Delta Electronics E48SR12007 User's Manual
Contents
1. m A PIN 1 mor 26 50 1 043 a T a 32 00 1 260 NN 00 0 157 hare SED CARRIER e 2 706 SS A u 9 be6906029 i b 6e9eoo04994 i i i c A i TaN dm Ee p pen m s LA i i G JI p S D S PE H B 3 Cat 7 TREE bE EE Oo 4 m Off 4 E Pat 1E at Q E i E dem SE o 200 pU DICID E in ad in S i m Y LL Lesen d BR a h EE eem Y i OO Eee A J EMBOSSED CARRIER 7 0 0 28 MIN AREA PICK AND PLACE LOCATION 330 0 13 00 13 0 0 51 n n NOTES f 5 uad EE ere ALL DIMENSIONS ARE IN MILLIMETERS AND INCHES v VELA WT SMPPED IN QUANTITIES OF 100 PER REEL TOLERANCES X Xmm 0 5mm X XX in 0 02 in WM TOLERANCES DEE T X XXmmzt0 25mm X XXX in X 0 010 in RECOMMENDED PAD LAYOUT SMD 58 4 2 30 3 8 0 Ol KS 50 80 2 000 O1 Vin mu i SENSE 7 O 02 ON OFF TRIM 6C SENSE 5C OS Vin Vout 40 2 60 0 102 PAL 8X 2 8 0 90 2 3 8 0 15 3 81 0 150 4X AJ ECOMENDED P W b PAD LAYOUT NOTES DIMENSIONS ARE IN MILLIMETERS AND INCHES TOLERANCES X Xmm 0 5mm X XX in 0 02 in X XXmmzt0 25mm X XXX in 0 010 in2. cooling of the power module is needed over the entire Heat can be removed by increasing airflow over the temperature range of the module Convection cooling is module To enhance system reliability the power module usually the dominant mode of heat transfer should always be operated below the maximum operating temperature If the temperature exceeds the maximum Hence the choice of equipment to characterize the module temperature reliability of the unit may be affected thermal performance of the power module is a wind tunnel THERMAL CURVES Thermal Testing Setup Delta s DC DC power modules are characterized in heated vertical wind tunnels that simulate the thermal k Tas d Siva O environments encountered in most electronics Aor a E E equipment This type of equipment commonly uses oak eg Kg vertically mounted circuit cards in cabinet racks in which d S ot o ol EM Pn the power modules are mounted 1 48 LL SR E ere n E The following figure shows the wind tunnel 8 3 characterization setup The power module is mounted Ose 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 x The allowed maximum hot spot temperature is defined at 115 C E48SR12007 Standard Output Current vs Ambient Temperature and Air Velocity
3. E48SR12007 05222008 S 11 LEADED Sn Pb PROCESS RECOMMEND TEMP PROFILE Peak temp 2nd Ramp up temp 210 230 C 5sec 1 0 3 0 C sec 250 Pre heat temp UR NNNM 140 180C 60 120sec ff 2 SR Ramp up temp gt Cooling down rate lt 3 C sec B 150 0 5 3 0 C sec g 100 Over 200 C E 50 40 50sec 0 60 120 180 240 300 Time sec Note The temperature refers to the pin of E48SR measured on the pin Vout joint LEAD FREE SAC PROCESS RECOMMEND TEMP PROFILE Temp TT Peak Temp 240 245 C 217 C pM Ramp down o max 4 C sec 200 E 150 C Preheat time 4 Doe Time Limited 90 sec above 217 C Ramp up max 3 C sec 25 C Time Note The temperature refers to the pin of E48SR measured on the pin Vout joint E48SR12007_05222008 12 MECHANICAL DRAWING WITHOUT HEATSPREADER Surface mount module Z Qf 5 6 0 1 LU EE 0 5 Nu cS V Z J bu 8 4 4778 af OW T N e RQ Al BO d C ZZ Ol o C5 3t J a u C oop 4 N 2 Pe J LO O fe C m s M Kap CO NN p E s oe ex 9 mm P D D Co G nmn Co Ee PE Sn 2 Jj OU 0U Z OOO S Co O We CO n B 00 HP NL Ne so es CS NO xl J j O0O N N UN mM lo Vin Vout 1 FAIL in B e B8 i d i SENSE n EK ON OFF TRIM i Vin TOP E AO o d Gem 00
4. Delphi Series E48SR12007 84W Eighth Brick DC DC Power Modules 48V in 12V 7A out The Delphi Series E48SR12007 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 provides 84 watts of power with 92 0 efficiency in an industry standard footprint With creative design technology and optimization of component placement this converter possesses outstanding electrical and thermal performances as well as extremely high reliability under highly stressful operating conditions All Delphi E48SR models are fully protected from abnormal input output voltage current temperature conditions and also meet all safety requirements with basic insulation DATASHEET DS E48SR12007 05222008 FEATURES High efficiency 92 0 12V 7A Size 58 4mmx22 80mmx8 4mm 2 30 x0 90 x0 33 Standard footprint Industry standard pin out 2 1 Input voltage range Fixed frequency operation Input UVLO Output OCP OVP OTP 2250V isolation and basic insulation No minimum load required ISO 9001 TL 9000 ISO 14001 QS9000 OHSAS 18001 certified manufacturing facility UL cUL 60950 1 US amp Canada recognized and TUV EN60950 1 certified CE mark meets 73 23 EEC and 93 68 EEC directive OPTIONS Positive On Off logic Short pin lengths SMD pin APPLICATIONS Te
