FEATURES High efficiency: 90.5% @ 12V/4A Size: 58.4x22.8x8.73mm (2.30”x0.90”x0.34”) Standard footprint Industry standard pin out Fixed frequency operation Input UVLO, Output OCP, OVP, OTP 1500V isolation and basic insulation ISO 9001, TL 9000, ISO 14001, QS9000, OHSAS18001 certified manufacturing facility UL/cUL 60950-1 (US & Canada) recognized Delphi E36SR Series DC/DC Power Modules: 18~60 in, 12V/4A out, 48W OPTIONS The Delphi E36SR series, Eighth brick sized, 24V/48V input, single Positive On/Off logic output, isolated DC/DC converter, is the latest offering from a world leader in power system technology and manufacturing ― Delta Electronics, Inc. The E36SR12V provides up to 48 watts of power in an industry standard footprint and pinout. 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 APPLICATIONS requirements with basic insulation. Telecom/Datacom Wireless Networks Optical Network Equipment Server and Data Storage Industrial/Test Equipment DATASHEET DS_E36SR12004_10292013 TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=300 LFM, Vin=24/48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS E36SR12004 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 2 Inrush Current (I t) 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 Over Current Protection 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 Io from2.8A o 4A 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 Over-Voltage Protection GENERAL SPECIFICATIONS MTBF Units 60 100 85 125 1500 Vdc Vdc °C °C Vdc 60 Vdc 18 16 3 3.5 120 10 1 Vdc Vdc Vdc A mA mA 2 As mA dB 12.000 12.180 Vdc ±24 ±24 ±48 ±48 ±180 12.2 mV mV mV Vdc 50 100 25 4 5.6 mV mV A A 200 200 100 400 400 mV mV us 15 15 25 25 2000 ms ms µF -40 -55 18 16 14 1 17 15 2 30 3 60 100% Load, 18Vin 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=18V to 60V 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 20 50 11.820 11.8 0.4 4.4 48V, 10µF Tan & 1µF Ceramic load cap, 0.1A/µs 50% Io.max to 75% Io.max 75% Io.max to 50% Io.max Full load; 5% overshoot of Vout at startup Vin From 18v to 55v 89.5 . % 1500 10 1000 Vdc MΩ pF 300 kHz Von/off at Ion/off=1.0mA Von/off at Ion/off=0.0 µA 0 3 0.8 12 V V 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=12V 0 3.5 0.8 12 1 50 V V mA uA 13.2 16.8 V Over full temp range; Io=100% of Io, max; Ta=25°C, airflow rate=200FLM Refer to Figure 21 for Hot spot location (48Vin,80%Io, 200LFM,Airflow from Vin- to Vin+) Over-Temperature Shutdown (NTC Resistor) Refer to Figure 21 for NTC resistor location Note: Please attach thermocouple on NTC resistor to test OTP function, the hot spot’s temperature is just for reference. DS_E36SR12004_10292013 Max. 100ms Weight Over-Temperature Shutdown (Hot Spot) Typ. 6.48 M hours 22.9 Grams 124 °C 120 °C 2 ELECTRICAL CHARACTERISTICS CURVES 5.5 90 5.0 88 4.5 86 4.0 84 LOSS(W) EFFICIENCY(%). 92 82 80 18V 24V 55V 48 78 76 3.5 3.0 2.5 18V 24V 55V 48v 2.0 1.5 74 1.0 72 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 4.4 OUTPUT CURRENT(A) 0.0 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 4.4 OUTPUT CURRENT(A) Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C, 300LFM airflow. Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25°C, 300LFM airflow. 3.6 INPUT CURRENT(A) 3.2 2.8 2.4 2.0 1.6 1.2 0.8 0.4 0.0 12 17 22 27 32 37 42 INPUT VOLTAGE(V) 47 52 57 Figure 3: Typical full load input characteristics at 25°C DS_E36SR12004_10292013 3 ELECTRICAL CHARACTERISTICS CURVES For Input Voltage On/Off Figure 4: Turn-on transient at full rated load current (5ms/div). Vin=48V. Top Trace: Input Voltage, 20V/div; Bottom Trace: Vout, 5V/div Figure 5: Turn-on transient at min load current (5ms/div). Vin=48V. Top Trace: Input Voltage, 20V/div; Bottom Trace: Vout, 5V/div For negative On/Off Logic Figure 6: Turn-on transient at full rated load current (5ms/div) for negative on/off mode. Vin=48V. Top Trace: Vout, 5V/div; Bottom Trace: ON/OFF input, 5V/div DS_E36SR12004_10292013 Figure 7: Turn-on transient at min load current (5ms/div) for negative on/off mode. Vin=48V. Top Trace: Vout, 5V/div; Bottom Trace: ON/OFF input, 5V/div 4 ELECTRICAL CHARACTERISTICS CURVES Figure 8: Output voltage response to step-change in load current (75%-50%-75% of Io, max; di/dt = 0.01A/µs). Load cap: 10µF tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (0.1V/div, 1ms/div), Bottom Trace: Iout (1A/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: 47µF, 35m ESR solid electrolytic capacitor and 1µF ceramic capacitor. Top Trace: Vout (0.1 V/div, 1ms/div), Bottom Trace: Iout (1A/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. Measured current as shown below Figure 11: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 12µH source impedance and 33µF electrolytic capacitor (200mA/div, 2us/div) DS_E36SR12004_10292013 5 ELECTRICAL CHARACTERISTICS CURVES Copper Strip Vo(+) 10u SCOPE 1u RESISTIVE LOAD