Delta Electronics E48SR User's Manual
Contents
1. Be 47 50 LEGAT 50 80 2 000 d O1 Vin m OD SENSE e Wi 2 ON OFF TRIM 6O Col 00 SENSE 50 d a Oe Vin Vout AC Z R E 2 60 0 102 sl P PAD 8X RO RECOMENDED P W B PAD LAYOUT NOTES DIMENSIONS ARE IN MILLIMETERS AND INCHES TOLERANCES X Xmm 0 5mm X XX in 0 02_ in X XXmm0 25mm X XXX in 0 010 in DS_E48SR15004_05222008 TOP COVER TAPE Eal Ei R ha gt Las E n I Cp N DIRECTION gj EMBOSSED CARRIER OTES CONFORMS TO EIA 481 SATNDARD MODULES ARE QUANTITIES TOLERANCES X Xmm 0 5mm X XX in 0 02 3 x XXmm 0 25mm X XXX in 0 010 in 100 PER REEL ALL DIMENSIONS ARE IN MILLIMETERS AND INCHES D in LEADED Sn Pb PROCESS RECOMMEND TEMP PROFILE 2nd Ramp up temp Peak DE 1 0 3 0 C feces 210 230 C 5sec2. Delphi Series E48SR 66W Eighth Brick Family DC DC Power Modules 48V in 15V 4A out SO The Delphi Series E48SR Eighth Brick 48V input single output isolated BW DC DC converter is the latest offering from a world leader in power systems technology and manufacturing Delta Electronics Inc This product family 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 DATASHEET DS_E48SR15004_ 05222008 FEATURES High Efficiency 91 5 15V 4A Size 58 4mmx22 8mmx8 4mm 2 30 x0 90 x0 33 Standard footprint Industry standard pin out 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 QS9000 OHSAS18001 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 APPLIC
3. Pre heat temp DE ee 140 180 C 60 120 sec g E Ramp up temp Cooling down rate lt 3 C sec S 150 4g_0 5 3 0 C sec aoe Over 200 C Nn 40 50sec 0 60 120 180 Time sec 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 It Peak Temp 240 245 C 217 C Ramp down e max 4 C sec Ee E 150 C peer Preheat time lt q __ gt eee Time Limited 90 sec above 217 C Ramp up max 3 C sec 25C Time Note The temperature refers to the pin of E48SR measured on the pin Vout joint DS_E48SR15004_05222008 13 MECHANICAL DRAWING Surface mount module Through hole module a eo e se a R S fr atl S a gt a i Ce 58 4 2 530 ol 2 o 8 2 38 4 2 bm pech el E En SE y m x oo rae Ey RR Qn s s Z QC BR BO 2N 9 5 8 0 50 80 2 000 So olol ol o 50 15 50 80 2 Ee cast a A S e NS lt C Hi zf SEA 00 N S S Ee x LO SE Vin Nout 8 U os E Vin D L d d O OD SENSE 7 3 a SNOT mm l U P d A gt A ON OF PRIM g S e o ON OFF D E 2 A R Di Z N L TOP VII T O P yI E W JO DO Sf 9 NATED E E NO A 7 B i gt N oT H s Cy a x N SE 00
4. O WAR i E ofl ry k dd ae AE Re IES NEN E PY EVO NTS A ae a a a A 2 ONLUS JUIA SOLDER PLAIED COPP Z S Name Vin ON OFF Vin Vout SENSE TRIM SENSE Vout CO zl CO OD P GA bi S DS_E48SR15004_ 05222008 EEE CUSTOMER BOARD 1 00 ma a een E ERKL REZEK ELLER ZZ D d C 0 040 an DIA 3 JOO J S SOLDER PLAT Ee A 3 0 1 teak VJ SIDE DIMENSIONS ARE IN MI LA DO A e mo IMETERS AND INCHES OLERANCES X Xmm 0 5mm X XX in 0 02 in EN PRT pee IY SE E Py GASB ee 3 X XXMMEOQ ZOMM A AXX in 0 010 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 WITH 2 0 0 08 SHOULDER R II SOLDER CIO N a mn f e H 23 TEN 14 PART NUMBERING SYSTEM E s s R 10 o n R EEE Type of Output Output ON OFF Pin Length E Option Code Product Voltage Outputs Series Voltage Current Logic E Eighth 48V S Single Feature 150 15V 04 4A N Negative R 0 170 F RoHS 6 6 A Standard ia Lead F Functions Default Default Lead Free P Positive N 0 145 K 0 110 M SMD pin MODEL LIST OUTPUT Default remote on off logic is negative and pin length is 0 170 For different remote on off logic a
5. 100 mV Total Output Voltage Range over sample load line and temperature V Output Voltage Ripple and Noise 5Hz to 20MHz bandwidth Peak to Peak Full Load 1uF ceramic 10uF tantalum 80 120 mV RMS Full Load 1uF ceramic 10uF tantalum 25 40 mV Operating Output Current Range 0 4 A Output DC Current Limit Inception Output Voltage 10 Low 110 140 DYNAMIC CHARACTERISTICS Positive Step Change in Output Current 50 lo max to 75 lo max 150 320 mV Negative Step Change in Output Current 75 lo max to 50 lo max 150 320 mV Settling Time within 1 Vout nominal 200 us Turn On Transient Start Up Time From On Off Control 6 12 ms Start Up Time From Input 6 12 me Maximum Output Capacitance Full load 5 overshoot of Vout at startup 1000 EFFICIENCY GENERAL SPECIFICATIONS 100 Load 91 5 60 Load 90 5 Input to Output 2250 Vdc Isolation Resistance 10 MQ Isolation Capacitance 1500 pF FEATURE CHARACTERISTICS OO 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 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 pA 2 18 V ON OFF Current for both remote on off logic lon off at Von off 0 0V 1 mA Leakage Current for both remote on off logic Logic High Von off 1
