FEATURES High efficiency: 94.2% @ 54V/ 10.2A Standard footprint: 58.4x61.0x11.2mm (2.30”x2.40”x0.44”) (without heat spreader) 58.4x61.0x12.7mm (2.30”x2.40”x0.50”) (with heat spreader) Industry standard pin out Monotonic startup into normal and pre-bias loads Fixed frequency operation Input UVLO, output OVP, OCP, OTP No minimum load required Output trim range : -5%，+5% 2250V isolation Basic insulation ISO 9001, TL 9000, ISO 14001, QS 9000, OHSAS 18001 certified manufacturing facility UL/cUL 60950-1 (US & Canada) Recognized, and TUV (EN60950-1) Certified Delphi Series H48SA53010, Half Brick Family DC/DC Power Modules: 48V in, 54V/10.2A out OPTIONS The Delphi Series H48SA53010 Half Brick, 38~60V input, 54V single output, isolated, open frame DC/DC converter is the latest offering from a world leader in power systems technology and manufacturing -- Delta Positive remote on/off Heat spreader available for extended operation Electronics, Inc. This product family provides up to 550 watts of power in an industry standard footprint. With creative design technology and optimization of component placement, these converters possess outstanding electrical and thermal performance, as well as extremely high reliability under highly stressful operating conditions. The Delphi Series converters meet all safety requirements with basic insulation. Typical efficiency of the 54V, 550W module is better than 94% and all modules are fully protected from abnormal input/output voltage, current APPLICATIONS and temperature conditions. Telecom / DataCom Wireless Networks Server and Data Storage Industrial/Test Equipment Power over Ethernet (PoE) DATASHEET DS_H48SA53010_10212014 TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS H48SA53010 (Standard) Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Transient Operating Case Temperature (With Heat spreader) Storage Temperature Input/Output Isolation Voltage INPUT CHARACTERISTICS Operating Input Voltage Input Under-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Hysteresis Voltage Maximum Input Current No-Load Input Current Off Converter Input Current Inrush Current(I2t) Input Terminal Ripple Current Input Reflected-Ripple Current Input Voltage Ripple Rejection OUTPUT CHARACTERISTICS Output Voltage Set Point Output Voltage Regulation Over Load Over Line Over Temperature Total Output Voltage Range Output Voltage Ripple and Noise Peak-to-Peak RMS Operating Output Current Range Operating Output Power Range Output DC Current Protection DYNAMIC CHARACTERISTICS Output Voltage Current Transient Positive Step Change in Output Current Negative Step Change in Output Current Settling Time (within 1% Vout nominal) Turn-On Transient Turn on Delay time Start-Up Time, enable on Maximum Output Capacitance EFFICIENCY 100% Load 20% Load ISOLATION CHARACTERISTICS Input to Output Isolation Resistance Isolation Capacitance FEATURE CHARACTERISTICS Switching Frequency ON/OFF Control, Negative Remote On/Off logic Logic Low (Module On) Logic High (Module Off) ON/OFF Control, Positive Remote On/Off logic Logic Low (Module Off) Logic High (Module On) ON/OFF Current (for both remote on/off logic) Leakage Current(for both remote on/off logic) Output Voltage Trim Range Output Voltage Trim Range Output Over-Voltage Protection GENERAL SPECIFICATIONS MTBF Weight(without heatspreader) Weight(with heatspreader) Over-Temperature Shutdown(With Heatspreader) Unit will withstand voltage transient for 10us Please refer to fig 20 for the measuring point Typ. -5 -55 Max. Units 60 100 108 125 2250 Vdc Vdc °C °C Vdc 38 48 60 Vdc Io= 100% load Io= 100% load Io= 50% load Vin=38V, 100% Load Vin=48V, Io= 0A. Vin=48V With 150uF external input cap RMS, Vin=48V, With 150uF/<0.1ohm input cap P-P thru 12µH inductor, 5Hz to 20MHz 120 Hz 32 30 2 34.5 32 36 34 Vdc Vdc Vdc A mA mA A2S mA mA dB Vin=48V, Io=Io, max 53.0 Vin=40V to 60V, Io=Io,min to Io,max Vin=40V to 60V, Io= 100% load