FEATURES High efficiency: 91% @ 3.3V/35A Size: 58.4x22.8x11.0mm (2.30”x0.90”x0.43”) w/o heat-spreader 58.4x22.8x12.7mm (2.30”x0.90”x0.50”) with heat-spreader Industry standard footprint and pinout Fixed frequency operation SMD and through-hole versions Input UVLO OTP and OVP Output OCP hiccup mode Output voltage trim down : -10% Output voltage trim up: +10% at Vin>20V 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) recognized Delphi Series E36SC3R3, Eighth Brick 116W DC/DC Power Modules: 18V~75Vin, 3.3V, 35Aout OPTIONS Positive remote On/Off The Delphi Series E36SC3R3, Eighth Brick, 18V~75Vin input, SMD pins single output, isolated DC/DC converters, are the latest offering from a Heat spreader world leader in power systems technology and manufacturing ― Delta Electronics, Inc. This product family provides up to 116 watts of power or 35A of output current. 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 3.3V/35A module is greater than 91%. DS_E36SC3R335_03282013 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 E36SC3R335(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 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 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% Vout nominal) Turn-On Transient Start-Up Time, From On/Off Control Start-Up Time, From Input Output Capacitance (note1) EFFICIENCY 100% Load 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) Leakage Current (for both remote on/off logic) Output Voltage Trim Range(note 2) Output Voltage Remote Sense Range Output Over-Voltage Protection GENERAL SPECIFICATIONS MTBF Weight Weight Typ. 0 100ms -40 -55 Max. Units 80 100 85 125 1500 Vdc Vdc Vdc °C °C Vdc 18 48 75 Vdc 16.5 15.5 0.3 17.2 16.2 1.0 17.9 17.9 1.8 8.2 Vdc Vdc Vdc A mA mA A2s mA dB 100% Load, 18Vin Vin=48V, Io=0A Vin=48V 65 5.5 P-P thru 12µH inductor, 5Hz to 20MHz 120 Hz 20 50 1 Vin=48V, Io=Io.max, Tc=25°C Io=Io, min to Io, max Vin=18V to 75V 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=18V to75V Output Voltage 10% Low 3.25 3.35 Vdc ±10 ±10 3.4 mV mV mV V 0 35 mV mV A 110 140 % 3.2 ±5 ±5 ±50 3.3 70 48Vin, 10µF Tan & 1µF Ceramic load cap, 0.1A/µs 75% Io.max to 50% Io.max 50% Io.max to 75% Io.max Full load; 5% overshoot of Vout at startup 3.3 100 100 mV mV µs 60 60 mS mS µF 0 Vin=24V Vin=48V Vin=48V 10000 91.5 91 91 % % % 1500 1000 Vdc MΩ pF 350 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 Over full temp range; % of nominal Vout Io=80% of Io, max; Ta=25°C, airflow rate=300FLM Without heat spreader 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 Vin-) Refer to Figure 22 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 19 for NTC resistor location Note: Please attach thermocouple on NTC resistor to test OTP function, the hot spots’ temperature is just for reference. 3.0 0.8 5 V V 3.0 0.8 5 V V mA 10 10 140 % % % -10 115 3.67 24.6 33.2 M hours grams grams 129 °C 120 °C 125 °C Note1: For applications with higher output capacitive load, please contact Delta Note2: Trim down range -10% for 18Vin ~75Vin, Trim up range +10% for 20Vin ~ 75Vin. DS_E36SC3R335_03282013 2 ELECTRICAL CHARACTERISTICS CURVES 93 12 90 11 EFFICIENCY(% 84 36Vin 48Vin POWER DISSIPATION(W 87 60Vin 24Vin 81 78 18Vin 75 72 69 10 9 8 7 5 66 4 63 3 60 2 3.5 7 10.5 14 17.5 21 24.5 28 31.5 35 OUTPUT CURRENT(A) Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C 60Vin 6 24Vin 18Vin 48Vin 3.5 7 10.5 14 17.5 36Vin 21 24.5 28 31.5 35 OUTPUT CURRENT(A) Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25°C. Figure 3: Typical full load input characteristics at room temperature DS_E36SC3R335_03282013 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Logic 0 0 Figure 4: Turn-on transient at full rated load current (resistive load) (10 ms/div). Vin=48V. Top Trace: Vout, 1.0V/div; Bottom Trace: ON/OFF input, 5V/div 0 0 Figure 