E54SJ3R350 165W DC/DC Power Modules FEATURES Electrical High efficiency: 94% @ 3.3V/50A 94% @ 3.3V/20A Industry standard footprint and pin-out Fixed frequency operation OTP, Input UVLO, Output OVP Output OCP Hiccup mode 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 Mechanical Size: Without heat-spreader 58.4x22.8x11.5mm (2.30”x0.90”x0.43”) With heat-spreader 58.4x22.8x12.7mm (2.30”x0.90”x0.50”) E54SJ3R350 Eighth Brick DC/DC Power Module Safety & Reliability 40~60V in, 3.3V/50A out, 165W UL 60950-1 & CSA C22.2 No.60950-1-07 IPC9592B ISO 9001, TL 9000, ISO 14001, QS 9000, OHSAS18001 certified manufacturing facility E54SJ3R350, Eighth Brick, 40~60V input, single output, isolated 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 165 watts of power with very high efficiency. With creative design technology and optimization of component placement, these converters possess outstanding electrical and operating conditions. Typical efficiency of the 3.3V/50A module is greater Datasheet_E54SJ3R350_05252016 Negative or Positive remote On/Off Open frame/Heat-spreader thermal performance, as well as extremely high reliability under highly stressful than 94%. OPTIONS APPLICATIONS Optical Transport Data Networking Communications Servers E-mail: [email protected] http://www.deltaww.com/dcdc P1 TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=100 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS E54SJ3R350 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 Inrush Current ( I2t) Input Reflected-Ripple Current Input Voltage Ripple Rejection OUTPUT CHARACTERISTICS Output Voltage Set Point Output Regulation Load Regulation Line Regulation Temperature Regulation Total Output Voltage Range Output Voltage Ripple and Noise Peak-to-Peak RMS Operating Output Current Range Output Over Current Protection(hiccup mode) DYNAMIC CHARACTERISTICS Output Voltage Current Transient Positive Step Change in Output Current Negative Step Change in Output Current Settling Time (within 1% nominal Vout) Turn-On Delay and Rise Time Start-Up Delay Time From Input Voltage Start-Up Delay Time From On/Off Control Output Voltage Rise Time Output Capacitance (note1) EFFICIENCY 100% Load 50% 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 Remote Sense Range Output Over-Voltage Protection GENERAL SPECIFICATIONS MTBF Weight Weight Typ. 0 100ms -40 -55 Vdc Vdc Vdc °C °C Vdc 60 Vdc 32.5 30.5 1 34.0 32.0 2 35.5 33.5 3 4.8 120 12 1 Vdc Vdc Vdc A mA mA A2s mA dB 3.35 Vdc 0.3 0.3 3.4 %Vo,set %Vo,set %Vo,set V 100 40 150 60 50 75 mV mV A A 70 70 100 120 120 200 mV mV µs 15 15 15 20 20 20 10000 mS mS mS µF P-P thru 12µH inductor, 5Hz to 20MHz 120 Hz 20 45 3.25 3.3 1 3.2 0 55 48Vin, 10µF Tan & 1µF Ceramic load cap, 0.1A/µs 75% Io.max to 50% Io.max 50% Io.max to 75% Io.max On/Off=On, from Vin=Turn-On Threshold to Vo=10% Vo,nom Vin=Vin,nom, from On/Off=On to Vo=10% Vo,nom Vo=10% to 90% Vo,nom Full load; 5% overshoot of Vout at startup 60 80 85 125 1500 48/54 80 8 Io=Io, min to Io, max Vin=40V to 60V Tc=-40°C to 85°C Over sample load, line and temperature 5Hz to 20MHz bandwidth Vin=48V, Full Load, 1µF ceramic, 10µF tantalum Vin=48V, Full Load, 1µF ceramic, 10µF tantalum Vin=40V to 60V Output Voltage 10% Low Units 40 Full Load, 40Vin Vin=48V, Io=0A Vin=48V, Io=0A Vin=48V, Io=Io.max, Tc=25°C Max. 10 10 10 Vin=48V Vin=48V 94.0 94.0 % % 1500 1100 Vdc MΩ pF 200 KHz 10 Von/off Von/off Von/off Von/off Ion/off at Von/off=0.0V Logic High, Von/off=5V Pout ≦ max rated power, Io ≦ Io.max Pout ≦ max rated power, Io ≦ Io.max % of nominal Vout 2 0.8 15 V V 2 0.8 15 V V mA -10 -10 120 10 0 140 %Vo,nom %Vo,nom %Vo,nom Io=80% of Io, max; Ta=25°C, airflow rate=300LFM Without heat-spreader With heat-spreader Refer to Figure 18 for Hot spot 1 location Over-Temperature Shutdown (without heat-spreader) (48Vin, 80% Io, 200LFM,Airflow from Vin+ to Vin-) Refer to Figure 20 for Hot spot 2 location Over-Temperature Shutdown (with heat-spreader) (48Vin, 80% Io, 200LFM,Airflow from Vin+ to Vin-) Over-Temperature Shutdown ( NTC resistor ) Refer to Figure 18 for NTC resistor location Note: Please attach thermocouple on NTC resistor to test OTP function, the hot spots’ temperature is just for reference. 