Delta E48SH User Manual

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Delphi Series E48SH, 120W Eighth Brick Family
DC/DC Power Modules: 48V in, 1.5V/40A out

The Delphi Series E48SH Eighth Brick, 48V input, single output, isolated
DC/DC converters are the latest offering from a world leader in powe
systems technology and manufacturing ― Delta Electronics, Inc. This
product family is available in either a through-hole or surface-mounted
package and provides up to 120 watts of power or 50A of output curren
(1.2V and below) in an industry standard footprint and pinout. The E48SH
converter operates from an input voltage of 36V to 75V and is available in
output voltages from 1.0V to 15V. Efficiency is 89% for 1.5V output at 40
full load. With creative design technology and optimization of componen
placement, these converters possess outstanding electrical and thermal
performance, as well as extremely high reliability under highly stressful
operating conditions.
input/output voltage, current, and temperature conditions. The Delphi Series
converters meet all safety requirements with basic insulation.

ll models are fully protected from abnormal

FEATURES

 High efficiency: 89% @1.5V/40A

 Size: 58.4mm x 22.8mm x 9.5mm

(2.30”x0.90”x0.37”)

 Industry standard pin out

 Fixed frequency operation

 Input UVLO, Output OTP, OCP, OVP

 Monotonic startup into normal and

pre-biased loads

 Secondary control, very fast transient

response

 2250V Isolation and basic insulation

 No minimum load required

 SMD and through-hole versions

 No negative current during power or enable

on/off

 ISO 9001, TL 9000, ISO 14001, QS 9000,

OHSAS 18001 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

 Short pin lengths available

 External Synchronization

 Output OVP latch mode

 Output OCP latch mode

 Heat spreader

APPLICATIONS

 Telecom/DataCom

 Wireless Networks

 Optical Network Equipment

 Server and Data Storage

 Industrial/Test Equipment

DATASHEET
DS_E48SH1R540_02272007

TECHNICAL SPECIFICATIONS

(TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.)

PARAMETER NOTES and CONDITIONS E48SH1R540 (Standard)

ABSOLUTE MAXIMUM RATINGS

Input Voltage

Continuous 75 Vdc

Transient (100ms) 100ms 100 Vdc
Operating Temperature Refer to Figure 21 for measuring point -40 125 °C
Storage Temperature -55 125 °C
Input/Output Isolation Voltage 2250 Vdc

INPUT CHARACTERISTICS

Operating Input Voltage 36 75 Vdc
Input Under-Voltage Lockout

Turn-On Voltage Threshold 33 34 35 Vdc

Turn-Off Voltage Threshold 31 32 33 Vdc

Lockout Hysteresis Voltage 1.5 2 2.5 Vdc

Maximum Input Current 100% Load, 36Vin 2.2 A
No-Load Input Current 50 mA
Off Converter Input Current 3 mA
Inrush Current(I2t) 1 A2s
Input Reflected-Ripple Current P-P thru 12µH inductor, 5Hz to 20MHz 20 mA
Input Voltage Ripple Rejection 120 Hz 50 dB

OUTPUT CHARACTERISTICS

Output Voltage Set Point Vin=48V, Io=Io.max, Tc=25°C 1.485 1.5 1.515 Vdc
Output Voltage Regulation

Over Load Io=Io,min to Io,max ±3 ±10 mV

Over Line Vin=36V to 75V ±3 ±10 mV

Over Temperature Tc=-40°C to 85°C ±15 mV

Total Output Voltage Range over sample load, line and temperature 1.47 1.53 V
Output Voltage Ripple and Noise 5Hz to 20MHz bandwidth

Peak-to-Peak Full Load, 1µF ceramic, 10µF tantalum 30 60 mV

RMS Full Load, 1µF ceramic, 10µF tantalum 10 20 mV

Operating Output Current Range 0 40 A
Output DC Current-Limit Inception Output Voltage 10% Low 110 140 %