5: Turn-on transient at zero load current (10 ms/div). Vin=48V. Top Trace: Vout: 1.0V/div, Bottom Trace: ON/OFF input, 5V/div 0 0 0 0 Figure 6: Output voltage response to step-change in load current (50%-75%-50% of Io, max; di/dt = 0.1A/µs; Vin is 24V). Load cap: 10µF tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (0.1V/div, 100us/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_E36SC3R335_03282013 Figure 7: Output voltage response to step-change in load current (50%-75%-50% of Io, max; di/dt = 0.1A/µs; Vin is 48V). Load cap: 10µF tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (0.1V/div, 100us/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 4 ELECTRICAL CHARACTERISTICS CURVES 0 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 above Figure 9: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage (Vin=48V) with 12µH source impedance and 33µF electrolytic capacitor (250mA/div, 2us/div) Copper Strip Vo(+) 10u 0 1u SCOPE RESISTIVE LOAD Vo(-) Figure 10: Input reflected ripple current, is, through a 12µH source inductor at nominal input voltage (Vin=48V) and rated load current (5mA/div, 2us/div) Figure 11: Output voltage noise and ripple measurement test setup 0 Figure 12: Output voltage ripple at nominal input voltage (Vin=48V) and rated load current (Io=35A) (20mV/div, 2us/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_E36SC3R335_03282013 Figure 13: Output voltage vs. load current showing typical current limit curves and converter shutdown points (Vin=48V) 5 DESIGN CONSIDERATIONS Safety Considerations Input Source Impedance 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. 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 E36SC3R335 series to meet class B in CISSPR 22. Schematic and Components List: Cin is 100uF low ESR Aluminum cap: CY is 1nF ceramic cap: CX1,CX2 are 2.2uF ceramic cap: CY1,CY2 are 3.3nF ceramic cap: L1,L2 are common-mode inductor ,L1=L2=0.63mH: Test Result:Vin=48V,Io=35A, dBµV 80.0 Limits 55022MQP 55022MAV 70.0 60.0 50.0 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 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 40.0 Transducer LISNPUL Traces PK+ AV 30.0 20.0 10.0 0.0 150 kHz 1 MHz 10 MHz 30 MHz Blue Line is quasi peak mode;green line is average mode. DS_E36SC3R335_03282013 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. 6 FEATURES DESCRIPTIONS Remote On/Off Over-Current Protection 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. The module 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 module will automatically shut down, and enter hiccup mode. 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. Over-Voltage Protection 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. 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. 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. 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. For auto-restart mode, the module will detect temperature after shutdown. If the over temperature condition still exists, the module will remain shutdown. This restart trial will continue until the over-temperature 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 This limit includes any increase in voltage due to remote sense compensation and output voltage set point adjustment (trim). Figure 15: Effective circuit configuration for remote sense operation DS_E36SC3R335_03282013 7 FEATURES DESCRIPTIONS (CON.) 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. 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: 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. Rtrim − up = 5 . 11 Vo (100 + ∆ ) 511 − − 10 . 2 (K Ω ) 1.225 ∆ ∆ Ex. When Trim-up +10% (3.3V×1.1=3.63V) Rtrim − up = 5.11× 3.3 × (100 + 10) 511 − − 10.2 = 90.12(KΩ ) 1.225 × 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. Figure 16: 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: Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. 