FEATURES High efficiency: 96.5% @ 9.6V/25A Size: 58.4mm x 22.8mm x 11.3mm (2.28” x 0.90” x 0.44”) Industry standard pinout Fully protected: Input UVLO, OVP, Output OCP and OTP 240W constant power output Parallelable for higher output power 2250V isolation Basic insulation Monotonic startup No minimum load required 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 directives Delphi Series E48SB, 240W Eighth Brick Bus Converter DC/DC Power Modules: 48Vin, 9.6V/25A out OPTIONS Delta Electronics, Inc., a world leader in power systems technology and manufacturing, has introduced the E48SB, eighth brick sized 240W bus converter, into their Delphi Series of board mounted DC/DC power converters to support the intermediate bus architecture to power multiple downstream non-isolated point-of-load (POL) converters. The E48SB product family features an input voltage of 38V to 55V, and provides up to 240W (9.6V and above) of power in an industry standard eighth brick footprint. Typical efficiency of 9.6V module is 96.5%. With optimized component placement, creative design topology, and numerous patented technologies, the E48SB bus converters deliver outstanding electrical and thermal performance. An optional heatsink is available for harsh thermal requirements. Positive On/Off logic Short pin lengths Heatsink available for extended operation OTP and OCP mode (Auto re-restart or latch) APPLICATIONS Datacom / Netowrking Wireless Networks Optical Network Equipment Server and Data Storage Industrial/Testing Equipment DATASHEET DS_E48SB9R625_01232007 TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS E48SB9R625 (Standard) Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous 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-Off Voltage Threshold Turn-On Voltage Threshold Lockout Hysteresis Voltage Maximum Input Current No-Load Input Current Off Converter Input Current Inrush Current (I2t) Input Reflected-Ripple Current 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 Power Range Output DC Powert-Limit Inception Current share accuracy (2 units in parallel) 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) Leakage Current (for both remote on/off logic) GENERAL SPECIFICATIONS MTBF Weight Over-Temperature Shutdown DS_E48SB9R625_01232007 Refer to Figure 17 for the measuring point, Tc Typ. -40 -55 Max. Units 60 117 125 2250 Vdc °C °C Vdc 38 48 55 Vdc 35 33 1 36.5 34.5 2 38 36 3 Vdc Vdc Vdc 58 57 1 60 58.5 1.5 62 60 2.5 6.65 120 15 0.03 25 Vdc Vdc Vdc A mA mA A2s mA 38V Vin , 100% Load 80 7 P-P thru 12µH inductor, 5Hz to 20MHz 15 Vin=48V, Io=no load, Ta=25°C 9.5 Io=Io,min to Io,max Vin=38V to 55V Tc=-40°C to 100°C Over sample load, line and temperature 5Hz to 20MHz bandwidth Full Load, 1µF ceramic, 10µF tantalum Full Load, 1µF ceramic, 10µF tantalum Full input voltage range Full input voltage range % of rated output current 300 3.4 400 3.6 200 11 mV V mV V 100 25 150 40 240 140% mV mV W W % 80 80 90 150 150 120 mV mV us 15 20 25 30 3000 ms ms µF 7.0 0 110% Vdc 10 48V, 10µF Tan & 1µF Ceramic load cap, 0.1A/µs 50% Io.max to 75% Io.max 75% Io.max to 50% Io.max 8 15 Vin=48V Vin=48V 96.5 96.0 % % 10 1000 2250 Vdc MΩ pF 130 kHz Von/off Von/off -0.7 2 0.8 18 V V Von/off Von/off Ion/off at Von/off=0.0V Logic High, Von/off=15V -0.7 2 0.8 18 0.3 30 V V mA uA Io=80% of Io, max; Ta=25°C Refer to Figure 17 for the measuring point, Tc 0.25 1.86 31.76 122 M hours grams °C 2 ELECTRICAL CHARACTERISTICS CURVES Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C Figure 2: Power loss vs. load current for minimum, nominal, and maximum input voltage at 25°C. 12 11 10 Output Voltage(V) 9 8 7 6 5 4 3 38Vin 2 48Vin 55Vin 1 0 0 3 6 9 12 15 18 21 24 27 30 Output Current(A) 33 36 39 42 45 Figure 3: Output voltage regulation vs load current showing typical current limit curves and converter shutdown points for minimum, nominal, and maximum input voltage at room temperature . DS_E48SB9R625_01232007 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Turn on Waveform 0 0 Figure 4: Turn-on transient at full rated load current (5 ms/div). Top Trace: Vout; 5V/div; Bottom Trace: ON/OFF input: 2V/div 0 0 Figure 5: Turn-on transient at zero load current (5 ms/div). Top Trace: Vout: 5V/div; Bottom Trace: ON/OFF input: 2V/div For Vin Input Turn on Waveform 0 0 0 0 Figure 6: Turn-on transient at full rated load current (5 ms/div). Top Trace: Vout; 5V/div; Bottom Trace: Vin; 50V/div. DS_E48SB9R625_01232007 Figure 7: Turn-on transient at zero load current (5 ms/div). Top Trace: Vout: 5V/div; Bottom Trace: Vin; 50V/div. 4 ELECTRICAL CHARACTERISTICS CURVES 0 0 0 0 Figure 8: Output voltage response to step-change in load current (50%-75%-50% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF, tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (100mV/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. Figure 9: Output voltage response to step-change in load current (50%-75%-50% of Io,max; di/dt=1A/µs). Load cap: 10uF ,tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (200mV/div, 100us/div), Bottom Trace: Iout (5A/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 10: 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 below DS_E48SB9R625_01232007 5 ELECTRICAL CHARACTERISTICS CURVES 0 0 Figure 11: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 10µH source impedance and 47µF electrolytic capacitor (200 mA/div, 2us/div). Figure 12: Input reflected ripple current, is, through a 10µH source inductor at nominal input voltage and rated load current (20 mA/div, 2us/div). Copper Strip Vo(+) 10u 1u SCOPE RESISTIVE LOAD Vo(-) Figure 13: Output voltage noise and ripple measurement test setup. DS_E48SB9R625_01232007 0 Figure 14: Output voltage ripple at nominal input voltage and rated load current (50 mV/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. 