DYNAMIC CHARACTERISTICS

Output Voltage Current Transient 48V, 10µF Tan & 1µF Ceramic load cap, 0.1A/µs

Positive Step Change in Output Current 50% Io.max to 75% Io.max 30 mV

Negative Step Change in Output Current 75% Io.max to 50% Io.max 30 mV

Settling Time (within 1% Vout nominal) 100 us

Turn-On Transient

Start-Up Time, From On/Off Control 10 ms

Start-Up Time, From Input 10 ms

Maximum Output Capacitance Full load; no overshoot of Vout at startup 40000 µF

EFFICIENCY

100% Load 89 %
60% Load 90.5 %

ISOLATION CHARACTERISTICS

Input to Output 2250 Vdc
Isolation Resistance 10 MΩ
Isolation Capacitance 1500 pF

FEATURE CHARACTERISTICS

Switching Frequency 200 kHz
ON/OFF Control, Negative Remote On/Off logic

Logic Low (Module On) Von/off at Ion/off=1.0mA 1.2 V

Logic High (Module Off) Von/off at Ion/off=0.0 µA 3 50 V

ON/OFF Control, Positive Remote On/Off logic

Logic Low (Module Off) Von/off at Ion/off=1.0mA 1.2 V

Logic High (Module On) Von/off at Ion/off=0.0 µA 3 50 V

ON/OFF Current (for both remote on/off logic) Ion/off at Von/off=0.0V 1 mA

Leakage Current (for both remote on/off logic) Logic High, Von/off=15V 50 uA

Output Voltage Trim Range
Output Voltage Remote Sense Range
Output Over-Voltage Protection Over full temp range; % of nominal Vout 1.8 V

GENERAL SPECIFICATIONS

MTBF Io=80% of Io, max; 300LFM @25C 2.05 M hours Weight 20 grams Over-Temperature Shutdown Refer to Figure 21 for measuring point 130 °C

Min. Typ. Max. Units

Across Pins 9 & 5, Pout ≦ max rated power

Pout ≦ max rated power

-20 10 %
10 %

E48SH1R540_02272007

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ELECTRICAL CHARACTERISTICS CURVES

92

90

88

86

84

82

80

78

76

EFFICIENCY (%)

74

72

70

4 8 12 16 20 24 28 32 36 40

48Vin 36Vin 75Vin

OUTPUT CURRENT (A)

Figure 1: Efficiency vs. load current for minimum, nominal, and
maximum input voltage at 25°C

3

2.5

2

9

48Vin 36Vin 75Vin

7

5

LOSS (W)

3

1

0 4 8 1216202428323640

OUTPUT CURRENT (A)

Figure 2: Power dissipation vs. load current for minimum,

nominal, and maximum input voltage at 25°C.

1.5

INPUT CURRENT(A)

1

0.5

0

30 34 38 42 46 50 54 58 62 66 70 74 78

INPUT VOLTAGE(V)

Figure 3: Typical full load input characteristics at room
temperature

E48SH1R540_02272007

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ELECTRICAL CHARACTERISTICS CURVES

For Negative Remote On/Off Logic

Figure 4: Turn-on transient at zero load current (5 ms/div).
Vin=48V.Top Trace: Vout, 1V/div; Bottom Trace: ON/OFF input,
5V/div

For Input Voltage Start up

Figure 5: Turn-on transient at full rated load current (constant

current load) (5 ms/div). Vin=48V.Top Trace: Vout, 1V/div;
Bottom T race: ON/OFF input, 5V/div

Figure 6: Turn-on transient at zero load current (2 ms/div).
Vin=48V.Top Trace: Vout, 1V/div, Bottom Trace: input voltage,
5V/div

0

0

Figure 7: Turn-on transient at full rated load current (constant

current load) (2 ms/div). Vin=48V.Top Trace: Vout, 1V/div;
Bottom Trace: input voltage, 5V/div

E48SH1R540_02272007

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ELECTRICAL CHARACTERISTICS CURVES

)

)

Figure 8: Output voltage response to step-change in load
current (75%-50% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF,
tantalum capacitor and 1µF ceramic capacitor. Trace: Vout
(20mV/div, 100us/div
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..

