FEATURES High efficiency: 84% @ 1.0V/50A Size: 33.0x22.8x9.5mm (1.30”x0.90”x0.37”) ( W/O heat-spreader ) 33.0x22.8x12.7mm (1.30”x0.90”x0.50”) ( With heat-spreader ) Industry standard footprint and pinout Fixed frequency operation SMD and through-hole versions Input UVLO OTP and output OCP, OVP Output voltage trim: -20%, +10% Monotonic startup into normal and pre-biased loads 1500V isolation and basic insulation No minimum load required No negative current during power or enable on/off ISO 9001, TL 9000, ISO 14001, QS 9000, OHSAS18001 certified manufacturing facility UL/cUL 60950-1 (US & Canada) th Delphi Series V48SH, 1/16 Brick 50W DC/DC Power Modules: 48V in, 1.0V, 50Aout The Delphi Series V48SH, 1/16 th Brick, 48V input, single output, OPTIONS isolated DC/DC converter, is the latest offering from a world leader in SMD pins power systems technology and manufacturing ― Delta Electronics, Short pin lengths available Inc. This product family provides up to 100 watts of power in an Positive/Negative remote On/Off Open Frame/Heat spreader industry standard 1/16 th brick form factor (1.30” x 0.90”). The 1.0V output offers one of the highest output currents available and provides up to 84% efficiency at full load. 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.For lower power needs, but in a similar small form factor, please check out Delta, V36SE (50W or 15A), S48SP (36W or 10A) and S36SE (17W or 5A) series standard DC/DC modules. DS_V48SH1R050_10282013 APPLICATIONS Optical Transport Data Networking Communications Servers TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS V48SH1R050 (Standard) Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Transient (100ms) Operating Ambient Temperature 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 2 Inrush Current (I t) 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 Output Over 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 Start-Up Time, From On/Off Control Start-Up Time, From Input Maximum Output Capacitance EFFICIENCY 100% Load 60% 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) Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection GENERAL SPECIFICATIONS 0 100ms -40 -55 36 32.5 30.5 1 DS_V48SH1R050_10282013 34 32 2 100% Load, 36Vin 30 10 With 100uF external input capacitor P-P thru 12µH inductor, 5Hz to 20MHz 120 Hz Vin=48V, Io=Io.max, Tc=25°C Io=Io, min to Io, max Vin=36V to 75V Tc=-40°C to 125°C Over sample load, line and temperature 5Hz to 20MHz bandwidth Full Load, 1µF ceramic, 10µF tantalum Full Load, 1µF ceramic, 10µF tantalum Output Voltage 10% Low Max. Units 80 100 85 125 1500 Vdc Vdc °C °C Vdc 75 Vdc 35.5 33.5 3 2.2 50 12 1 Vdc Vdc Vdc A mA mA 2 As 20 mA dB 1.015 Vdc 1.03 mV mV mV V 120 50 50 140 mV mV A % -60 0.985 1.0 ±5 ±5 ±10 0.97 80 20 0 110 48V, 10µF Tan & 1µF Ceramic load cap, 0.1A/µs 50% Io.max to 75% Io.max 75% Io.max to 50% Io.max Cap ESR>=3mohm; Full load; 5% overshoot of Vout at startup; 50 50 100 mV mV us 15 15 25 25 ms ms 0 10000 µF Vin=48V Vin=48V 84 85 % % 1500 1000 Vdc MΩ pF 250 kHz 10 Von/off Von/off 0 2.4 0.8 5 V V Von/off Von/off Max rated current guaranteed at full trim range Max rated current guaranteed at full remote sense range Over full temp range; % of nominal Vout 0 2.4 -20 0.8 5 10 V V % 10 % Per Telecordia SR-332 Issue 2, 80% load, 25°C, 48Vin, 300LFM Weight Without heat spreader Weight With heat spreader Refer to Figure 19 for Hot spot 1 location Over-Temperature Shutdown ( Without heat spreader) (48Vin,80% Io, 200LFM,Airflow from Vin+ to Vo+) Refer to Figure 21 for Hot spot 2 location Over-Temperature Shutdown (With heat spreader) (48Vin,80% Io, 200LFM,Airflow from Vin+ to Vo+) Over-Temperature Shutdown ( NTC resistor ) Refer to Figure 19 for NTC resistor location Note: Please attach thermocouple on NTC resistor to test OTP function, the hot spots’ temperature is just for reference. MTBF Typ. 150 % 4.3 M hours 13.3 21.5 grams grams 129 °C 122 °C 125 °C 2 ELECTRICAL CHARACTERISTICS CURVES 7 48Vin EFFICIENCY(%) 82 36Vin 75Vin 79 76 73 1 1 85 6 POWER DISSIPATION(W) 88 5 4 36Vin 3 2 75Vin 1 70 48Vin 0 5 10 15 20 25 30 35 40 45 50 5 OUTPUT CURRENT(A) 10 15 20 25 30 35 40 45 50 OUTPUT CURRENT(A) Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25°C. 1 2.1 INPUT CURRENT (A) 1.8 1.5 1.2 0.9 0.6 0.3 0 25 30 35 40 45 50 55 60 65 70 75 INPUT VOLTAGE (V) Figure 3: Typical full load input characteristics at room temperature DS_V48SH1R050_10282013 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Start up 0 0 0 0 Figure 4: Turn-on transient at full rated load current (10 ms/div). Vin=48V. Top Trace: Vout, 0.5V/div; Bottom Trace: ON/OFF input, 5V/div Figure 5: Turn-on transient at zero load current (10 ms/div). Vin=48V. Top Trace: Vout: 0.5V/div, Bottom Trace: ON/OFF input, 5V/div For Input Voltage Start up 0 0 0 0 Figure 6: Turn-on transient at full rated load current (10 ms/div). Vin=48V. Top Trace: Vout, 0.5V/div; Bottom Trace: Vin, 20V/div Figure 7: Turn-on transient at zero load current (10 ms/div). Vin=48V. Top Trace: Vout, 0.5V/div; Bottom Trace: Vin, 20V/div 0 0 Figure 8: Output voltage response to step-change in load current (75%-50%-75% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (50mV/div, 500us/div), Bottom Trace: Iout (10A/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 DS_V48SH1R050_10282013 4 ELECTRICAL CHARACTERISTICS CURVES is ic Vin+ + 0 + Vin- Cs: 220uF 100uF, ESR=0.2 ohm @ 25oC 100KHz Figure 9: 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 above Figure 10: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 12µH source impedance and 33µF electrolytic capacitor (200 mA/div, 1us/div) Copper Strip Vo(+) 0 10u 1u SCOPE RESISTIVE LOAD Vo(-) Figure 11: Input reflected ripple current, is, through a 12µH source inductor at nominal input voltage and rated load current (20 mA/div, 1us/div) Figure 12: Output voltage noise and ripple measurement test setup 0 Figure 13: Output voltage ripple at nominal input voltage and rated load current (50 mV/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_V48SH1R050_10282013 5 Safety Considerations 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 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 V48SH1R050 series to meet class B in CISSPR 22. Schematic and Components List: 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 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. Cin is 100uF low ESR Aluminum cap: CY is 1nF ceramic cap CX is 3.3uF ceramic cap: CY1 is 3.3nF ceramic cap: CY2 is 3.3nF ceramic cap: L1 is common-mode inductor ,L1=1mH: The power module has extra-low voltage (ELV) outputs when all inputs are ELV. Test Result:Vin=48V,Io=50A, 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 Fast-acting fuse with 20A 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. 60.0 Soldering and Cleaning Considerations 50.0 40.0 Transducer LISNPUL Traces PK+ AV 30.0 20.0 10.0 0.0 150 kHz 1 MHz 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. Blue Line is quasi peak mode;green line is average mode. DS_V48SH1R050_10282013 6 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, and enter hiccup mode or latch mode, the default is hiccup mode. 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 floating. For hiccup mode, the module will try to restart after shutdown. If the over current condition still exists, the module will shut down again. This restart trial will continue until the over-current condition is corrected. Vi(+) Vo(+) Sense(+) ON/OFF 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. Sense(-) Vi(-) Vo(-) 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, and enter in hiccup mode or latch mode, The default is hiccup mode. For hiccup mode, the module 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. 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 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. Over-Temperature Protection 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, and enter in auto-restart mode or latch mode, the default is auto-restart mode. For auto-restart mode, the module will monitor the module temperature after shutdown. Once the temperature is dropped and within the specification, the module will be auto-restart. Vi(+) Vo(+) Sense(+) Sense(-) Vi(-) Contact Resistance Vo(-) Contact and Distribution Losses 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: Effective circuit configuration for remote sense operation Remote On/Off 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. 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. DS_V48SH1R050_10282013 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. 7 FEATURES DESCRIPTIONS (CON.) 