FEATURES High efficiency: 93.2% @ 12V/ 25A Standard footprint: 58.4 x 61.0 x 11.2 mm (2.30” x2.40”x0.44”) Industry standard pin out Single board construction Fixed frequency operation 2250V Isolation Basic insulation Monotonic startup into normal and prebias loads Fully protected: input UVLO, output OVP, OCP, OTP No minimum load required Wide output trim range: -20%, +10% 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 H48SA, Half Brick Family DC/DC Power Modules: 48V in, 12V/25A out The Delphi Series H48SA Half Brick, 48V input, single output, isolated, open frame DC/DC converters are the latest offering from a world leader in power systems technology and manufacturing — Delta Electronics, Inc. This product family provides up to 300 watts of power or up to 25A of output current in an industry standard footprint. This product represents the next generation of design technology required by today’s leading-edge circuitry. 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. Typical efficiency of the 12V, 300W module is better than 93.2% and all modules are fully protected from abnormal input/output voltage, current and temperature conditions. The Delphi Series converters meet all safety requirements with basic insulation. A variety of optional heatsinks are available for extended thermal operation. DATASHEET DS_H48SA12025_05112009 1 CE mark meets 73/23/EEC and 93/68/EEC directives OPTIONS Positive on/off Heatspreader available for extended operation APPLICATIONS Telecom / DataCom Wireless Networks Optical Network Equipment Server and Data Storage Industrial / Test Equipment TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS H48SA12025 (Standard) Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Transient (100ms) Operating Device Temperature(Openframe) Operating Device Temperature(Heatspreader) 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 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) ON/OFF Current (for both remote on/off logic) ON/OFF Current (for both remote on/off logic) Leakage Current(for both remote on/off logic) Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection GENERAL SPECIFICATIONS MTBF Weight Over-Temperature Shutdown(Openframe) Over-Temperature Shutdown(Heatspreader) 100ms Please refer to fig24. for the measuring point Please refer to fig25. for the measuring point Typ. -40 -40 -55 80 100 122 109 125 2250 Vdc Vdc °C °C °C Vdc 48 75 Vdc 32.5 30.5 1 34 32 2 35.5 33.5 3 9.5 240 18 1 0.42 Vdc Vdc Vdc A mA mA A2S A mA dB 12.18 Vdc 12.36 mV mV mV V 120 60 25 300 150 mV mV A W % 170 With 100uF external input cap RMS, With 100uF/0.1ohm input cap, 100% Load Pk-Pk, thru 12µH inductor, 5Hz to 20MHz, 100% Load 120 Hz Io=Io,min to Io,max Vin=36V to 75V Tc=-40℃ to 100℃ over sample load, line and temperature 5Hz to 20MHz bandwidth 100% Load, 1µF ceramic, 10µF tantalum 100% Load, 1µF ceramic, 10µF tantalum Full input range Full input range Full input range 7 50 11.82 12 ±10 ±10 ±120 11.64 60 30 0 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 400 400 400 12 12 Vin=48V Vin=48V mV mV uS 28 28 10000 100% Resistor load; 5% overshoot of Vout at startup 93.2 92.5 2250 Von/off Von/off Ion/off at Von/off=0.0V Ion/off at Von/off=3V Logic High, Von/off=15V Pout <= max rated power Pout <= max rated power Over full input range; Over full temp range Io=80% of Io, max; Ta=25°C,airflow rate=300 LFM Open frame Please refer to Fig 24. for the measuring point Please refer to Fig 25. for the measuring point mS mS µF % % 1500 Vdc MΩ pF 300 kHz 10 Von/off Von/off Units 36 Vin=36V, 100% Load Vin=48V, Io=Io.max, Tc=25℃ Max. -2 3 1.2 18 V V -2 3 1.2 18 0.3 V V mA uA uA V % % 10 100 13.2 10 140 9.6 115 1.5 80 127 116 M hours grams °C °C 2 DS_H48SA12025_05112009 ELECTRICAL CHARACTERISTICS CURVES 95 30 90 25 EFFICIENCY (%) 85 POWER DISSIPATION (W) 75Vin 48Vin 36Vin 80 75 70 75Vin 20 48Vin 36Vin 15 10 5 65 0 60 5 10 15 20 0 25 5 10 OUTPUT CURRENT (A) Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C. Vout=12V. 20 25 Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25°C. Vout=12V. 95 30 90 POWER DISSIPATION (W) 25 85 EFFICIENCY (%) 15 OUTPUT CURRENT (A) 75Vin 48Vin 36Vin 80 75 70 75Vin 20 48Vin 36Vin 15 10 5 65 0 60 5 10 15 20 25 OUTPUT CURRENT (A) Figure 3: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C. Vout=9.6V. 0 5 10 15 20 25 OUTPUT CURRENT (A) Figure 4: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25°C. Vout=9.6V. 3 DS_H48SA12025_05112009 ELECTRICAL CHARACTERISTICS CURVES 95 30 90 25 48Vin 85 EFFICIENCY (%) POWER DISSIPATION (W) 75Vin 36Vin 80 75 70 75Vin 20 48Vin 36Vin 15 10 5 65 0 60 5 10 15 20 0 25 5 10 15 20 25 OUTPUT CURRENT (A) OUTPUT CURRENT (A) Figure 5: Efficiency vs. output voltage for minimum, nominal, and maximum input