511 Rtrim − down = − 10 .2 (K Ω ) ∆ Ex. When Trim-down -10% (3.3V×0.9=2.97V) 511 Rtrim − down = − 10 .2 (K Ω ) = 40 .9 (K Ω ) 10 DS_E36SC3R335_03282013 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 F LOW 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_E36SC3R335_03282013 9 THERMAL CURVES (WITH HEAT SPREADER) THERMAL CURVES (WITHOUT HEAT SPREADER) NTC RESISTOR AIRFLOW AIRFLOW HOT SPOT 1 HOT SPOT 2 Figure 19: * Hot spot 1& NTC resistor temperature measured points Figure 22: * Hot spot 2 temperature measured point E36SC3R335(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 24V (Transverse Orientation) E36SC3R335(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 24V (Transverse Orientation,with Heat Spreader) Output Current (A) Output Current (A) 35 35 Natural Convection 30 100LFM 25 Natural Convection 30 100LFM 25 200LFM 200LFM 20 20 300LFM 300LFM 15 500LFM 500LFM 10 400LFM 15 400LFM 10 600LFM 5 5 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=24V(Transverse orientation, airflow from Vin+ to Vin-,without heat spreader) 0 25 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 23: Output current vs. ambient temperature and air velocity @Vin=24V(Transverse orientation, Airflow from Vin+ to Vin-,with heat spreader) E36SC3R335(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation) E36SC3R335(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin =48V (Transverse Orientation,with Heat Spreader) Output Current (A) 35 30 Output Current (A) 35 Natural Convection 30 100LFM 25 Natural Convection 30 100LFM 25 200LFM 200LFM 20 20 300LFM 300LFM 15 400LFM 15 400LFM 500LFM 500LFM 10 10 600LFM 600LFM 5 5 0 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 21: Output current vs. ambient temperature and air velocity @Vin=48V(Transverse orientation, airflow from Vin+ to Vin-,without heat spreader) DS_E36SC3R335_03282013 0 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 24: Output current vs. ambient temperature and air velocity @Vin=48V(Transverse orientation, airflow from Vin+ to Vin-,with heat spreader) 10 PICK AND PLACE LOCATION RECOMMENDED PAD LAYOUT (SMD) SURFACE-MOUNT TAPE & REEL DS_E36SC3R335_03282013 11 LEADED (SN/PB) PROCESS RECOMMEND TEMP. PROFILE(FOR SMD MODELS) Temperature (°C ) 250 200 150 Ramp-up temp. 0.5~3.0°C /sec. 2nd Ramp-up temp. Peak temp. 1.0~3.0°C /sec. 210~230°C 5sec. Pre-heat temp. 140~180°C 60~120 sec. Cooling down rate <3°C /sec. 100 Over 200°C 40~50sec. 50 0 60 120 Time ( sec. ) 180 240 300 Note: The temperature refers to the pin of E36SC, measured on the +Vout pin joint. LEAD FREE (SAC) PROCESS RECOMMEND TEMP. PROFILE(FOR SMD MODELS) 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 pin of E36SC, measured on the +Vout pin joint. DS_E36SC3R335_03282013 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_E36SC3R335_03282013 13 MECHANICAL DRAWING (WITHOUT HEAT-SPREADER) Note：All pins are copper alloy with matte tin(Pb free) plated over Ni under-plating. DS_E36SC3R335_03282013 14 PART NUMBERING SYSTEM E Type of Product E - 1/8 Brick 36 S Input Number of Voltage Outputs 36 18V~75V S - Single C 3R3 35 N R F Product Series Output Voltage Output Current ON/OFF Logic Pin Length/Type C-Serial number 3R3 – 3.3V 35 - 35A N- Negative P- Positive R - 0.170” N - 0.146” K - 0.110” M-SMD A Option Code A - Standard Space - RoHS 5/6 Functions F - RoHS 6/6 H-with heat spreader (Lead Free) MODEL LIST MODEL NAME E36SC3R335NRFA INPUT 18V~75V OUTPUT 8.2A 3.3V EFF @ 100% LOAD 35A 91.0% @ 48Vin Default remote on/off logic is negative and pin length is 0.170” * 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 (0)20 655 09 67 Fax: +31 (0)20 655 09 99 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_E36SC3R335_03282013 15