ms/div Vo(+) scope r Resistor load Vo(-) Figure 9: Output voltage noise and ripple measurement test setu out put vol t age( V) 14 12 10 8 6 OCL 4 2 0 0 1 2 3 4 5 Out put cur r ent ( A) Figure 10: Output voltage ripple at nominal input voltage and max load current (10 mV/div, 2us/div) Bandwidth: 20 MHz. DS_HA1SV12004_01282015 Figure 11: Output voltage vs. load current showing typical current limit curves and converter shutdown points. E-mail: [email protected] http://www.deltaww.com/dcdc P4 DESIGN CONSIDERATIONS Input Source Impedance Test Result: At T = +25C , Vin = 110V and full load black line is QP model; 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 150μF 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. Below is the reference design for an input filter tested with HA1SV12004PRFA to meet class A in CISSPR 22. Figure 13 EMI test positive line Schematic and Components List Figure 12 EMC test schematic C121=120Uf/400V C123,C124,C127,C132 =220pF/275VAC C128,C129,C130,C131=2200pF/300VAC C122,C125,C126=0.47uF/250V T1=3.4mH, common choke R110,R111,R112,R113,R114=300kohm/1206 DS_HA1SV12004_01282015 Safety Considerations The power module must be installed in compliance with the spacing and separation requirements of the 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 110 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 110 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. E-mail: [email protected] http://www.deltaww.com/dcdc P5 . 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. Remote On/Off The power module has extra-low voltage (ELV) outputs when all inputs are ELV. 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. 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 normal-blow fuse with 5A 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. 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. 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. Soldering and Cleaning Considerations 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. FEATURES DESCRIPTIONS Over-Current Protection 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 shut down, and will try to restart after shutdown(hiccup mode). 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 protection circuit will constrain the max duty cycle to limit the output voltage, if the output voltage continuously increases the modules will shut down, and then restart after a hiccup-time (hiccup mode). Over-Temperature Protection The over-temperature protection consists of circuitry that provides protection from thermal damage. If the module will shut down.The module will restart after the temperature is within specification DS_HA1SV12004_01282015 Figure 14: Remote on/off implementation Output Voltage Adjustment (TRIM) To increase or decrease the output voltage set point, connect an external resistor between the TRIM pin and SENSE(+) pin or SENSE(-) pin. The TRIM pin should be left open if this feature is not used. For trim down, the external resistor value required to obtain a percentage of output voltage change △% is defined as: 10 *Vnom * (1 ) Rtrim down K Vnom Vnom * (1 ) Ex. When Trim-down -10% (12V×0.9=10.8V) 10 *12 * 0.9 Rtrim down K 90K 12 12 * 0.9 For trim up, the external resistor value required to obtain a percentage output voltage change △% is defined as: Rtrim up Vnom * 7.92(1 ) K Vnom *（1 ）* 0.208 2.5 Ex. When Trim-up +10% (12V×1.1=13.2V) Rtrim up 12 7.92 (1 0.1） 419K 12 *（1 0.1）* 0.208 2.5 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. E-mail: [email protected] http://www.deltaww.com/dcdc P6 THERMAL CONSIDERATIONS 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 of the module remains at or below the maximum rated power. Pin function The pin was difine as follow in figure 20 ,we will explain the pin function: +IN, -IN .DC voltage inputs. Gate IN . The Gate IN pin on a driver module may be used as a logic enable/disable input.When Gate IN is pull low (<1V,referenced to –Vin ),the module is turned off . when Gate IN is floating (open collector) ,the module is turned on .The open circuit voltage of Gate in PIN is less than 5V. Gate OUT . the pulsed signal at the Gate OUT pin of a regulating driver module is used to synchronously drive the surge circuit in order to meet the IRA12 surge needed. If you don’t used this function, please floating it. +OUT, -OUT .DC voltage outputs. T(TRIM). Provides fixed or variable adjustment of the module output. Trimming down. Allows output voltage of the module to be trimmed down, with a decrease in efficiency .ripple as a percent of output voltage goes up and input range widens since input voltage dropout(loss of regulation) moves down Trimming up. Reverses the above effects. -Sense,+Sense.Provides for locating the point of optimal voltage regulation external to the converter. 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 AIR VELOCITY AND AMBIENT TEMPERATURE SURED BELOW THE MODULE 50.8(2.00") 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. AIR FLOW Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) Figure 15: 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_HA1SV12004_01282015 E-mail: [email protected] http://www.deltaww.com/dcdc P7 THERMAL CURVES THERMAL CURVES Figure 16: * temperature measured point Figure 17: Output current vs. ambient temperature and air velocity @Vin=110V(Either Orientation, airflow from input to ouput,with heat spreader) THERMAL CURVES Figure 18: NTC resistor location DS_HA1SV12004_01282015 E-mail: [email protected] http://www.deltaww.com/dcdc P8 LEAD FREE (SAC) PROCESS RECOMMEND TEMP. PROFILE Figure 19 recommended temperature profile for lead-free wave soldering MECHANICAL DRAWING(BASEPLATE) Figure 20 the pin function and mechanical drawing DIMENSIONAL TOLERANCE X ±0.3mm x.x ±0.2mm x.xx ±0.1mm DS_HA1SV12004_01282015 E-mail: [email protected] http://www.deltaww.com/dcdc P9 MECHANICAL DRAWING(WITHOUT MOUNTING HOLE) Figure 21 the pin function and mechanical drawing DIMENSIONAL TOLERANCE X ±0.3mm x.x ±0.2mm x.xx ±0.1mm DS_HA1SV12004_01282015 E-mail: [email protected] http://www.deltaww.com/dcdc P10 PART NUMBERING SYSTEM H A1 Form Input Factor Voltage H- S Number of Product Outputs S– 110- Half Brick 53V~154V V Single Series V- 12 004 P R Output Output ON/OFF Pin Voltage Current Logic Length 12- Series 004- 12V 4.2A Number N– Negative F A Option Code N - 0.145” F- R - 0.170” RoHS 6/6 M - SMD pin (Lead Free) A – Baseplate H-without mounting hole Space - RoHS5/6 PPositive MODEL LIST MODEL NAME INPUT OUTPUT EFF @ 100% LOAD HA1SV12004PRFA 53V~154V 1.1A 12V 4.2A 86% HA1SV12004PRFH 53V~154V 1.1A 12V 4.2A 86% Default remote on/off logic is negative and pin length is 0.170” For different remote on/off logic and pin length, please refer to part numbering system above or contact your local sales office. 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. CONTACT: www.deltaww.com/dcdc Email: [email protected] USA: Telephone: East Coast: 978-656-3993 West Coast: 510-668-5100 Fax: (978) 656 3964 Europe: Phone: +31-20-655-0967 Fax: +31-20-655-0999 Asia & the rest of world: Telephone: +886 3 4526107 ext 6220~6224 Fax: +886 3 4513485 WARRANTY Delta offers a five (5) 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_HA1SV12004_01282015 E-mail: [email protected] http://www.deltaww.com/dcdc P11