6. 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_E48SR15004_05222008 ae 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 UH we advise adding a 10 to 100 UF electrolytic capacitor ESR lt 0 7 Q 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 applyi
7. 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 is constantly kept at 6 35mm 0 25 FACING PWB PWB MODULE AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE 50 8 2 0 12 7 0 5 Note Wind Tunnel Test Setup Figure Dimensions are in millimeters and Inches Figure 20 Wind tunnel test setup DS_E48SR15004_ 05222008 Thermal Derating Heat can be removed by increasing airflow over the module The hottest point of the module is less than 106 C To enhance system reliability the power module should always be operated below the maximum operating temperature If module the temperature exceeds the maxim
8. 5V 50 uA Output Voltage Trim Range Across Pins 9 amp 5 Pout lt max rated power 13 05 16 95 V Output Voltage Remote Sense Range Pout lt max rated power 10 Output Over Voltage Protection Over full temp range of nominal Vout 17 25 21 75 V DS_E48SR15004_ 05222008 MTBF lo 80 of lo max Ta 25 C 2 11 M hours Weight 19 6 grams Over Temperature Shutdown Refer to Fig 21 for the measuring point 114 C ELECTRICAL CHARACTERISTICS CURVES 96 6 2 93 5 8 54 a 5 0 ze 64 6 Sh S SC S E 75 e 72 33 4 69 3 0 66 2 6 63 2 2 60 1 8 04 08 12 16 20 24 28 32 36 40 04 08 12 16 20 24 28 32 36 40 OUTPUT CURRENT A OUTPUT CURRENT A 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 nominal and maximum input voltage at 25 C 2 9 INPUT CURRENT A n 0 30 35 40 A8 50 55 DU 6S 70 D GU INPUT VOLTAGEIV Figure 3 Typical full load input characteristics at room temperature DS_E48SR15004_05222008 ae 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On Off Logic D4 Mainzi gt gt S S S c 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 inp
9. ATIONS Telecom Datacom Wireless Networks Optical Network Equipment Server and Data Storage Industrial Testing Equipment DELTA Delta Electronics Inc g TECHNICAL SPECIFICATIONS PARAMETER T 25 C airflow rate 300 LFM V 48Vdc nominal Vout unless otherwise noted NOTES and CONDITIONS SE See NES Min Max Units Input Voltage Continuous 80 Vdc Transient 100ms 100ms 100 Vdc Operating Case Temperature Please refer to Fig 21 for the measuring point 40 106 C Storage Temperature 55 125 C Input Output Isolation Voltage 2250 Vdc INPUT CHARACTERISTICS Output Voltage Current Transient 48V 10uF Tan amp 1uF Ceramic load cap 0 1A us 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 2 2 A No Load Input Current 60 100 mA Off Converter Input Current 4 10 mA Inrush Current I t 1 A s Input Reflected Ripple Current P P thru 12uH inductor 5Hz to 2OMHz 25 mA Input Voltage Ripple Rejection 120 Hz dB OUTPUT CHARACTERISTICS Output Voltage Set Point Vin 48V lo lo max Tc 25 C 14 850 15 000 15 150 Vdc Output Voltage Regulation Over Load lo lo min to lo max 5 15 mV Over Line Vin 36V to 75V 5 15 mV Over Temperature c 40 C to 85 C
10. d 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 gt GG Maint4k gt gt S Figure 11 Input Terminal Ripple Current i at full rated output current and nominal input voltage with 12uH source impedance and 33uF electrolytic capacitor 500 mA div 2us div RESISTIM LOAD Figure 13 Output voltage noise and ripple measurement test setup DS_E48SR15004_ 05222008 ELECTRICAL CHARACTERISTICS CURVES z Maint4dk gt gt Figure 12 Input reflected ripple current LG through a 12uH source inductor at nominal input voltage and rated load current 20 mA d v 2us div a ELECTRICAL CHARACTERISTICS CURVES GG Maint4k gt gt S 16 0 14 0 12 0 10 0 8 0 OUTPUT YOLTAGE Gi 6 0 4 0 2 0 Oo Ving Re a ads rane ne a er ee a 0 0 0 0 05 1 0 15 20 25 30 35 40 45 50 55 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 4A 50 mV div 2us div current limit curves and converter shutdown points Load capacitance 1uF ceramic capacitor and 10uF tantalum capacitor Bandwidth 20 MHz Scope measurement should be made using