Vo(-) Figure 12: Input reflected ripple current, is, through a 12µH source inductor at nominal input voltage and rated load current (100 mA/div, 2us/div) Figure 13: Output voltage noise and ripple measurement test setup 13 12 OUTPUT VOLTAGE(V) 11 10 9 8 7 6 5 4 3 2 0.4 0.9 1.4 1.9 2.4 2.9 3.4 3.9 4.4 4.9 5.4 5.9 OUTPUT CURRENT(A) Figure 14: Output voltage ripple at nominal input voltage and rated load current (Io=4A)(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_E36SR12004_10292013 Figure 15: Output voltage vs. load current showing typical current limit curves and converter shutdown points 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 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 to 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., UL60950-1, 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 60 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 60 Vdc, for the module’s output to meet SELV requirements, all of the following must be met: DS_E36SR12004_10292013 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. 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 (SELV) outputs when all inputs are SELV. 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 10A 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 are 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. 7 FEATURES DESCRIPTIONS Vi(+) Over-Current Protection Sense(+) ON/OFF 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. 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 Over-Temperature Protection Vi(+) Vo(+) Sense(+) 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. Vo(+) Sense(-) Vi(-) Contact Resistance Vo(-) Contact and Distribution Losses Figure 17: Effective circuit configuration for remote sense operation 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 logic high. Positive logic turns the modules on during logic high and off during 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. DS_E36SR12004_10292013 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 the remote sense; When using the remote sense 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. 8 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. 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: Rtrim up 5.1Vo (100 ) 510 10K 1.225 Ex. When Trim-up +10% (12V×1.1=13.2V) Rtrim up 5.1 12 (100 10 ) 510 10 488.55K 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. 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. 18). The external resistor value required to obtain a percentage of output voltage change △% is defined as: Rtrim down 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. 510 10K Ex. When Trim-down -20% (12V×0.8=9.6V) 510 Rtrim down 10 15.5K 20 Figure 19: Circuit configuration for trim-up (increase output voltage DS_E36SR12004_10292013 9 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. THERMAL CURVES NTC RESISTOR HOT SPOT 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’’). AIRFLOW Figure 21: * Hot spot& NTC resistor temperature measured points. Output Current (A) 4.5 E36SR12004(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 24V (Transverse Orientation) 4.0 3.5 Natural Convection 3.0 100LFM 200LFM 2.5 300LFM 2.0 400LFM 1.5 PWB FANCING PWB 1.0 MODULE 0.5 0.0 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 22: Output current vs. ambient temperature and air velocity@Vin=24V (Transverse orientation,airflow from Vin- to Vin+) 50.8(2.00") AIR VELOCITY AND AMBIENT TEMPERATURE SURED BELOW THE MODULE Output Current (A) 4.5 E36SR12004(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation) 4.0 AIR FLOW Natural Convection 3.5 100LFM 3.0 200LFM Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) 2.5 300LFM 2.0 Figure 20: 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_E36SR12004_10292013 1.5 1.0 0.5 0.0 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature (℃) Figure 23: Output current vs. ambient temperature and air velocity@Vin=48V (Transverse orientation, airflow from Vin- to Vin+) 10 MECHANICAL DRAWING (WITHOUT HEAT SPREADER) NOTE: have a typical height of the lowest component (who has to dissipate) of 7.25mm with a tolerance plus max height module/minus 0 mm. Pin No. 1 2 3 4 5 6 7 8 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 underplating. DS_E36SR12004_10292013 11 PART NUMBERING SYSTEM E 36 S R 120 04 N K Form Input Number of Product Output Output ON/OFF Pin Factor Voltage Outputs Series Voltage Current Logic Length 24/48- S- Single 12V 4A N- Negative K-0.11’’ E- Eighth Brick 18V~60V R – Regular product F A Option Code Space- RoHs 5/6 A- Standard Functions F- RoHS 6/6 (Lead Free) 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: +31-20-655-0967 Fax: +31-20-655-0999 Email: [email protected] Asia & the rest of world: Telephone: +886 3 4526107 x 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_E36SR12004_10292013 12