5 28 38 Mhours grams grams 125 °C 115 °C 125 °C Note: For applications with higher output capacitive load, please contact Delta. Datasheet_E54SJ3R350_05252016 E-mail: [email protected] http://www.deltaww.com/dcdc P2 ELECTRICAL CHARACTERISTICS CURVES TA=25°C Figure 1: Efficiency vs. Output Current Figure 2: Power Dissipation vs. Output Current Figure 3: Full Load Input Characteristics Figure 4: Output Voltage vs. Output Current showing typical current limit curves and converter shutdown points. Datasheet_E54SJ3R350_05252016 E-mail: [email protected] http://www.deltaww.com/dcdc P3 ELECTRICAL CHARACTERISTICS CURVES TA=25°C, Vin=48Vdc Figure 5: Remote On/Off (negative logic) at full load Time: 10ms/div. Vout (top trace): 1V/div; Vremote On/Off signal (bottom trace): 5V/div. Figure 6: Input Voltage Start-up at full load Time: 10ms/div. Vout (top trace): 1V/div; Vin (bottom trace): 20V/div. Figure 7: Transient Response (0.1A/µs step change in load from 50% to 75% to 50% of Io, max) Vout (top trace): 0.1V/div, 200us/div; Iout (bottom trace): 10A/div. 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 Figure 8: Transient Response (1A/µs step change in load from 50% to 75% to 50%of Io, max) Vout (top trace):0.1V/div, 200us/div; Iout (bottom trace): 10A/div. 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 Datasheet_E54SJ3R350_05252016 E-mail: [email protected] http://www.deltaww.com/dcdc P4 ELECTRICAL CHARACTERISTICS CURVES TA=25°C, Vin=48Vdc Figure 9: Test Setup Diagram for Input 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. Figure 10: Input Terminal Ripple Current, ic, at max output current and nominal input voltage with 12µH source impedance and 33µF electrolytic capacitor (100 mA/div, 2us/div). Figure 11: Input Reflected Ripple Current, is, through a 12µH source inductor at nominal input voltage and max load current (20mA/div, 2us/div). Figure 12: Test Setup for Output Voltage Noise and Ripple Figure 13: Output Voltage Ripple and Noise at nominal input voltage and max load current (100 mV/div, 2us/div) Load cap: 1µF ceramic capacitor and 10µF tantalum capacitor. Bandwidth: 20MHz. Datasheet_E54SJ3R350_05252016 E-mail: [email protected] http://www.deltaww.com/dcdc P5 DESIGN CONSIDERATIONS Input Source Impedance Safety Considerations 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 100μF electrolytic capacitor (ESR < 0.7Ω at 100kHz) mounted close to the input of the module to improve the stability. 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. 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 same family product to meet class B in CISSPR 22. Schematic and Components List Vin(+) Vo(+) CY1 Vin Cin DCDC CX LOAD L1 - Basic insulation based on 75Vdc 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 60Vdc and less than or equal to 75Vdc, 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. Module CY2 Vin(-) Vo(-) CY Figure 14-1: Recommended Input Filter Cin is 100uF*2 low ESR Aluminum cap; CX is 2.2uF ceramic cap; CY1 are 10nF ceramic caps; CY2 are 10nF ceramic caps; CY is 1nF ceramic cap; L1 is common-mode inductor, L1=0.88mH; 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. 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 fast acting 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. The input of E54SJ3R350 meets SELV requirement, but the design still meets basic insulation. Soldering and Cleaning Considerations Figure 14-2: Test Result of EMC Vin=48V, Io=25A. Yellow line is quasi peak mode; Blue line is average mode. Datasheet_E54SJ3R350_05252016 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. E-mail: [email protected] http://www.deltaww.com/dcdc P6 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. The modules will try to restart after shutdown in a default 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. E54SJ3R350 provides an option for a latch OCP mode, customer need contact to Delta for this option. Under 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. Fi gure 15: Remote On/Off Implementation Output Voltage Adjustment (TRIM) To decrease the output voltage set point, connect an external resistor between the TRIM pin and the SENSE(-) pin. The TRIM pin should be left open if this feature is not used. 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). E54SJ3R350 provides an option for a latch OVP mode, customer need contact to Delta for this option. Under 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. The module will restart after the temperature is within specification. Figure 16-1: Circuit Configuration for Trim-Down (decrease output voltage) If the external resistor is connected between the TRIM and Vo(-) pins, the output voltage set point decreases (Fig.16-1). The external resistor value required to obtain a percentage of output voltage change △% is defined as: 511 Rtrim down 10.22K Ex. When Trim-down -30% (3.3V×0.9=2.97V) 511 Rtrim down 10.22K 15.33K 20 Remote On/Off The remote On/Off feature on the module can be either negative or positive logic depend on the part number options on the last page. For Negative logic version, turns the module on during a external logic low and off during a logic high. If the remote on/off feature is not used, please short the On/Off pin to Vi(-). For Positive logic version, turns the modules on during a external logic high and off during a logic low. If the remote On/Off feature is not used, please leave the On/Off pin to floating. 