11. nd pin length please refer to part numbering system above or contact your local sales office CONTACT www delta com tw dcdc USA Europe Asia amp the rest of world Telephone Telephone 41 31 998 53 11 Telephone 886 3 4526107 x 6220 East Coast 888 335 8201 Fax 41 31 998 53 53 Fax 886 3 4513485 West Coast 888 335 8208 Email DCDC delta es tw Email DCDC delta com tw Fax 978 656 3964 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 otherwise under any patent or patent rights of Delta Delta reserves the right to revise these specifications at any time without notice DS_E48SR15004_05222008 wae 15
12. ng 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_E48SR15004_ 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 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 modules 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 5A maximum rating to be i
13. nstalled 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 gt 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 af
14. pins and the output terminals must not exceed the output voltage sense range given here Vo Vo SENSE SENSE lt 10 x Vout This limit includes any increase in voltage due to remote sense compensation and 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 Sense R i Load Trim Sense Vo Figure 18 Circuit configuration for trim down decrease output voltage If the exte
15. rnal 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 A is defined as Rtrim down E 10 2 K9 Ex When Trim down 10 15Vx0 9 13 5V Rtrim down K DIS 40 9 KQ DS_E48SR15004_ 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 27 The external resistor value required to obtain a percentage output voltage change is defined as 5 l1xVox 100 A 511 Rtrim up ETT 7 10 2 KQ x Ex When Trim up 10 15 Vx1 1 16 5V S L1x15x 100 10 511 10 2 627 0 KQ 1 225 x10 10 Rtrim up 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 10 a THERMAL CONSIDERATIONS Thermal management is an important part of the system design To
16. ter 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 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 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 DS_E48SR15004_ 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
17. um temperature reliability of the unit may be affected THERMAL CURVES Figure 21 Hot spot temperature measured point The allowed maximum hot spot temperature is defined at 106 C E48SR15004 standard Output Current vs Ambient Temperature and Air Velocity Vin 48V Transverse Orientation 3 5 r Natural F Convection 3 0 L 100LFM 2 5 i j 200LFM 2 0 300LFM Output Current A 4 5 400LFM 80 85 Ambient Temperature C Figure 22 Output current vs ambient temperature and air velocitv Vin 48V Transverse Orientation 11 58 4 2 30 A PIN 1 a 26 50 1 043 8 2 i D s Hl 2 o e CO 3 K 00 al O i O 27 0 0 28 MIN AREA PICK AND PLACE LOCATION NOTES ALL DIMENSIONS ARE IN MILLIMETERS AND INCHES TOLERANCES X Xmm 0 5mm X XX in 0 02 in X XXmmM 0 25mmM X XXX in 40 010 in RECOMMENDED PAD LAYOUT SMD
18. ut Trace ON OFF input 5V div 5V div For Positive Remote On Off Logic GG Mainz iM aa GG Mainz iM gt gt Figure 6 Turn on transient at full rated load current resistor Figure 7 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 inpu 5V div 5V div DS_E48SR15004_05222008 wer a ELECTRICAL CHARACTERISTICS CURVES GG Mainz 40k zz 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 SF ESR 0 5 o B20 100KHz cse e0ur ESRe01 o B20 100KHz 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 Measure current as shown above DS_E48SR15004_ 05222008 GG Mainz 40k zz Figure 9 Output voltage response to step change in load current 75 50 75 of lo max di dt 2 5A us Load cap du 35mQ ESR soli
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