FEATURES High efficiency: 91.5% @ 28V/25A Industry standard size and pinout: 61.0 x 116.8 x 12.7mm (2.40”x 4.60”x 0.50”) Fixed frequency operation Remote sense Input UVLO, Output OCP, OVP & OTP Auxiliary bias power Basic insulation 2250V isolation ISO 9001, TL 9000, ISO 14001, QS9000, OHSAS18001 certified manufacturing facility UL/cUL 60950 (US & Canada) recognized, and TUV (EN60950) certified CE mark meets 73/23/EEC and 93/68/EEC directive Delphi Series F48SA, 700W Full Brick Family DC/DC Power Module: 48Vin, 28Vout The Delphi Series F48SA, 48V input, single output, full brick sized isolated DC/DC converter is the latest offering from a world leader in power systems technology and manufacturing ― Delta Electronics, Inc. The Delphi F48SA series provides up to 700 watts of power or up to 25A of output current. This product family operates from a wide input range of 36V to 75V. 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. All models are protected from abnormal input/output voltage and current conditions, and feature 2250V input/output isolation and basic insulation. An optional heatsink is available for extended operation. OPTIONS Negtive On/Off logic Heatsink for extended operation Output current monitoring Delayed overcurrent shutdown Parallel operation using forced current sharing APPLICATIONS Telecom/DataCom Wireless Networks Optical Network Equipment Server and Data Storage Industrial/Test Equipment DATASHEET DS_F48SA28025_06062006 TECHNICAL SPECIFICATIONS (TA=25°C, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS F48SA28025 (Standard) Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Transient (100ms) Operating 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 Input Over-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Hysteresis Voltage Maximum Input Current Inrush Current(I2t) 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 DC Current-Limit Inception 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 Output Capacitive Load EFFICIENCY 100% Load 60% Load ISOLATION CHARACTERISTICS Input to Output Input to Case Output to Case Isolation Resistance Isolation Capacitance FEATURE CHARACTERISTICS Switching Frequency Output overshoot Voltage during start up Power good pin max applied voltage Auxiliary output voltage Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection GENERAL SPECIFICATIONS MTBF Weight Over-Temperature Shutdown DS_F48SA28025_06062005 100ms Please refer to Fig 20 for measuring point Typ. -40 -55 80 100 95 125 2250 Vdc Vdc °C °C Vdc 48 75 Vdc 33 31 34.5 32.5 2 36 34 Vdc Vdc Vdc 76 78 78 80 2 80 82 Vdc Vdc Vdc A A2s mA dB 23 1 P-P thru 15µH inductor, 5Hz to 20MHz 120 Hz Io=Io,min to Io,max Vin=36V to 75V Tc=-40°C to 100°C over all load, line and temperature 5Hz to 20MHz bandwidth Full Load, 1µF ceramic, 10µF Low ESR cap Full Load, 1µF ceramic, 10µF Low ESR cap Units 36 100% Load, 36Vin Vin=48V, Io=Io.max, Tc=25°C Max. 20 50 27.72 28.00 28.28 Vdc 27.25 28 28 100 28.00 56 56 300 28.75 mV mV mV V 25 150 mV mV A % 200 65 2 Output Voltage 10% Low 120 48V, Tested with a 10µF, a 1µF Ceramic cap and a 470uF low ESR aluminum load cap, ΔIo/Δt=1A/µs 50% Io.max to 75% Io.max 75% Io.max to 50% Io.max 450 450 500 20 20 470 mV mV us 35 35 6000 91.5 91.5 % % 2250 2250 500 10 1800 300 0 Max sink current 5mA Aux pin source current <=20mA Referenced to Sense(-) pin Pout ≦ max rated power Pout ≦ max rated power Over full temp range; % of nominal Vout Io=80% of Io, max; Ta=25°C Please refer to Fig.20 for measuring point 7 10 115 1.14 168 100 Vdc Vdc Vdc MΩ pF kHz 35 -15 ms ms µF V 13 V +10 0.5 140 % V % M hours grams °C 2 ELECTRICAL CHARACTERISTICS CURVES 80.0 36Vin 48Vin 75Vin POWER DISSIPATION (W) EFFICIENCY (%) 95 90 36Vin 75.0 48Vin 75Vin 70.0 65.0 60.0 55.0 85 50.0 45.0 40.0 80 35.0 30.0 25.0 75 20.0 15.0 10.0 70 0 5 10 15 20 25 30 OUTPUT CURRENT (A) 5.0 0.0 0 5 10 15 20 25 30 OUTPUT CURRENT(A) Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C. DS_F48SA28025_06062005 Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25°C. 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Logic Figure 3: Turn-on transient at full rated load current (resistive load). CH3: Vout;5V/div; CH1: ON/OFF input: 5V/div Figure 4: Turn-on transient at minimum load current . CH3: Vout: 5V/div; CH1: ON/OFF input:5V/div For Positive Remote On/Off Logic Figure 5: Turn-on transient at full rated load current (resistive load) (10ms/div). Top Trace: Vout; 5V/div; Bottom Trace: ON/OFF input: 2V/div DS_F48SA28025_06062005 Figure 6: Turn-on transient at minimum load current (10ms/div). Top Trace: Vout: 5V/div; Bottom Trace: ON/OFF input: 2V/div 4 ELECTRICAL CHARACTERISTICS CURVES Figure 7: Output voltage response to step-change in load current (75%-50% of Io, max; di/dt = 1A/µs). Load cap: 470µF aluminum ,10uF Low ESR capacitor and 1µF ceramic capacitor. Top Trace: Vout (200mV/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. Figure 8: Output voltage response to step-change in load current (50%-75% of Io, max; di/dt = 1A/µs). Load cap: 470µF aluminum,10uF Low ESR capacitor and 1µF ceramic capacitor. Top Trace: Vout (200mV/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. 