FEATURES High Efficiency: 90.5% @ 1.8V/25A Size: 58.4mmx22.8mmx8.35mm (2.30”x0.90”x0.33”) Industry standard pin out SMT and through-hole versions Fixed frequency operation: 350KHz Input UVLO, Output OCP, OVP, OTP Basic insulation No minimum load required 2:1 Input voltage range ISO 9001, TL 9000, ISO 14001, QS 9000, OHSAS 18001 certified manufacturing facility UL/cUL 60950 (US & Canada) recognized, TUV (EN60950) certified CE mark meets 73/23/EEC and 93/68/EEC directives Delphi Series E48SR, 66W Eighth Brick Family DC/DC Power Modules: 48V in, 1.8V/25A out The Delphi Series E48SR Eighth Brick, 48V input, single output, isolated DC/DC converter is the latest offering from a world leader in power systems technology and manufacturing -- Delta Electronics, Inc. This product family is available in a surface mount or through-hole package and provides up to 66 watts of power or 25A of output current (1.8V and below) in an industry standard footprint. With creative design technology and optimization of component placement, these converters possess outstanding electrical and thermal performances, as well as extremely high reliability under highly stressful operating conditions. All models are fully protected from abnormal input/output voltage, current, and temperature conditions. The Delphi Series converters meet all safety requirements with basic insulation. OPTIONS SMT or through-hole versions Positive On/Off logic Short pin lengths available APPLICATIONS Telecom/Datacom Wireless Networks Optical Network Equipment Server and Data Storage Industrial/Testing Equipment DATASHEET DS_E48SR1R825_02272007 TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted) PARAMETER NOTES and CONDITIONS E48SR1R825 (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-Off Voltage Threshold Turn-On Voltage Threshold 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 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 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) Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection GENERAL SPECIFICATIONS MTBF Weight Over-Temperature Shutdown DS_E48SR1R825_02272007 100ms Refer to fig. 21 for the measuring point Typ. -40 -55 36 Max. Units 75 100 107 125 1500 Vdc Vdc °C °C Vdc 75 Vdc 33 31 1.5 34 32 2 35 33 2.5 Vdc Vdc Vdc 100 97 105 102 107 104 1.5 Vdc Vdc A mA mA A2s mA dB 100% Load, 36Vin 40 4 1 P-P thru 12µH inductor, 5Hz to 20MHz 120 Hz Vin=48V, Io=Io.max, Tc=25°C Io=Io, min to Io, max Vin=36V to 75V Tc=-40°C to 85°C Over sample load, line and temperature 5Hz to 20MHz bandwidth Full Load, 1µF ceramic, 10µF tantalum Full Load, 1µF ceramic, 10µF tantalum Output Voltage 10% Low 15 60 1.773 1.8 1.827 Vdc ±3 ±3 ±15 ±10 ±10 1.836 mV mV mV V 75 25 25 150 mV mV A % 1.764 40 12 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 80 80 150 mV mV us 7.5 7.5 ms ms µF Full load; 5% overshoot of Vout at startup 15000 90.5 90 % % 1500 Vdc MΩ pF 350 kHz 1500 10 Von/off at Ion/off=1.0mA Von/off at Ion/off=0.0 µA Von/off at Ion/off=1.0mA Von/off at Ion/off=0.0 µA Ion/off at Von/off=0.0V Logic High, Von/off=15V Across Pins 9 & 5, Pout ≦ max rated power Pout ≦ max rated power Over full temp range; % of nominal Vout Io=80% of Io, max; Tc=40°C Average PCB Temperature 0.7 18 V V 0.7 18 1 50 10% 10 2.2 V V mA uA % % V 4.54 19.6 119 M hours grams °C 2 2 -10% 2 ELECTRICAL CHARACTERISTICS CURVES Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C 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_E48SR1R825_02272007 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Logic 0 0 0 0 Figure 5: Turn-on transient at zero load current (2 ms/div). Vin=48V Top Trace: Vout, 0.5V/div; Bottom Trace: ON/OFF input, 5V/div Figure 4: Turn-on transient at full rated load current (resistive load) (2 ms/div). Vin=48V Top Trace, Vout, 0.5V/div; Bottom Trace: ON/OFF input, 5V/div For Positive Remote On/Off Logic 0 0 0 0 Figure 6: Turn-on transient at full rated load current (resistive load) (2 ms/div). Vin=48V Top Trace: Vout, 0.5V/div; Bottom Trace: ON/OFF input, 5V/div DS_E48SR1R825_02272007 Figure 7: Turn-on transient at zero load current (2 ms/div). Vin=48V Top Trace: Vout, 0.5V/div; Bottom Trace: ON/OFF input, 5V/div 4 ELECTRICAL CHARACTERISTICS CURVES 0 0 0 0 Figure 8: Output voltage response to step-change in load current (75%-50%-75% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (50mV/div, 200us/div), Bottom Trace: I out (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 9: Output voltage response to step-change in load current (75%-50%-75% of Io, max; di/dt = 2.5A/µs). Load cap: 470µF, 35mΩ ESR solid electrolytic capacitor and 1µF ceramic capacitor. Top Trace: Vout (50mV/div, 200us/div), Bottom Trace: I out (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 above DS_E48SR1R825_02272007 5 ELECTRICAL CHARACTERISTICS CURVES 0 0 Figure 11: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 12µH source impedance and 33µF electrolytic capacitor (500 mA/div, 2us/div) Figure 12: Input reflected ripple current, is, through a 12µH 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_E48SR1R825_02272007 6 ELECTRICAL CHARACTERISTICS CURVES 0 Figure 14: Output voltage ripple at nominal input voltage and rated load current (Io=25A)(10 mV/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_E48SR1R825_02272007 Figure 15: 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 10 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. 