Tc=-5℃ to 55℃ Vin=40V to 60V, over sample load and temperature 5Hz to 20MHz bandwidth Full Load, 100µF ceramic, 220µF electrolytic Full Load, 100µF ceramic, 220µF electrolytic Full input range Full input range Full input range, Output Voltage 10% Low 200 7 280 60 55.0 Vdc 55.5 mV mV mV V 100 30 150 50 10.2 550 13 mV mV A W A 300 300 800 800 60 mV mV µS 50 100 1080 mS mS µF 54.0 ±50 ±50 ±200 52.5 0 0 11 48V, 220µF Electrolytic & 100µF Ceramic load cap, 2.5A/µs 50% Io,max to 75% Io,max 75% Io,max to 50% Io,max Defined as time between enable and 10% Vout Defined as time between Vout at 10% and 90% Full load; 5% overshoot of Vout at startup 15.2 250 15 1 400 100 4 5 240 Vin=48V V Vin=48V 94.2 91.0 % % 2250 1000 Vdc MΩ pF 140 kHz 10 Von/off Von/off Von/off Von/off Ion/off at Von/off=0.0V Logic High, Von/off=15V Vin=42V to 60V; Pout <= max rated power Vin=38V to 42V; Pout <= max rated power Over full input range; Over full temp range Io=80% of Io, max; Ta=25°C, airflow rate=300 LFM Please refer to Fig 20. for the measuring point -2 3 1.2 18 V V -2 3 1.2 18 1 50 56.7 54 60 V V mA µA V V V 51.3 51.3 58 2.95 74 112 116 M hours grams grams °C DS_H48SA53010_10212014 2 ELECTRICAL CHARACTERISTICS CURVES 96 40 35 94 Power Loss (W) Efficiency (%) 30 92 90 88 25 20 15 10 86 38V 48V 5 60V 84 38V 48V 60V 0 1 2 3 4 5 6 7 8 9 10 Output Current (A) Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C. Vout=54V. 0 1 2 3 4 5 6 7 8 9 10 Output Current (A) Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25°C. Vout=54V. 16 14 Output Current (A) 12 10 8 6 4 2 0 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 Input Voltage (V) Figure 3: Typical input characteristics at room temperature. Figure 4: Turn-on transient at full rated load current (resistive load) (10 ms/div). Top Trace: Vout; 10V/div; Bottom Trace: ON/OFF input: 5V/div. DS_H48SA53010_10212014 3 ELECTRICAL CHARACTERISTICS CURVES Figure 5: Turn-on transient at zero load current (10 ms/div). Top Trace: Vout, 10V/div; Bottom Trace: ON/OFF input, 5V/div. Figure 6: Output voltage response to step-change in load current (75%-50% of Io, max; di/dt = 2.5A/µs). Load cap: 300µF, electrolytic capacitor and 100µF ceramic capacitor. Top Trace: Vout (100mV/div), Bottom Trace: Iout (5A/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%-75% of Io, max; di/dt = 2.5A/µs). Load cap: 300µF, electrolytic capacitor and 100µF ceramic capacitor. Top Trace: Vout (100 mV/div), Bottom Trace: Iout (5A/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 12 μH. Capacitor Cs offset possible battery impedance. Measure current as shown below. DS_H48SA53010_10212014 4 ELECTRICAL CHARACTERISTICS CURVES Figure 9: Input Terminal Ripple Current, ic, at nominal input voltage and rated load current with 12µH source impedance and 150µF electrolytic capacitor (200 mA/div). Figure 10: Input reflected ripple current, is, through a 12µH source inductor at nominal input voltage and rated load current (50 mA/div). Figure 11: Output voltage noise and ripple measurement test setup. Figure 12: Output voltage ripple at nominal input voltage and rated load current (20 mV/div). Load capacitance: 100µF ceramic capacitor and 220µF electrolytic capacitor. Bandwidth: 20 MHz. 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. DS_H48SA53010_10212014 5 ELECTRICAL CHARACTERISTICS CURVES 60 Output voltage(V) Output Voltage (V) 50 40 30 20 54 53.5 53 52.5 52 51.5 51 37 10 37.5 38 38.5 39 Input voltage(V) 39.5 40 0 0 2 4 6 8 10 12 Output Current (A) Figure 13: Output voltage vs. load current showing typical current limit curves and converter shutdown points. Figure 14: Output voltage VS low line input voltage at full load DS_H48SA53010_10212014 6 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. Below is the reference design for an input filter tested with H48SA53010XXXX meet class B in CISSPR 22. 