5. Output Current A Vin 48V Transverse Orientation 7 0 FACING PWB PWB lt atural BU Convection C MODULE 5 0 100LFM 200LFM 10 300LFM 400LFM 3 0 500LFM AIR VELOCITY AND AMBIENT TEMPERATURE am MEASURED BELOW THE MODULE 50 8 2 0 10 0 0 20 25 30 35 40 45 50 55 60 65 70 5 75 80 8 Ambient Temperature C To Figure 22 Output current vs ambient temperature and air Note Wind Tunnel Test Setup Figure Dimensions are in millimeters and Inches velocity Vin 45V Transverse Orientation Figure 20 Wind tunnel test setup E48SR12007 05222008 P s 140 58 4 2 30
6. N Oz o geg eec co zl CO OD P GA bi 2 E DIA SOLDER PLATED DARK Aen 2 OOCO 080 E XX Neda x HEC AL NU CODPE ER SIDE KZ l VIF Z x Name Vin ON OFF Vin Vout SENSE TRIM SENSE Vout E48SR12007_05222008 fo 8X NOTES DIMENSIONS AR OLERANCES A Xx aN 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 Through hole module IN MIL AN LAM AUN a m OR 4 a bs Q A Z B CC e E a LO C LE A s NO S Of dE M ER ONLO ner TN CO E S E Je E 50 60 2 000 olol ojc 0O ela dona A x 4 N M N N j oO O d CN mE NO T Sc LO l o TViN Vout g 8 C SENSE 7 i i i A C3 2 6 ON OFF TRIM e 6 i IL Y OO SENSE 9 9 CN 3 yin Vout 4 9 5 5 mp X7 TAT P Vu TOI VIEW gU DCH NI CN 7 NE gt aas a ab ND gt Au ut C Ky METERS AND INCHES NOE 7 BN E D TS AMMLO SMM XXX in 0 02 in X XXmm zt0 25mm X XXX in 0 010 1 OK de e 4 C Kaz YA ch M aac e Ex e ju FN m A F PN ON p p M B5 IDE F J GW JN BOARD lca DE DL D H P 6X E are Aw a SER Ar en IEN POPNOD
7. X XX in x0 02 in X XXmmzi0 25mm X XXX in 0 010 in No excess than 2 0mm for screws PART NUMBERING SYSTEM E 4 S R mo o N R A Product Voltage Outputs Series Voltage Current Logic E Eighth 48V S Single R Regular 120 12V 07 7A N Negative R 0 170 F RoHS 6 6 Standard Brick Default Default Lead Free Functions P Positive N 0 145 perau K 0 110 H with Heat Spreader M SMD pin MODEL LIST OUTPUT 91 2 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 office E48SR05012NRFA 36V 75V CONTACT www delta com tw dcdc USA Europe Asia amp the rest of world Telephone Phone 41 31 998 53 11 Telephone 886 3 4526107 ext 6220 East Coast 888 335 8201 l Fax 886 3 4513485 West Coast 888 335 8208 eg EE Email DCDC delta com tw Fax 978 656 3964 Email DCDC delta es com Email DCDC delta corp com 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 otherw
8. 2 ko Ex When Trim down 10 12Vx0 9 10 8V Rtrim down E 10 22 ka 40 88 KQ E48SR12007_05222008 Vo Sense Trim Load Sense Vo Figure 19 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 obtaining a percentage output voltage change is defined as 5 l1xVox 100 A 511 Rtrim up SE 1022 KQ X Ex When Trim up 10 12 Vx1 1213 2V EE ten ee Se 1 225 x10 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 THERMAL CONSIDERATIONS Thermal management is an important part of the system Thermal Derating design To ensure proper reliable operation sufficient
9. ILIANIL II aOR 1 LOU U U OU jJ JAN ITH 2 0 0 08 JSHOULDER SOLDER PLATED COPPER i AL LA we WITT EI J H E E A ue d 5 0 107 SHOULDER VV N MECHANICAL DRAWING WITH HEATSPREADER THROUGH HOLE MODULE E48SR12007 05222008 4 0 0 16 7 50 40 1 984 M3X0 5 THREADED A N MOUNTING HOLES i Si SA MAN SCREW TORQUE 0 48 N m 4 3 Ib in no 3 0 0 12 MAX p Cp SCREW INSERTION LENGTH x O A S Ne c CO if 1 5 lI OP EW CO C2 CN LO 12 7 0 50 MAX 0 50 0 012 MIN Y v i i UJ L or W OARD Gi 1 00 0 040 DIA SOLDER PLATED COPPER F D gt 6X 1 50 0 060 DIA 2X KR WITH 2 5 0 10 SHOULDER SIDE VIEW 582 905 eno e A E 50 80 2 000 Vin Vouw Z C 3 4 i O gt SENSE 5 i CO 2 ics ORDER TRIM amp 6 00 SENSE 7 T i ch Ss wat 8 4 ER Sat Sait Gl O co NO XS lm mw Ny eel wl X f c ol Ei M ox IW o5 e Si ON NOTES IMENSIONS ARE IN MILLIM RS AND INCHES OLERANC ES X Xmmzt0 5mm