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. Max rated current is guaranteed at full output voltage remote sense range. Output Voltage Adjustment (TRIM) To increase or decrease the output voltage set point, connect 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) If the external resistor is connected between the TRIM and SENSE (+) the output voltage set point increases (Fig. 19). The external resistor value required to obtain a percentage output voltage change △% is defined as: Rtrim up 5.11Vo (100 ) 511 10.22K 0.6 Ex. When Trim-up +10% (1.0V×1.1=1.1V) 5.11 1.0 (100 10) 511 10.22 32.36K 0.6 10 10 Figure 16: Circuit configuration for trim-down (decrease output voltage) Rtrim up If the external resistor is connected between the TRIM and SENSE (-) pins, the output voltage set point decreases (Fig. 18). The external resistor value required to obtain a percentage of output voltage change △% is defined as: Trim resistor can also be connected to Vo+ or Vo- but it would introduce a small error voltage than the desired value. 511 Rtrim down 10.22 K Ex. When Trim-down -10% (1.0V×0.9=0.9V) 511 Rtrim down 10.22 K 40.88K 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 increases the power output of the module with the same output current. Max rated current is guaranteed at full output voltage trim range. DS_V48SH1R050_10282013 8 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_V48SH1R050_10282013 9 THERMAL CURVES (WITHOUT HEAT SPREADER) THERMAL CURVES (WITH HEAT SPREADER) HOT SPOT1 HOT SPOT2 AIRFLOW AIRFLOW NTC RESISTOR Figure 19: * Hot spot 1& NTC resistor temperature measured points Output Current (A) Figure 21: * Hot spot 2 temperature measured point V48SH1R050(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Either Orientation) 50 Output Current (A) V48SH1R050(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Either Orientation; With Heatspreader) 50 45 45 Natural Convection 40 Natural Convection 40 100LFM 35 30 100LFM 35 200LFM 200LFM 30 300LFM 400LFM 25 400LFM 500LFM 500LFM 20 300LFM 25 20 600LFM 600LFM 15 15 10 10 5 5 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(Either Orientation, airflow from Vin+ to Vout+, without heat spreader) DS_V48SH1R050_10282013 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(Either Orientation, airflow from Vin+ to Vout+, with heat spreader) 10 PICK AND PLACE LOCATION RECOMMENDED PAD LAYOUT (SMD) SURFACE-MOUNT TAPE & REEL DS_V48SH1R050_10282013 11 LEADED (Sn/Pb) PROCESS RECOMMEND TEMP. PROFILE(for SMD models) Note: The temperature refers to the pin of V48SH, measured on the pin +Vout joint. LEAD FREE (SAC) PROCESS RECOMMEND TEMP. PROFILE(for SMD models) Temp. Peak Temp. 240 ~ 245 ℃ 217℃ Ramp down max. 4℃/sec. 200℃ Preheat time 100~140 sec. 150℃ Time Limited 90 sec. above 217℃ Ramp up max. 3℃/sec. 25℃ Time Note: The temperature refers to the pin of V48SH, measured on the pin +Vout joint. DS_V48SH1R050_10282013 12 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_V48SH1R050_10282013 13 MECHANICAL DRAWING (WITHOUT HEAT-SPREADER) Surface-mount module Pin No. 1 2 3 4 5 6 7 8 Name +Vin ON/OFF -Vin -Vout -Sense Trim +Sense +Vout Through-hole module Function Positive input voltage Remote ON/OFF Negative input voltage Negative output voltage Negative remote sense Output voltage trim Positive remote sense Positive output voltage Pin Specification: Pins 1-3,5-7 Pins 4 & 8 1.00mm (0.040”) diameter 2. 1.50mm (0.060”) diameter All pins are copper alloy with matte-tin(Pb free) plated over Nickel under-plating. DS_V48SH1R050_10282013 14 RECOMMENDED PAD LAYOUT (FOR THROUGH-HOLE MODULE) DS_V48SH1R050_10282013 15 PART NUMBERING SYSTEM V 48 Type of Product V - 1/16 Brick S H 1R0 50 N R Input Number of Voltage Outputs Product Series Output Voltage Output Current ON/OFF Logic Pin Length/Type 4836V~75V H - High Power 1R0 - 1.0V 50 - 50A N- Negative P- Positive R - 0.170” N - 0.145” K - 0.110” M-SMD S - Single F A Option Code F- RoHS 6/6 A - Standard Functions (Lead Free) H - with Heatspreader MODEL LIST MODEL NAME V48SH1R050NNFA INPUT 36V~75V OUTPUT 2.2A 1.0V EFF @ 100% LOAD 50A 84% 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 USA: Telephone: East Coast: 978-656-3993 West Coast: 510-668-5100 Fax: (978) 656 3964 Email: [email protected] Europe: Phone: +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_V48SH1R050_10282013 16