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. When the input source is 60 Vdc or below, 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 any hazardous voltages, including the ac mains, with reinforced insulation. One Vi pin and one Vo pin are grounded, or all the input and output pins are kept floating. The input terminals of the module are not operator accessible. A SELV reliability test is conducted on the system where the module is used to ensure that under a single fault, hazardous voltage does not appear at the module’s output. Do not ground one of the input pins without grounding one of the output pins. This connection may allow a non-SELV voltage to appear between the output pin and ground. The power module has extra-low voltage (ELV) outputs when all inputs are ELV. For Single Module Application C1=C4=100uF/100V, low ESR Aluminum cap C2=C3=2.2uF/100V, ceramic cap C5=C6=C7=C8=4.7nF/2kV, ceramic cap C9=C10=1nF/2.5kV, ceramic cap Test result:Vin=48V, Io=10A, Vo=54V dBμV 80.0 Limits 55022MQP 55022MAV 70.0 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 50A 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 60.0 50.0 40.0 Transducer 8130 Traces PK+ AV 30.0 20.0 10.0 0.0 150.1 kHz 1 MHz Safety Considerations 10 MHz 30 MHz 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. DS_H48SA53010_10212014 7 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 automatically shut down, the hiccup mode is default and latch mode is optional. For hiccup mode, the module 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. Remote On/Off 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. Remote on/off can be controlled by an external switch between the on/off terminal and the Vin (-) terminal. The switch can be an open collector or open drain. For latch mode, the module will latch off once it shutdown. The latch is reset by either cycling the input power or by toggling the on/off signal for one second. Vin(+) Vout(+) Imon Enable Trim Rload Ishare Vin(-) Vout(-) Over-Voltage Protection The modules include an internal output over-Voltage protection circuit, which will endure output voltage limiting. If the output voltage exceeds the OVP set point, the modules will automatically shut down, the latch mode is default and the hiccup mode is optional. For hiccup mode, the module will try to restart after shutdown. If the overvoltage condition still exists, the module will shut down again. This restart trial will continue until the over-voltage condition is corrected. For latch mode, the module will latch off once it shutdown. The latch is reset by either cycling the input power or by toggling the on/off signal for one second. Figure 15: Remote on/off implementation Current Share The modules can operate in parallel up to 3 units and provide up to 1600W output power without any or-ing FET or diode. Between 50% and 100% max load rating, current–sharing accuracy is +/-2.5%. The equation of Ishare PIN voltage vs. Io is: Ishare = 0.25*Io+0.25 Ishare unit is Volt, and Io unit is Amp. Over-Temperature Protection 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 hiccup mode is default and latch mode is optional. In parallel application, if the load current is larger than one module’s full current, the modules can not restart automatically even in hiccup mode. Either cycling the input power or toggling the on/off signal for one second can startup the modules. For hiccup mode, the module will monitor the module temperature after shutdown. Once the temperature is within the specification, the module will be auto-restarted. Current Monitor For latch mode, the module will latch off once it shutdown. The latch is reset by either cycling the input power or by toggling the on/off signal for one second. Imon shall sink a current proportional to output current and reference to Vout (-). This pin can be pulled up through an external resistor to an external voltage, the external voltage ranges from 1.5V to Vout (+) +3.3V. Output