Delta Electronics 33W Family User's Manual

Delphi Series S48SA, 33W Family

DC/DC Power Modules: 48V in, 1.8V/12A out

The Delphi Series S48SA, surface mountable, 48V input, single output, isolated DC/DC converter is the latest offering from a world leader in power system and technology and manufacturing – Delta

Electronics, Inc. This product family provides up to 33 watts of power or up to 12A of output current (for output voltage 1.8V or below). 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.

FEATURES

High efficiency: 88.5% @ 1.8V/ 12A

Size: 47.2mm x 29.5mm x 8.35mm

(1.86" x 1.16" x 0.33")

Low profile: 0.33"

Industry standard footprint and pin out

Surface mountable

Fixed frequency operation

Input UVLO, Output OCP, OVP

No minimum load required

2:1 input voltage range

Basic insulation

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

OPTIONS

Positive on/off logic

Through hole version

APPLICATIONS

Telecom/DataCom

Wireless Networks

Optical Network Equipment

Server and Data Storage

Industrial/Test Equipment

DATASHEET

DS_S48SA1R812_06012006

Delta Electronics, Inc.

TECHNICAL SPECIFICATIONS

(T

A

=25°C, airflow rate=300 LFM, V in

=48Vdc, nominal Vout unless otherwise noted.)

PARAMETER

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

Maximum Input Current

No-Load Input Current

Off Converter Input Current

Inrush Current(I 2 t)

Input Reflected-Ripple Current

Input Voltage Ripple Rejection

OUTPUT CHARACTERISTICS

Output Voltage Set Point

Output

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 to 1% of Final value

Turn-On Transient

Start-Up Time, From On/Off Control

Start-Up Time, From Input

Maximum Output Capacitance

EFFICIENCY

100% Load

ISOLATION CHARACTERISTICS

Isolation Voltage

Isolation Resistance

Isolation Capacitance

FEATURE CHARACTERISTICS

Switching Frequency

ON/OFF Control, (Logic Low-Module ON)

Logic Low

Logic High

ON/OFF Current

Leakage Current

Output Voltage Trim Range

Output Over-Voltage Protection(Hiccup)

GENERAL SPECIFICATIONS

MTBF

Weight

Over-Temperature Shutdown

NOTES and CONDITIONS

100ms

Refer to Figure 18 for measuring point

1 minute

100% Load, 36Vin

P-P thru 12µH inductor, 5Hz to 20MHz

120 Hz

Vin=48V, Io=50%Io.max, Ta=25℃

Io=Io,min to Io,max

Vin=36V to75V

Ta=-40C to 85C

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

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

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 Trim Pin & +Vo or –Vo, Pout≦max rated

Over full temp range; % of nominal Vout

Io=80% of Io, max; Tc=40°C

Refer to Figure 18 for measuring point

S48SA1R812NRFA

Min. Typ. Max. Units

Vdc

-40

-55

1500

36 48

100

100

125

75

Vdc

°C

°C

Vdc

V

32.5 34 35.5 V

30.5 32 33.5 V

1 2 3 V

1.73

0

30

7

0.01

5

50

0.85 A mA mA

A 2 s mA dB

1.77 1.80 1.83 V

0

13.2

86

1500

10

±2

±2

100

30

5

15.6

35

35

200

6

6

88

1500

330

±10

±5

300

1.87

75

20

12

18

100

100

12

12

2200

0.8

15

1

50 mV mV ppm/℃

V mV mV

A

A mV mV

µs ms ms

µF

%

V

MΩ pF kHz

V

V mA uA

-10

115 125

6.29

+10

140

%

%

M hours

115 °C

2

DS_S48SA1R812_06012006

ELECTRICAL CHARACTERISTICS CURVES

95

4.0

90 3.5

85 3.0

80 2.5

75

2.0

70

1.5

65

60

36Vin

48Vin

75Vin

1.0

36Vin

48Vin

75Vin

0.5

55

1 2 3 4 5 6 7 8 9 10 11 12

OUTPUT CURRENT (A)

0.0

1 2 3 4 5 6 7 8 9 10 11 12

OUTPUT CURRENT (A)

Figure 1:

Efficiency vs. load current for minimum, nominal, and

Figure maximum input voltage at 25 ° C.

nominal, and maximum input voltage at 25 ° C.

