Delta Electronics F48SA User Manual

r
A
t
Delphi Series F48SA, 700W Full Brick Family DC/DC Power Module: 48Vin, 28Vout
The Delphi Series F48SA, 48V input, single output, full brick sized
isolated DC/DC converter is the latest offering from a world leader in
power systems technology and manufacturing Delta Electronics,
Inc. The Delphi F48SA series provides up to 700 watts of power o
up to 25A of output current. This product family operates from a wide
input range of 36V to 75V. 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.
are protected from abnormal input/output voltage and curren
conditions, and feature 2250V input/output isolation and basic
insulation. An optional heatsink is available for extended operation.
ll models
FEATURES
High efficiency: 91.5% @ 28V/25A
Industry standard size and pinout:
61.0 x 116.8 x 12.7mm (2.40”x 4.60”x 0.50”)
Fixed frequency operation
Remote sense
Auxiliary bias power
Basic insulation
2250V isolation
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
Heatsink for
Output current monitoring
Delayed overcurrent shutdo
Parallel operation using forced
current sharing
extended operation
wn
APPLICATIONS
Telecom / DataCom
Wireless Networks
Optical Network Equ
Server and Data Storage
Industrial / Test Equipmen
ipment
t
DATASHEET DS_F48SA28025_12072007
TECHNICAL SPECIFICATIONS
Output overshoo
age du
0
(TA=25°C, Vin=48Vdc, nominal Vout unless otherwise noted.)
PARAMETER NOTES and CONDITIONS F48SA28025 (Standard)
ABSOLUTE MAXIMUM RATINGS
Input Voltage
Continuous 80 Vdc
Transient (100ms) 100ms 100 Vdc Operating Temperature Please refer to Fig 20 for measuring point -40 95 °C Storage Temperature -55 125 °C Input/Output Isolation Voltage 2250 Vdc
INPUT CHARACTERISTICS
Operating Input Voltage 36 48 75 Vdc Input Under-Voltage Lockout
Turn-On Voltage Threshold 33 34.5 36 Vdc
Turn-Off Voltage Threshold 31 32.5 34 Vdc
Lockout Hysteresis Voltage
Input Over-Voltage Lockout
Turn-On Voltage Threshold 76 78 80 Vdc
Turn-Off Voltage Threshold 78 80 82 Vdc
Lockout Hysteresis Voltage 2 Vdc
Maximum Input Current 100% Load, 36Vin 23 A Inrush Current(I2t) 1 A2s Input Reflected-Ripple Current P-P thru 15µH 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 27.44 28.00 28.56 Output Voltage Regulation
Over Load Io=Io,min to Io,max 28 56 mV
Over Line Vin=36V to 75V 28 56 mV
Over Temperature Tc=-40°C to 100°C 100 300 mV
Total Output Voltage Range over all load, line and temperature 27.25 28.00 28.75 V Output Voltage Ripple and Noise 5Hz to 20MHz bandwidth
Peak-to-Peak Full Load, 1µF ceramic, 10µF Low ESR cap 200 mV
RMS Full Load, 1µF ceramic, 10µF Low ESR cap 65 mV
Operating Output Current Range 2 25 A Output DC Current-Limit Inception Output Voltage 10% Low 120 150 %
DYNAMIC CHARACTERISTICS
Output Voltage Current Transient
Positive Step Change in Output Current 50% Io.max to 75% Io.max 450 mV
Negative Step Change in Output Current 75% Io.max to 50% Io.max 450 mV
Settling Time (within 1% Vout nominal) 500 us
Turn-On Transient
Start-Up Time, From On/Off Control 20 35 ms
Start-Up Time, From Input 20 35
Output Capacitive Load 470 6000 µF

EFFICIENCY

100% Load 60% Load 91.5 %

ISOLATION CHARAC TERISTICS

Input to Output 2250 Vdc Input to Case Output to Case 1500 Vdc Isolation Resistance 10 M Isolation Capacitance 1800 pF

FEATURE CHARACTERISTICS

Switching Frequency 300 kHz
t Volt
Power good pin max applied voltage Max sink current 5mA 35 V
Auxiliary output voltage
Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection Over full temp range; % of nominal Vout 115 140 %

GENERAL SPECIFICATIONS

MTBF Io=80% of Io, max; Ta=25°C 1.14 M hours Weight 168 grams Over-Temperature Shutdown Please refer to Fig.20 for measuring point 100 °C