current equals Imon×10,000. Accuracy is +/0.5A. DS_H48SA53010_10212014 8 FEATURES DESCRIPTIONS (CON.) Vout(+) Imon Output Voltage Adjustment (TRIM) 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 Vout (+) or Vout (-). The TRIM pin should be left open if this feature is not used. Vout(+) Imon Rtrimup Trim Rload Ishare Vout(-) Figure 16: Circuit configuration for trim-up (increase output voltage) If the external resistor is connected between the TRIM and Vout (+) pins, the output voltage set point increases (Fig. 15). The external resistor value required to obtain a percentage of output voltage change △% is defined as: Vout 100 % 100 2% K % 1.225% Rtrimup Rtrimdown Rload Ishare Vout(-) Figure 17: Circuit configuration for trim-down (decrease output voltage) If the external resistor is connected between the TRIM and Vout (-), the output voltage set point decreases (Fig. 16). The external resistor value required to obtain a percentage of output voltage change △% is defined as Rtrimdown 100 % 2 K Ex. When trim down to 51.3V from 54V %= 100*(54-51.3)/54 = 5 Rtrimdown 100 5 2 K Rtrim_down = 18 kΩ The typical resistor value can be seen in below figure17. Ex. When trim up to 56.7V from 54V % = 100*(56.7-54)/54 = 5 Rtrimup 54 ( 100 5) 1.2255 100 2 5 Rtrim_up = 903.7 kΩ 5 K Output voltage Resistor value ( k ) 56.7V 903.7 51.3V 18 Figure 18: Trim resistor value example for popular output voltages When using trim function to increase output voltage, the output power should increase accordingly. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. DS_H48SA53010_10212014 9 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. THERMAL CURVES (WITH HEATSPREADER) 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’’). Figure 20: Temperature measurement location * The allowed maximum hot spot temperature is defined at 108℃ H48SA53010(Standard) Output Power vs. Ambient Temperature and Air Velocity @Vin = 48V (Either Orientation,With Heatspreader) Thermal De-rating Output Power (W) 550 600LFM Heat can be removed by increasing airflow over the module. The module’s maximum device temperature is to be defined and the measured location is illustrated in Figure 19. 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. 500 500LFM 450 400 350 300 250 Natural Convection 200 100LFM 150 PWB FACING PWB 200LFM 100 300LFM 400LFM 50 MODULE 0 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 21: Output Power vs. ambient temperature and air velocity @ Vin=48V, Vout=54V (Either Orientation) AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE 50.8 (2.0”) AIR FLOW 12.7 (0.5”) Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) Figure 19: Wind tunnel test setup DS_H48SA53010_10212014 10 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. DS_H48SA53010_10212014 11 MECHANICAL DRAWING (WITHOUT HEAT SPREADER) Pin No. Name Function 1 2 3 4 5 6 7 8 9 Vin(+) On/Off Case Vin(-) Vout(-) Ishare TRIM Imon Vout(+) Positive input voltage Turns unit On (low) or Off (high or open) Optionl connection to baseplate Input voltage return Output voltage return Current share Output voltage trim Current monitor Positive output voltage Notes: 1 2 3 Pins 1-4, 6-8 are 1.00mm (0.040”) diameter Pins 5 and 9 are 2.00mm (0.079”) diameter All pins are copper with Tin plating. DS_H48SA53010_10212014 12 PART NUMBERING SYSTEM H Form Factor 48 S Input Number of Voltage outputs H - Half-Brick 48- S - Single A Output Voltage 530 10 N N Mounting Output Current ON/OFF Logic Pin Length A - Advanced 530 - 54V 10 - 10.2A N - Negative 38V~60V P - Positive N - 0.145” R - 0.170” F A Option Code F-RoHS 6/6 A - Standard Functions (Lead Free) H - With Heatspreader K - 0.110” MODEL LIST Efficiency 48Vin @ Full load Model Name Input Voltage Output Voltage Output Current H48SA53010NNFA 38V~60V 54V 10.2A 94.2% H48SA53010NNFH 38V~60V 54V 10.2A 94.2% 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_H48SA53010_10212014 13