0.8

0.7

Io=12A

Io=7.2A

Io=1.2A

0.6

0.5

0.4

0.3

0.2

0.1

0.0

30 35 40 45 50 55 60 65 70 75

INPUT VOLT AGE (V)

Figure 3: Typical input characteristics at room temperature. Figure Turn-on transient at full rated load current (1 ms/div).

Top Trace: Vout (500mV/div); Bottom Trace: ON/OFF Control

(5V/div).

3

DS_S48SA1R812_06012006

ELECTRICAL CHARACTERISTICS CURVES

Figure5 :

Turn-on transient at zero load current (1 ms/div). Top

Trace: Vout (500mV/div); Bottom Trace: ON/OFF Control

(5V/div). current (50%-75% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF,

100 m Ω ESR tantalum capacitor and 1µF ceramic capacitor.

Top Trace: Vout (50mV/div), Bottom Trace: Iout (5A/div).

Figure 7 :

Output voltage response to step-change in load Figure 8: Test set-up diagram showing measurement points current (75%-50% of Io, max; di/dt = 0.1A/µs). Load cap:

10µF, 100 m Ω ESR tantalum capacitor and 1µF ceramic for Input Reflected Ripple Current (Figure 9).

Note: Measured input reflected-ripple current with a simulated capacitor. Top Trace: Vout (50mV/div), Bottom Trace: Iout

5A/div).

source Inductance (L

TEST

) of 12 µH. Capacitor Cs offset possible battery impedance.

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DS_S48SA1R812_06012006

ELECTRICAL CHARACTERISTICS CURVES

Vo(+)

Vo(-)

Copper Strip

10u 1u

SCOPE RESISTIVE

LOAD

Figure 9 :

Input Reflected Ripple Current, is, at full rated output current and nominal input voltage with 12 µ H source impedance and 33 µ F electrolytic capacitor (2 mA/div).

setup. 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.

2.1

1.8

1.5

1.2

0.9

0.6

0.3

Vin=48V

0.0

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

LOAD CURRENT (A)

Figure 11: Output voltage ripple at nominal input voltage and rated load current (20 mV/div). Load capacitance: 1 µ F ceramic capacitor and 10 µ F tantalum capacitor. Bandwidth: 20 MHz.

Figure 12: Output voltage vs. load current showing typical current limit curves and converter shutdown points.

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DS_S48SA1R812_06012006

DESIGN CONSIDERATION

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. these issues are pending release.

Application notes to assist designers in addressing

Safety Considerations

The power module must be installed in compliance with the spacing and separation requirements of the enduser’s safety agency standard if the system in which the power module is to be used must meet safety agency requirements.

When the input source is 60Vdc or below, 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 any hazardous voltages, including the ac mains, with reinforced insulation.

One Vi pin and one Vo pin are grounded, or all the input and output pins are kept floating.

The input terminals of the module are not operator accessible.

A SELV reliability test is conducted on the system where the module is used to ensure that under a single fault, hazardous voltage does not appear at the module’s output.

Do not ground one of the input pins without grounding one of the output pins. This connection may allow a non-SELV voltage to appear between the output pin and ground.

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 3A 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.

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DS_S48SA1R812_06012006

FEATURES DESCRIPTIONS

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 (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 overvoltage 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.

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 overtemperature 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.

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 to floating.

Sense(-)

Vi(-) Vo(-)

Contact

Resistance

Figure 14: E ffective 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.

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DS_S48SA1R812_06012006

Vi(+) Vo(+)

Sense(+)

ON/OFF

Sense(-)

Vi(-) Vo(-)

Figure 13: Remote on/off implementation

Remote Sense (Optional)

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).

Vi(+) Vo(+)

Sense(+)

O utput Voltage Adjustment (TRIM)

T o increase or decrease the output voltage set point, the modules may be connected with an external resistor between the TRIM pin and either the Vo+ or Vo -. The

TRIM pin should be left open if this feature is not used.

Rtrim

−

up

=

23 .

8 ( 100

+ ∆

Vo

∆

Vo

%

%)

−

1089

−

104

[ ]

Ex. When trim-up +10% (1.8V X 1.1 = 1.98V)

Rtrim

−

up

=

23 .

8 ( 100

+

10

10

)

−

1089

−

104

=

48 .

9

C are should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power.

Figure 15:

Circuit configuration for trim-down (decrease output voltage)

If the external resistor is connected between the TRIM and Vo- pins, the output voltage set point decreases.