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 15 µH. Capacitor Cs offset possible battery impedance. Measure current as shown above. DS_F48SA28025_06062005 5 ELECTRICAL CHARACTERISTICS CURVES Figure 10: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 15µH source impedance and 220µF electrolytic capacitor (1A/div). Figure 11: Input reflected ripple current, is, through a 15µH source inductor at nominal input voltage and rated load current (10 mA/div) Copper Strip Vo(+) 10u 1u SCOPE RESISTIVE LOAD Vo(-) Figure 12: Output voltage noise and ripple measurement test setup DS_F48SA28025_06062005 6 ELECTRICAL CHARACTERISTICS CURVES OUTPUT VOLTAGE (V) 30.0 25.0 20.0 15.0 10.0 5.0 Vin=48V 0.0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 LOAD CURRENT (A) Figure 13: Output voltage ripple at nominal input voltage and rated load current (100 mV/div). Load capacitance:470uF aluminum, 1µF ceramic capacitor and 10µFlow ESR 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_F48SA28025_06062005 Figure 14: Output voltage vs. load current showing typical current limit curves and converter shutdown points. 7 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 220 to 470 µF electrolytic capacitor (ESR < 0.1 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. Application notes to assist designers in addressing these issues are pending release. 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, 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. 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, 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: DS_F48SA28025_06062005 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. If the metal baseplate is grounded, one Vi pin and one Vo pin shall also be grounded. 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. 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 normal-blow 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. 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. 8 FEATURES DESCRIPTIONS Aux Over-Current Protection -Sense 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 (hiccup mode). +On/Off -On/Off The modules 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. Figure 15: Remote on/off implementation Over-Voltage Protection Remote Sense 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 latch off. The over-voltage latch is reset by either cycling the input power or by toggling the on/off signal for one second. 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: 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. Output side on off control [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(+) The module will try to restart after shutdown. If the over-temperature condition still exists during restart, the module will shut down again. This restart trial will continue until the temperature is within specification. Remote On/Off Sense(-) Contact Resistance +Vin -Vin +On/Off -On/Off Input side on off control Sense(+) Vi(-) Vo(-) Contact and Distribution Losses Figure 16: 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. DS_F48SA28025_06062005 9 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 18: Circuit configuration for trim-up (increase output voltage) Figure 17: Circuit configuration for trim-down (decrease output voltage) 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: ⎛ 1 − 2 ⎞ ⋅kΩ ⎝∆ ⎠ Rt_dn := ⎜ Ex. When Trim-down -10% ( 28V * (1 – 10%) = 25.2V ) 1 Rt_dn = --------- － 2 = 8k 10% 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: ⎡ Vo⋅( 1 + ∆ ) 1 ⎤ − − 2⎥ ⋅kΩ ∆ ⎣ 1.24 ⋅∆ ⎦ Rt_up := ⎢ Ex. When Trim-up +10% (28.0V * (1+10%) = 30.8V) 28*(1+10%) 1 Rt_up = ------------------- － -------- － 2 = 236.39k 1.24*10% 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. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. DS_F48SA28025_06062005 10 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 Derating Heat can be removed by increasing airflow over the module. The module’s maximum case temperature is 95℃ . 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. THERMAL CURVES 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 viewed from the IMS side The allowed maximum hot spot temperature is defined at 95℃ PWB FACING PWB 750 MODULE Output Power (W) F48SA28025(Standard) Output Power vs. Hot Spot Temperature (Either Orientation) 700 650 600 AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE 550 500 50.8 (2.0”) 450 AIR FLOW 400 350 12.7 (0.5”) 25 35 45 55 65 75 85 95 Hot spot Temperature(℃) Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) Figure 19: Wind tunnel test setup DS_F48SA28025_06062005 Figure 21: Output power vs. hot spot temperature (Either Orientation) 11 MECHANICAL DRAWING Pin No. 1 2 3 4 5 6 7 8 9 10 Name Function -Vin +Vin -ON/OFF +ON/OFF +Vout +Vout +Vout -Vout -Vout -Vout Negative input voltage Positive input voltage Negative Remote ON/OFF Positive Remote ON/OFF Positive output voltage Positive output voltage Positive output voltage Negative output voltage Negative output voltage Negative output voltage Pin Specification: Pins 3-4, 11-16 Pins 1-2, 6-10 1.00mm (0.040”) diameter 2.00mm (0.079”) diameter All pins are copper with Tin plating. DS_F48SA28025_06062005 12 PART NUMBERING SYSTEM F Form Factor 48 S Input Number of Voltage Outputs F- Full Brick 48V S- Single A 280 25 P R Product Series Output Voltage Output Current ON/OFF Logic Pin Length A- Advanced 280- 28V 25- 25A N- Negative R- 0.170” P- Positive N- 0.145” F A Option Code F- RoHS 6/6 (Lead Free) K- 0.110” A - Standard Functions B - No thread heatsink mounting hole MODEL LIST MODEL NAME F48SA28025PRFA INPUT 36V~75V OUTPUT 21.4A 28V EFF @ 100% LOAD 25A 91.5 % 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 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. DS_F48SA28025_06062005 13