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. Datasheet_E54SJ3R350_05252016 Figure 16-2: Circuit Configuration for Trim-Up (increase output voltage) If the external resistor is connected between the TRIM and Vo(+) the output voltage set point increases (Fig.16-2) The external resistor value required to obtain a percentage output voltage change △% is defined as: Rtrim up 5.11Vo (100 ) 511 10.2K 1.225 Ex. When Trim-up +10% ( 3.3*1.1=3.63V ) 5.11 3.3 (100 10) 511 Rtrim up 10.2 90.1K 1.225 10 10 E-mail: [email protected] http://www.deltaww.com/dcdc P7 FEATURES DESCRIPTIONS 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 17: 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. Datasheet_E54SJ3R350_05252016 E-mail: [email protected] http://www.deltaww.com/dcdc P8 THERMAL CONSIDERATIONS Thermal Curves (without heat-spreader) AIRFLOW AIRFLOW NTC RESISTOR Thermal Curves (with heat-spreader) HOT SPOT1 Figure 18: * Hot spot 1& NTC resistor temperature measured points. The allowed maximum hot spot temperature is defined at 120℃. Figure 20: * Hot spot 2 temperature measured point. The allowed maximum hot spot temperature is defined at 110 ℃. Figure 19: Output current vs. ambient temperature and air velocity @Vin=48V(Transverse Orientation, airflow from Vin+ to Vin-, without heat-spreader) Figure 21: Output current vs. ambient temperature and air velocity @Vin=48V(Transverse Orientation, airflow from Vin+ to Vin-, with heat-spreader) Datasheet_E54SJ3R350_05252016 E-mail: [email protected] http://www.deltaww.com/dcdc P9 MECHANICAL DRAWING Mechanical Drawing (with heat-spreader) For modules with through-hole pins and the optional heat-spreader, they are intended for wave soldering assembly onto system boards; please do not subject such modules through reflow temperature profile. Datasheet_E54SJ3R350_05252016 E-mail: [email protected] http://www.deltaww.com/dcdc P10 MECHANICAL DRAWING Mechanical Drawing (without heat-spreader) SMD Module Pin No. 1 2 3 4 5 6 7 8 Through-Hole Module Name +Vin ON/OFF -Vin -Vout -SENSE TRIM +SENSE +Vout 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 (0.059”) diameter Note: All pins are copper alloy with matte Tin (Pb free) plated over Nickel under plating. Datasheet_E54SJ3R350_05252016 E-mail: [email protected] http://www.deltaww.com/dcdc P11 RECOMMENDED PAD LAYOUT Recommended Pad Layout (Through-hole Module) Recommended Pad Layout (SMD Module) Datasheet_E54SJ3R350_05252016 E-mail: [email protected] http://www.deltaww.com/dcdc P12 MANUFACTURING CONSIDERATION Pick and Place Location Tape & Reel Package for SMD Model Datasheet_E54SJ3R350_05252016 E-mail: [email protected] http://www.deltaww.com/dcdc P13 MANUFACTURING CONSIDERATION Leaded (Sn/Pb) Process Recommend Temp. Profile (for SMD model) Note: The temperature refers to the pins, measured on the +Vout pin joint. Lead Free (Sac) Process Recommend Temp. Profile (for SMD model) 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 pins, measured on the +Vout pin joint. Datasheet_E54SJ3R350_05252016 E-mail: [email protected] http://www.deltaww.com/dcdc P14 PART NUMBERING SYSTEM E 54 S J Form Input Factor Voltage E - 1/8 Brick Number Of Outputs Product Series 3R3 Output Voltage 3R3 – 3.3V 54 - S- J- 40V~60V Single Series Number 50 N Output ON/OFF Pin Current Logic Length 50 - 50A R NNegative F H RoHS Option Code K - 0.110’’ F - RoHS 6/6 A - Open Frame N - 0.145” (Lead Free) H - With heat-spreader R - 0.170” Space - RoHS5/6 M - SMD pin MODEL LIST Model Name E54SJ3R350NRFA Input 40V~60V Output 4.5A 3.3V Eff. @ 100% Load 50A 94% @ 48Vin 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 heat-spreader, they are intended for wave soldering assembly onto system boards; please do not subject such modules through reflow temperature profile. CONTACT US: Website: www.deltaww.com/dcdc Email: [email protected] USA: Telephone: East Coast: 978-656-3993 West Coast: 510-668-5100 Fax: (978) 656 3964 Europe: Telephone: +31-20-655-0967 Fax: +31-20-655-0999 Asia & the rest of world: Telephone: +886 3 4526107 Ext. 6220/6221/6222/6223/6224 Fax: +886 3 4513485 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. Datasheet_E54SJ3R350_05252016 E-mail: [email protected] http://www.deltaww.com/dcdc P15