voltage at 25°C, Vout=13.2V. Figure 6: Power dissipation vs. output voltage for minimum, nominal, and maximum input voltage at 25°C, Vout=13.2V. 12 Output Voltage (V) 10 8 0 6 4 0 2 0 30.0 31.3 33.6 35.0 40.0 45.0 50.0 55.0 60.0 65.0 70.0 75.0 Output Current (A) Figure 7: Typical input characteristics at room temperature. Figure 8: Turn-on transient at full rated load current, 4ms/div: Top Trace: Vout, 5V/div; Bottom Trace: ON/OFF input, 5V/div. 4 DS_H48SA12025_05112009 ELECTRICAL CHARACTERISTICS CURVES 0 0 0 Figure 9: Turn-on transient at zero load current, 4 ms/div; Top Trace: Vout, 5V/div; Bottom Trace: ON/OFF input, 5V/div. Figure 10: Output voltage response to step-change in load current, 200mV/div, 200us/div. 75%-50%-75% of Io, max, di/dt = 0.1A/µs. Load cap: 10µF, tantalum capacitor and 1µF ceramic capacitor. 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.. is ic Vin+ + + Vin- Cs: 220uF 100uF, ESR=0.2 ohm @ 25oC 100KHz 0 Figure 11: Output voltage response to step-change in load current, 200mV/div, 1ms/div. 75%-50%-75% of Io, max, di/dt = 1A/µs. Load cap: 5000µF tantalum capacitor and 1µF ceramic capacitor. 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 12: 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. Measured current as shown below. 5 DS_H48SA12025_05112009 ELECTRICAL CHARACTERISTICS CURVES 0 0 Figure 13: Input Terminal Ripple Current, ic, at nominal input voltage and rated load current with 12µH source impedance and 100µF electrolytic capacitor, 500 mA/div, 2us/div. Copper Strip Figure 14: Input reflected ripple current, is, through a 12µH source inductor at nominal input voltage and rated load current, 20 mA/div, 2us/div. Vo(+) 10u SCOPE 1u RESISTIVE LOAD 0 Vo(-) Figure 15: Output voltage noise and ripple measurement test setup Figure 16: Output voltage ripple at nominal input voltage and rated load current, 50mV/div, 2us/div. Load capacitance: 1µF ceramic capacitor and 10µF tantalum 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. 12 Output Voltage (V) 10 8 6 4 2 0 0 5 10 15 20 25 30 35 Output Current (A) Figure 17: Output voltage vs. load current showing typical current limit curves and converter shutdown points. 6 DS_H48SA12025_05112009 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 33 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 H48SA12025NN A to meet class B in CISSPR 22. Schematic and Components List + CX1 L1 - The power module must be installed in compliance with the spacing and separation requirements of the enduser’s safety agency standard, i.e., UL60950, CAN/CSA-C22.2 No. 60950-00 and EN60950:2000 and IEC60950-1999, 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. If the metal baseplate is grounded the output must be also grounded. 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. Vin(+) Vo(+) CY1 CX Vin Safety Considerations Cin L2 CY1 H48SA12025 Vin(-) LOAD Vo(-) CY CX is 4.7uF ceramic cap; CX1 is 4.7uF ceramic cap; CY is 3.3nF ceramic cap; CY1 is 4.7nF ceramic cap; L1 is common-mode inductor, L1=0.08mH; L2 is common-mode inductor, L1=0.24mH; Test Result Test result is in compliance with CISPR 22 class B, which is shown as below: 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. 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 30A 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 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. Vin=48V, Io=25A, Yellow line is quasi peak mode; Blue line is average mode. DS_H48SA12025_05112009 7 FEATURES DESCRIPTIONS Over-Current Protection The modules include an internal output over-current protection circuit. If the output current exceeds the OCP set point, the modules will automatically shut down, and enter hiccup mode or latch mode, which 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. Hiccup mode is default mode. 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-Voltage Protection The modules include an internal output over-Voltage protection circuit. If the output voltage exceeds the OVP set point, the modules will automatically shut down, and enter hiccup mode or latch mode, which is optional. 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. Hiccup mode is default mode. 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 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, which is optional. For auto-restart mode, the module will monitor the module temperature after shutdown. Once the temperature is within the specification, the module will be auto-restarted. Auto-restart mode is default mode. 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. 