6 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 220µF electrolytic capacitor (ESR < 0.5 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. 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. 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-restart. 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. 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. Vi(+) FEATURES DESCRIPTIONS Vo(+) R ON/OFF Load 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, which is optional. Vi(-) Vo(-) Figure 15: Remote on/off implementation 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. 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. DS_E48SB9R625_01232007 7 DESIGN CONSIDERATIONS Current Sharing The modules are capable of operating in parallel without any external current sharing circuitry. For a normal parallel operation, the following precautions must be observed: 1. The current sharing accuracy calculation equation is: Current sharing accuracy=((I load/n)-I)*100%)/I rated Where, I load=Total load current; I= Output current of per converter; Irated=Converter’s rated output current at different Vin; n=the numberous of parallel modules 2. The maximum load current for N converters is Imax=(1-X%)*N*Irated. Where, X% is current sharing load accuracy. Irated is 100% load for different Vin This unit has been tested with up to 2 units in parallel. 3. To ensure a better steady current sharing accuracy, below design guideline should be followed: a) The inputs of the converters must be connected to the same voltage source b) The PCB trace resistance from Input voltage source to Vin+ and Vin- of each converter should be as equalize as possible. c) The PCB trace resistance from each converter’s output to the load should be equalized as much as possible. 4. To ensure a better transient current sharing, and the monotonic startup of the parallel module a) The ON/OFF pin of the converters should be connected together to keep the parallel modules start up at the approximately same time. b) The under voltage lockout point will slightly vary from unit to unit. The dv/dt of the rising edge of the input source voltage must be greater than 1V/ms to ensure that the parallel can start up at the approximately same time. DS_E48SB9R625_01232007 8 THERMAL CONSIDERATIONS THERMAL CURVES 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. Figure 17: Temperature measurement location The allowed maximum hot spot temperature is defined at 117℃ Output Current(A) E48SB9R625(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation) 25 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 FACING PWB Natural Convection 20 100LFM 15 200LFM 300LFM 400LFM 10 500LFM 5 MODULE 0 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 18: Output current vs. ambient temperature and air velocity@Vin=48V (Transverse Orientation). 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 16: 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_E48SB9R625_01232007 9 MECHANICAL DRAWING Pin No. Name Function 1 2 3 4 5 -Vin ON/OFF +Vin +Vout -Vout Negative input voltage Remote ON/OFF Positive input voltage Positive output voltage Negative output voltage Pin Specification: Pins 1-3 1.0mm (0.040”) diameter Pins 4-5 1.5mm (0.060”) diameter All pins are copper with Tin plating (Pb free) DS_E48SB9R625_01232007 10 PART NUMBERING SYSTEM E 48 S B 9R6 25 N R Type of Product Input Voltage Number of Outputs Product Series Output Voltage Output Current ON/OFF Logic Pin Length 48- 38V~55V S- Single 9R6- 9.6V 25- 25A N- Negative R- 0.170” F- RoHS 6/6 A- OCP, OTP P- Positive N- 0.145” (Lead Free) hiccup E- Eighth B- Bus Brick Converter F A Option Code K- 0.110” B- OCP, OTP latch-up MODEL LIST MODEL NAME E48SB9R625NRFA E48SB12020NRFA INPUT 38V~55V 38V~55V OUTPUT 6.65A 6.5A 9.6V 12V 25A 20A EFF @ 100% LOAD 240W 240W 96.5% 96.3% Note: 1. 2. 3. 4. Default remote on/off logic is negative; Default Pin length is 0.170”; Default OTP and output OVP, OCP mode is auto-restart. For different option, please refer to part numbering system above or contact your local sales office. 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: Telephone: +41 31 998 53 11 Fax: +41 31 998 53 53 Email: [email protected] Asia & the rest of world: Telephone: +886 3 4526107 x 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_E48SB9R625_01232007 11