The external resistor value required to obtain a percentage of output voltage change △Vo% is defined as:

Rtrim

−

down

=

1089

∆

Vo

%

−

104

[ ]

E x. When trim-down –10% (1.8V X 0.9 = 1.62V)

Rtrim

−

down

=

1089

10

−

104

=

4 .

9

[ ]

Figure 16: Circuit configuration for trim-up (increase output voltage)

If the external resistor is connected between the TRIM and Vo+ the output voltage set point increases. The external resistor value required to obtain a percentage output voltage change △Vo% is defined as:

DS_S48SA1R812_06012006

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 or a heat sink is

6.35mm (0.25”).

Thermal Derating

Heat can be removed by increasing airflow over the module. Figure 18 and 19 show maximum output is a function of ambient temperature and airflow rate. 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.

FACING PWB PWB

MODULE

THERMAL CURVES

12

10

8

6

4

2

Natural

Convection

100LFM

200LFM

300LFM

400LFM

0

65 70 75 80 85 90 95 100

Ambient Temperature (℃)

Figure 19: Output current vs. ambient temperature and air velocity

@V in

< 60 V

AIR VELOCITY

AND AMBIENT

TEMPERATURE

MEASURED BELOW

THE MODULE 50.8 (2.0”)

Figure 18: Hot spot temperature measured point

＊ The allowed maximum hot spot temperature is defined at

110 ℃

14

Output Current(A)

S48SA1R812(Standard) Output Current vs. Ambient Temperature and Air Velocity

@ Vin < 60V

600LFM

500LFM

AIR FLOW

10 (0.4”)

Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches)

Figure 17:

Wind tunnel test setup

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DS_S48SA1R812_06012006

PICK AND PLACE LOCATION SURFACE-MOUNT TAPE & REEL

RECOMMENDED PAD LAYOUT (SMD)

10

DS_S48SA1R812_06012006

LEADED (Sn/Pb) PROCESS RECOMMEND TEMP. PROFILE

250

200

2nd Ramp-up temp.

1.0~3.0°C /sec.

Peak temp.

210~230°C 5sec.

Pre-heat temp.

140~180°C 60~120 sec.

Cooling down rate <3°C /sec.

150

Ramp-up temp.

0.5~3.0°C /sec.

100

Over 200°C

40~50sec.

50

60

Time ( sec. )

180

Note: The temperature refers to the pin of S48SA, measured on the pin +Vout joint.

LEAD FREE (SAC) PROCESS RECOMMEND TEMP. PROFILE

Temp

.

Peak Temp. 240 ~ 245 ℃

217℃

200℃

Ramp down

max. 4℃/sec.

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 S48SA, measured on the pin +Vout joint.

DS_S48SA1R812_06012006

11

MECHANICAL DRAWING

SMD Through-Hole

Pin No.

1

2

6

Name

+Vout

-Vout

Trim

8 ON/OFF

11 -Vin

12 +Vin

Optional Pin Name

4 +Sense (Option)

5

9

-Sense (Option)

NC

Function

Positive output voltage

Negative output voltage

Output voltage trim

Negative input voltage

Positive input voltage

Function

Positive sense pin

Negative sense pin

No connection

DS_S48SA1R812_06012006

12

PART NUMBERING SYSTEM

S 48 S A 1R8 12 N R F

Form Input Number of Product Output Output

Factor Voltage Outputs Series Voltage Current

S- Small

Power

48V S- Single A- Advanced 1R2-1.2V

1R5-1.5V

1R8-1.8V

2R5-2.5V

3R3- 3.3V

050- 5.0V

120- 12V

03- 3.0V

06- 6.6A

10- 10A

12- 12A

* Option code A includes 9 pins. Pins 4, 5, and 9 have no connection

Option code B excludes pin 4, 5 , and 9 (total 6 pins).

.

Option code C features 9 pins with sense function.

ON/OFF

Logic

N- Negative

P- Positive

Pin Type

R- SMD

T-Through hole

F- RoHS 6/6

(Lead Free)

MODEL LIST

A*

Option

Code

A- 9 pin, no sense

B- 6 pin, no sense

C- 9 pins with sense

(12V has option B only)

MODEL NAME INPUT OUTPUT EFF @ 100% LOAD

84.0%

88.0%

88.0%

88.5%

90.5%

90.5%

90.0%

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_S48SA1R812_06012006