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. DS_H48SA12025_05112009 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. Vi(+) Vo(+) Sense(+) ON/OFF Trim R Sense(-) Vi(-) Vo(-) Distribution resistor Figure 18: 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). Vi(+) Vo(+) Sense(+) ON/OFF Trim R Sense(-) Vi(-) Vo(-) Distribution resistor Figure 19: Effective circuit configuration for remote sense operation 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 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. Care should be taken to ensure that the maximum output power does not exceed the maximum rated power. 8 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 21: Circuit configuration for trim-down (decrease output voltage) Figure 20: Circuit configuration for trim-up (increase output voltage) If the external resistor is connected between the TRIM and SENSE (+) pins, the output voltage set point increases (Fig. 20). The external resistor value required to obtain a percentage of output voltage change △% is defined as: If the external resistor is connected between the TRIM and SENSE (-) the output voltage set point decreases (Fig. 21). The external resistor value required to obtain a percentage of output voltage change △% is defined as: 100 Rtrim_down ⎛⎜ − 2⎞⎟ kΩ ⎝ Δ ⎠ Ex. When trim down to 9.6V from 12V Δ = 100*(12-9.6)/12 = 20 Rtrim_down = ( 100 − 2) kΩ 20 Rtrim_down = 3 kΩ ⎡ ⎛ 12 − 2⎞ ⋅ ( 100 + Δ ) + 100⎤ ⎢ ⎜⎝ 1.225 ⎟⎠ ⎥ Rtrim_up ⎢ ⎥ kΩ Δ ⎣ ⎦ Ex. When trim up to 13.2V from 12V Δ = 100*(13.2-12)/12 = 10 ⎡ ⎛ 12 − 2⎞ ⋅ ( 100 + 10) + 100⎤ ⎢ ⎜⎝ 1.225 ⎟⎠ ⎥ Rtrim_up ⎢ ⎥ kΩ 10 ⎣ ⎦ Rtrim_up = 95.755 kΩ I The typical resistor value can be seen in below figure22. Output voltage 13.2V 12.6V 10.8V 9.6V Resistor value ( kΩ ) 95.8 183.7 8.0 3.0 Figure 22: Trim resistor value example for popular output voltages 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. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. 9 DS_H48SA12025_05112009 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 Thermal Derating 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 24. 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. PWB FACING PWB MODULE 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’’). 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 23: Wind tunnel test setup 10 DS_H48SA12025_05112009 THERMAL CURVES H48SA12025(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Either Orientation) Output Current (A) 600LFM 25 500LFM 20 Natural Convection 15 100LFM 200LFM 10 300LFM 5 400LFM 0 25 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature 85 (℃) Figure 24: Temperature measurement location for openframe version - The allowed maximum hot spot temperature is defined at 122℃. Figure 26: Output current vs. ambient temperature and air velocity @ Vin=48V, Vout=12V(Openframe Version, Either Orientation). H48SA12025(standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Either Orientation,With Heatspreader) Output Current (A) 25 20 Natural Convection 15 100LFM 200LFM 10 300LFM 400LFM 5 500LFM 600LFM 0 25 30 35 40 45 50 55 60 65 70 75 80 Ambient Temperature (℃) Figure 25: Temperature measurement location for heatspreader version - The allowed maximum hot spot temperature is defined at 109℃. Figure 27: Output current vs. ambient temperature and air velocity @ Vin=48V, Vout=12V(Heatspreader version, Either Orientation). 11 DS_H48SA12025_05112009 85 MECHANICAL DRAWING (WITHOUT HEATSPREADER) Pin No. 1 2 3 4 5 6 7 8 9 Notes: 1 2 3 Name Function +Vin ON/OFF CASE -Vin -Vout -SENSE TRIM +SENSE +Vout Positive input voltage Remote ON/OFF Case pin Negative input voltage Negative output voltage Negative remote sense Output voltage trim Positive remote sense Positive output voltage 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. 12 DS_H48SA12025_05112009 MECHANICAL DRAWING (WITH HEATSPREADER) For modules with optional heatspreader, they are intended for wave soldering assembly onto system boards, please do not subject modules with optional heatspreader through reflow temperature profile. 13 DS_H48SA12025_05112009 PART NUMBERING SYSTEM H 48 Form Factor S Input Number of Voltage Outputs H - HalfBrick 48V S- Single A 120 25 N N Product Series Output Voltage Output Current ON/OFF Logic Pin Length A - Advanced 120- 12V 25- 25A N - Negative P - Positive N - 0.145” F A Option Code F- RoHS 6/6 (Lead Free) A - Standard Functions H - with Heatspreader MODEL LIST Part Number H48SA12025NNFA INPUT 36V~75V OUTPUT 11A 12V EFF @ 100% LOAD 25A 93.2% * 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.delta.com.tw/dcdc USA: Telephone: East Coast: (888) 335 8201 West Coast: (888) 335 8208 Fax: (978) 656 3964 Email: [email protected] Europe: Phone: +41 31 998 53 11 Fax: +41 31 998 53 53 Email: [email protected] Asia & the rest of world: Telephone: +886 3 4526107 ext 6220 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. 14 DS_H48SA12025_05112009