10. d 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 Ea MES 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 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 Over Temperature Protection The over temperature protec
11. e 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 EA8SR12007 05222008 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 ev 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 Il 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 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 boar
12. electrolytic capacitor and 1uF ceramic capacitor Top Trace Vout 0 2V div 200us div Bottom Trace lout 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 DES Mainzdk b gt Figure 11 Input Terminal Ripple Current ic at full rated output current and nominal input voltage with 12uH source impedance and 33uF electrolytic capacitor 500 mA div 2us div ELECTRICAL CHARACTERISTICS CURVES DES Mainzdk gt RESISTIV LOAD Figure 12 Input reflected ripple current is through a 12uH Figure 13 Output voltage noise and ripple measurement test source inductor at nominal input voltage and rated load current setup 20 mA div 2us div DES HMainzdk gt gt OUTPUT VOLTAGE V 0 1 2 3 4 5 6 7 8 9 10 LOAD CURRENT A Figure 14 Output voltage ripple at nominal input voltage and Figure 15 Output voltage vs load current showing typical rated load current lo 7A 20 mV div 2us div current limit curves and converter shutdown points Load capacitance 1uF ceramic capacitor and 10uF 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 EA8SR12007 05222008 Ea MES DESIGN CONSIDERATIONS Input Source Impedance The i
13. ise under any patent or patent rights of Delta Delta reserves the right to revise these specifications at any time without notice E48SR12007_05222008 a 15
14. lecom Datacom Wireless Networks Optical Network Equipment Server and Data Storage Industrial Test Equipment Ad neLTA Delta Electronics qe TECHNICAL SPECIFICATIONS T 25 C airflow rate 300 LFM Vj 248Vdc nominal Vout unless otherwise noted PARAMETER NOTES and CONDITIONS udi SD E NDS Min Max Units Input Voltage Continuous 80 Vdc Transient 100ms 100ms 100 Vdc Operating Temperature Refer to Figure21 for measuring point 40 115 C Storage Temperatures ee LN EL Es Input Output Isolation Voltage 2250 Vdc INPUT CHARACTERISTICS Operating Input Voltage Vdc Input Under Voltage Lockout Turn On Voltage Threshold 33 34 35 Vdc Turn Off Voltage Threshold 31 32 33 Vdc Lockout Hysteresis Voltage 1 2 3 Vdc Maximum Input Current 100 Load 36Vin 3 0 A No Load Input Current 60 100 mA Off Converter Input Current 3 10 mA Inrush Current CH 1 A s Input Reflected Ripple Current P P thru 12pH inductor 5Hz to 20MHz es us Input Voltage Ripple Rejection 120 Hz OUTPUT CHARACTERISTICS Output Voltage Current Transient 48V 10uF Tan amp 1uF Ceramic load cap 0 1A us Output Voltage Set Point Vin 48V lo lo max Tc 25 C 11 880 12 000 12 120 Vdc Output Voltage Regulation Over Load lo lo min to lo max 10 15 mV Over Line Vin 36V to 75V 10 15 mV Over Temperature Tc 40 C to 85 C 100 mV Total Output Voltage Range Over sample l
15. mpedance 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 UH we advise adding a 10 to 100 uF electrolytic capacitor ESR lt 0 7 O 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 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 th