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 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: DS_E48SR1R825_02272007 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 2A 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 Vi(+) 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). 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. 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 module will shut down (Hiccup mode). The modules will try to restart after shutdown. If the fault condition still exists, the module will shut down again. This restart trial will continue until the fault condition is corrected. Vo(+) ON/OFF Sense(-) Vi(-) Vo(-) Figure 16: 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). 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 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 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. Vi(+) Vo(+) Sense(+) Sense(-) Contact Resistance Vi(-) Vo(-) Contact and Distribution Losses Figure 17: 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. 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. 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. 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. 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_E48SR1R825_02272007 9 FEATURES DESCRIPTIONS (CON.) 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. Figure 19: Circuit configuration for trim-up (increase output voltage) Figure 18: 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. 26). The external resistor value required to obtain a percentage of output voltage change △% is defined as: ⎡ 511 ⎤ Rtrim − down = ⎢ − 10 .2 ⎥ (K Ω ) ∆ ⎣ ⎦ Ex. When Trim-down -10%(1.8V×0.9=1.62V) ⎡ 511 ⎤ Rtrim − down = ⎢ − 10 .2 ⎥ (K Ω ) = 40 .9 (K Ω ) 10 ⎣ ⎦ If the external resistor is connected between the TRIM and SENSE (+) the output voltage set point increases (Fig. 27). The external resistor value required to obtain a percentage output voltage change △% is defined as: Rtrim − up = 5 . 11 Vo (100 + ∆ ) 511 − − 10 . 2 (K Ω ) 1.225 ∆ ∆ Ex. When Trim-up +10%(1.8V×1.1=1.98V) Rtrim − up = 5 .11 × 1 .8 × (100 + 10 ) 511 − − 10 .2 = 21 .29 (K Ω ) 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. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. DS_E48SR1R825_02272007 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 hottest point temperature of the module is +107°C.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 21: Hot spot temperature measured point The allowed maximum hot spot temperature is defined at 107℃ E48SR1R825(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation) PWB FACING PWB MODULE Output Current(A) 25 Natural Convection 20 100LFM 15 AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE 200LFM 10 300LFM 50.8 (2.0”) AIR FLOW 5 0 12.7 (0.5”) Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 22: Output current vs. ambient temperature and air velocity@Vin=48V(Transverse Orientation) Figure 20: Wind tunnel test setup DS_E48SR1R825_02272007 11 PICK AND PLACE LOCATION SURFACE-MOUNT TAPE & REEL RECOMMENDED PAD LAYOUT (SMD) DS_E48SR1R825_02272007 12 LEADED (Sn/Pb) PROCESS RECOMMEND TEMP. PROFILE 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 E48SR, measured on the pin +Vout joint. LEAD FREE (SAC) PROCESS RECOMMEND TEMP. PROFILE 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 E48SR, measured on the pin +Vout joint. DS_E48SR1R825_02272007 13 MECHANICAL DRAWING Surface-mount module Pin No. 1 2 3 4 5 6 7 8 Name +Vin ON/OFF -Vin -Vout -SENSE TRIM +SENSE +Vout DS_E48SR1R825_02272007 Through-hole module 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 14 PART NUMBERING SYSTEM E 48 Type of Product E - Eighth Brick S R Input Number of Product Voltage Outputs Series 48V S - Single R- Regular 1R8 25 N R Output Voltage Output Current ON/OFF Logic Pin Length/Type 1R8 - 1.8V 25 - 25A N- Negative (Default) P- Positive R - 0.170” (Default) N - 0.145” K - 0.110” M - SMD pin F A Option Code F- RoHS 6/6 (Lead Free) A – Standard functions MODEL LIST MODEL NAME E48SR1R225NRFA E48SR1R525NRFA E48SR1R825NRFA E48SR2R520NRFA E48SR3R320NRFA E48SR05012NRFA E48SR12005NRFA E48SR12007NRFA E48SR15004NRFA INPUT 36V~75V 36V~75V 36V~75V 36V~75V 36V~75V 36V~75V 36V~75V 36V~75V 36V~75V OUTPUT 1.3A 1.5A 1.8A 1.9A 2.5A 2.1A 2.2A 3.0A 2.2A 1.2V 1.5V 1.8V 2.5V 3.3V 5.0V 12V 12V 15V EFF @ 100% LOAD 25A 25A 25A 20A 20A 12A 5A 7A 4A 88.0% 89.5% 90.5% 89.0% 90.5% 91.5% 92.0% 93.0% 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: 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_E48SR1R825_02272007 15