, Scope measurement should be made

Figure 9: Output voltage response to step-change in load

current (50%-75% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF,
tantalum capacitor and 1µF ceramic capacitor. Trace: Vout
(20mV/div, 100us/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 (L
possible battery impedance. Measure current as shown above

of 12 µH. Capacitor Cs offset

TEST

Figure 11: Input Terminal Ripple Current, i

current and nominal input voltage with 12µH source impedance
and 33µF electrolytic capacitor (200 mA/div, 2us/div).

, at full rated output

c

E48SH1R540_02272007

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ELECTRICAL CHARACTERISTICS CURVES

E

StripCopper

Vo(+)

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).

10u

Vo(-)

SCOPE RESISTIV

1u

LOAD

Figure 13: Output voltage noise and ripple measur ement test

setup

2

1.5

1

0.5

Output voltage (V)

Figure 14: Output voltage ripple at nominal input voltage and
rated load current (Io=40A)(20 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.

E48SH1R540_02272007

0

0 5 10 15 20 25 30 35 40 45 50 55 60

Output current (A)

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
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:

 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 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 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.

E48SH1R540_02272007

7

FEATURES DESCRIPTIONS

n

Over-Current Protection

The E48SH modules include an internal output
over-current protection circuit, which will endure current
limiting for an unlimited duration during output overload.
When the output current exceeds the OCP set point, the
current limit function will work by initially reduce duty
cycle of the module, the unit will go out of regulation but
remains in safe operating area before the output drops
below 50%. When output drops below 50%, the
modules will automatically shut down and enter hiccup
mode.

During hiccup, 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 and restart after
200mS. latch off mode is optional. Under latch off mode
the over-voltage latch is reset by either cycling the input
power or by toggling the on/off signal for one second.

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.

E48SH1R540_02272007

Vo(+)Vi(+)

Sense(+)

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).

Vi(+)

Vo(+)

Sense(+)

Sense(-)

Vi(-)

Contact

Resistance

Vo(-)

Contact and Distributio

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.

8

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.

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:

511

=− KdownRtrim 2.10

∆

Ex. When Trim-down -10%(1.5V×0.9=1.35V)

511

10

()

Ω−

()

Ω=−=− KdownRtrim 9.402.10

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:

∆+

511

) (100 Vo11.5

=− KupRtrim 2.10

1.225

∆

−
∆

()

Ω−

Ex. When Trim-up +10%(1.5V×1.1=1.65V)

Rtrim up K

5.11 1.5 (100 10 ) 511

=−−

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.

Frequency Synchronization

This product family can be synchronized with external clock
signal to the TRIM pin. This reduces system noise and
interference in multiple converter systems.

×+

1.225 10 10

×

10.2 7.5

=Ω

()

Figure 19: Circuit configuration for trim-up (increase output
voltage)

E48SH1R540_02272007

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THERMAL CONSIDERATIONS

A

Y

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 is constantly kept at

6.35mm (0.25’’).

FACING PWB

AIR VELOCIT
AND AMBIENT

TEMPERATURE

MEASURED BELOW

THE MODULE

PWB

MODULE

50.8 (2.0”)

IR FLOW

12.7 (0.5”)

Thermal Derating

Heat can be removed by increasing airflow over the module.
The hottest point temperature of the module is 130℃. 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

Figure 21: Case temperature measurement location.
Pin locations are for reference only.