16. oad line and temperature 11 76 12 24 Vdc Output Voltage Ripple and Noise 5Hz to 20MHz bandwidth Peak to Peak Full Load 1uF ceramic 10uF tantalum 40 120 mV RMS Full Load 1uF ceramic 10uF tantalum 10 25 mV Operating Output Current Range 0 7 5 Output Over Current Protection 110 140 DYNAMIC CHARACTERISTICS Positive Step Change in Output Current 5096 lo max to 7596 lo max 200 360 mV Negative Step Change in Output Current 7596 lo max to 5096 lo max 200 360 mV Settling Time within 196 Vout nominal 200 us Turn On Transient Start Up Time From On Off Control 6 12 ms Start Up Time From Input 6 12 d Maximum Output Capacitance Full load 596 overshoot of Vout at startup 2000 EFFICIENCY 10096 Load 92 0 60 Load 92 0 ISOLATION CHARACTERISTICS Input to Output 2250 Vdc Isolation Resistance 100 MQ Isolation Capacitance FEATURE CHARACTERISTICS Switching Frequency 350 kHz ON OFF Control Negative Remote On Off logic Logic Low Module On Von off at lon off 1 0mA 0 0 7 V Logic High Module Off Von off at lon off 0 0 uA 2 4 18 V ON OFF Control Positive Remote On Off logic Logic Low Module Off Von off at lon off 1 0mA 0 0 7 V Logic High Module On Von off at lon off 0 0 uA 2 4 18 V ON OFF Current for both remote on off logic lon off at Von off 0 0V 0 7 1 mA Leakage Current for both remote on off logic Logic High Von off 15V 50 uA Output Voltage Trim Range Pou
17. ote On Off Logic SE amp Maini iM gt gt D448 Hainzsl1M gt gt Figure 6 Turn on transient at full rated load current resistor Figure 7 Turn on transient at zero load current 2ms div for load 2ms div for positive on off mode Vin 48V Top Trace positive on off mode Vin 48V Top Trace Vout 5V div Bottom Vout 5V div Bottom Trace ON OFF input 5V div Trace ON OFF input 5V div EA8SR12007 05222008 ELECTRICAL CHARACTERISTICS CURVES DES Maint400k zx Figure 8 Output voltage response to step change in load current 75 50 75 of lo max di dt 0 1A us Load cap 10uF tantalum capacitor and 1uF ceramic capacitor Top Trace Vout 0 2V div 200us div Bottom Trace lout 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 33uF ESR 0 3 o R20C 100KH Csz2uF ESRZU o B20 10UKHz 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 reel of 12 uH Capacitor Cs offset possible battery impedance Measured current as shown below EA8SR12007 05222008 DES Mainzd Dk 55 Figure 9 Output voltage response to step change in load current 75 50 75 of lo max di dt 2 5A us Load cap 47uF 35mQ ESR solid
18. output voltage set point adjustment trim Contac and Distributior 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 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 FEATURES DESCRIPTIONS CON Output Voltage Adjustment TRIM To increase or decrease the output voltage set point the modules may be connected with 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 Vo 4 Sense R f Load Trim Sense Vo 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 A is defined as Rtrim down E 10 2
19. t lt max rated power 10 10 Output Voltage Remote Sense Range Pout lt max rated power 10 Output Over Voltage Protection Over full temp range 14 4 V GENERAL SPECIFICATIONS MTBF lo 80 of lo max Ta 25 C airflow rate 200FLM 2 03 M hours Weight 19 6 Grams Over Temperature Shutdown Refer to Figure 21 for measuring point 120 C E48SR12007_05222008 zc ELECTRICAL CHARACTERISTICS CURVES 35 12 66 92 DU 3 F BY E 5g gt Z 248 Li 242 83 z 48 LL 3 0 80 24 ET 18 1 2 4 5 D i 1 2 3 4 2 D D OUTPUT CURRENT A OUTPUT CURRENTIA Figure 1 Efficiency vs load current for minimum nominal and Figure 2 Power dissipation vs load current for minimum maximum input voltage at 25 C 300LFM airflow nominal and maximum input voltage at 25 C 300LFM airflow 3 2 5 INPUT CURRENT A in M 0 5 o 30 35 40 45 5 55 B 55 ZU L INPUT VOLTAGE Figure 3 Typical full load input characteristics at 25 C E48SR12007_05222008 we 3 Ea MES ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On Off Logic SE amp Maini iM za SE amp Mainz iM gt gt Figure 4 Turn on transient at full rated load current resistor Figure 5 Turn on transient at zero load current 2ms div load 2ms div Vin 48V Top Trace Vout 5V div Bottom Vin 48V Top Trace Vout 5V div Bottom Trace ON OFF input Trace ON OFF input 5V div 5V div For Positive Rem
20. tion 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 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 EA8SR12007 05222008 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 x 10 x Vout This limit includes any increase in voltage due to remote sense compensation and
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