＊

The allowed maximum hot spot temperature is defined at 130℃

Output Current(A)

40

35

30

25

20

15

10

5

0

25 30 35 40 45 50 55 60 65 70 75 80 85

E48SH1R540(Standard) Output Current vs. Ambient Temperature and Air Velocity

Natural

Convection

@Vin = 48V (Transverse Orientation)

100LFM

200LFM

300LFM

400LFM

500LFM

Ambient Temperature (℃)

Figure 22: Output current vs. ambient temperature and air velocity

= 48V (Transverse Orientation)

@V

in

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

Figure 20: Wind tunnel test setup

E48SH1R540_02272007

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PICK AND PLACE LOCATION SURFACE-MOUNT TAPE & REEL

RECOMMENDED PAD LAYOUT (SMD)

E48SH1R540_02272007

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LEADED (Sn/Pb) PROCESS RECOMMEND TEMP. PROFILE

℃

Peak temp.

210~230°C 5sec.

Cooling down rate <3°C /sec.

40~50sec.

300 60 0 120 180 240

Temperature (°C )

250

150

100

50

Ramp-up temp.

0.5~3.0°C /sec.

2nd Ramp-up temp.

Pre-heat temp.

140~180°C 60~120 sec.

Time ( sec. )

1.0~3.0°C /sec.

Over 200°C

Note: The temperature refers to the pin of E48SH, measured on the pin +Vout joint.

LEAD FREE (SAC) PROCESS RECOMMEND TEMP. PROFILE

217℃

℃

200

.

Peak Temp. 240 ~ 245

Ramp down
max. 4℃/sec.

Temp

150

℃

Ramp up
max. 3℃/sec.

Preheat time

100~140 sec.

Time Limited 90 sec.
above 217

℃

25℃

Time

Note: The temperature refers to the pin of E48SH, measured on the pin +Vout joint.

E48SH1R540_02272007

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MECHANICAL DRAWING (WITHOUT HEATSPREADER)

SURFACE-MOUNT MODULE THROUGH-HOLE MODULE

Pin No. Name Function

1
2
3
4
5
6
7
8

+Vin
ON/OFF

-Vin

-Vout

-SENSE
TRIM
+SENSE
+Vout

Positive input voltage
Remote ON/OFF
Negative input voltage
Negative output voltage
Negative remote sense
Output voltage trim
Positive remote sense
Positive output voltage

E48SH1R540_02272007

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MECHANICAL DRAWING (WITH HEATSPREADER)

THROUGH-HOLE MODULE

E48SH1R540_02272007

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PART NUMBERING SYSTEM

E 48 S H 1R5 40 N R F A

Type of

Product

E- Eighth

Brick

Input

Voltage

48-36V~75V S- Single H-50A series 1R5 - 1.5V 40 - 40A N- Negative

Number of

Outputs

Product

Series

Output

Voltage

Output

Current

ON/OFF

Logic

P- Positive

Pin Length

/Type

R- 0.170”
N- 0.145”
K- 0.110”
M- SMD

Option Code

F-RoHS 6/6
(Lead Free)

A- Standard

Functions

H - with

heatspreader

MODEL LIST

MODEL NAME INPUT OUTPUT EFF @ 100% LOAD

E48SH1R250NRFA 36V~75V 2.3A 1.2V 50A 86.5%

E48SH1R540NRFA 36V~75V 2.2A 1.5V 40A 89%

E48SH1R840NRFA 36V~75V 2.7A 1.8V 40A 90%

E48SH2R535NRFA 36V~75V 2.9A 2.5V 35A 89.5%

E48SH3R330NRFA 36V~75V 3.6A 3.3V 30A 92%

E48SH05020NRFA 36V~75V 3.7A 5.0V 20A 90%

E48SH12010NRFA 36V~75V 4.3A 12V 10A 93.5%

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
office

.

CONTACT: www.delta.com.tw/dcdc

USA:

Telephone:
East Coast: [phone]
West Coast: [phone]
Fax: [phone]

[e-mail]

Email:

Europe:

Telephone: [phone]
Fax: [phone]

[e-mail]

Email:

Asia & the rest of world:

Telephone: [phone] x 6220
Fax: [phone]

[e-mail]

Email:

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

.

E48SH1R540_02272007

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