Min. Typ. Max. Units
48V, Tested with a 10µF, a 1µF Ceramic cap and a
470uF low ESR aluminum load cap,
ΔIo/Δt=1A/µs
ring start up
Aux pin source current <=20mA
Referenced to Sense(-) pin
Pout max rated power Pout max rated power
2 Vdc
Vdc
ms
91.5 %
1500 Vdc
7 10 13 V
-15 +10 %
0.5 V
DS_F48SA28025_12072007
2
ELECTRICAL CHARACTERISTICS CURVES
95
EFFICIENCY (%)
90
85
80
75
70
0 5 10 15 20 25 30
36Vin 48Vi n 75Vin
OUT PUT CURRENT (A)
Figure 1: Efficiency vs. load current for minimum, nominal, and
maximum input voltage at 25°C.
Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25°C.
DS_F48SA28025_12072007
3
ELECTRICAL CHARACTERISTICS CURVES
For Negative Remote On/Off Logic
Figure 3: Turn-on transient at full rated load current (resistive
load). CH3: Vout;5V/div; CH1: ON/OFF input: 5V/div
For Positive Remote On/Off Logic
Figure 5: Turn-on transient at full rated load current (resistive
load) (10ms/div). Top Trace: Vout; 5V/div; Bottom Trace: ON/OFF input: 2V/div
Figure 4: Turn-on transient at minimum load current
. CH3: Vout: 5V/div; CH1: ON/OFF input:5V/div
Figure 6: Turn-on transient at minimum load current
(10ms/div). Top Trace: Vout: 5V/div; Bottom Trace: ON/OFF input: 2V/div
DS_F48SA28025_12072007
4
ELECTRICAL CHARACTERISTICS CURVES
A
Figure 7: Output voltage response to step-change in load
current (75%-50% of Io, max; di/dt = 1A/µs). Load cap: 470µF aluminum ,10uF Low ESR capacitor and 1µF ceramic capacitor. Top Trace: Vout (200mV/div), Bottom Trace: Iout (10A/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 8: Output voltage response to step-change in load
current (50%-75% of Io, max; di/dt = 1A/µs). Load cap: 470µF aluminum,10uF Low ESR capacitor and 1µF ceramic capacitor. Top Trace: Vout (200mV/div), Bottom Trace: Iout (10 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.
/div).
Figure 9: 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 15 μH. Capacitor Cs offset
TEST
DS_F48SA28025_12072007
5
ELECTRICAL CHARACTERISTICS CURVES
E
Figure 10: Input Terminal Ripple Current, i current and nominal input voltage with 15µH source impedance and 220µF electrolytic capacitor (1A/div).
, at full rated output
c
Copper Strip
Vo(+)
10u 1u
Vo(-)
Figure 12: Output voltage noise and ripple measurement test setup
SCOPE RESISTIV
LOAD
Figure 11: Input reflected ripple current, i
source inductor at nominal input voltage and rated load current (10 mA/div)
, through a 15µH
s
DS_F48SA28025_12072007
6
ELECTRICAL CHARACTERISTICS CURVES
Figure 13: Output voltage ripple at nominal input voltage and rated load current (100 mV/div). Load capacitance:470uF
aluminum, 1µF ceramic capacitor and 10µFlow ESR capacitor. Bandwidth: 20 MHz. 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 14: Output voltage vs. load current showing typical current limit curves and converter shutdown points.
DS_F48SA28025_12072007
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 μH, we advise adding a 220 to 470 μF electrolytic capacitor (ESR < 0.1 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, 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 20A 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.
DS_F48SA28025_12072007
8
FEATURES DESCRIPTIONS
n
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 and latch off. 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
+Vin
-Vin
+On/Off
-On/Off
Input side on off control
DS_F48SA28025_12072007
Aux
-Sense
+On/Off
-On/Off
Output side on off control
Figure 15: 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% × Vo ut
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 16: 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.
9
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 17: 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:
Rt_dn
Ex. When Trim-down -10% ( 28V * (1 – 10%) = 25.2V )
1 Rt_dn = --------- - 2 = 8k 10%
1
2
Δ
kΩ:=
Figure 18: 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 to obtain a percentage output voltage change % is defined
as:
Rt_up
Vo 1 Δ+
1.24 Δ⋅
1
2
Δ
kΩ:=
Ex. When Trim-up +10% (28.0V * (1+10%) = 30.8V)
28*(1+10%) 1 Rt_up = ------------------- -------- 2 = 236.39k
1.24*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.
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.
DS_F48SA28025_12072007
10
THERMAL CONSIDERATIONS
A
B
Y
E
E
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’’).
FACI NG PW
PWB
MODULE
Thermal Derating
Heat can be removed by increasing airflow over the module. The module’s maximum case temperature is
95. 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 20: Temperature measurement location viewed from the
IMS side The allowed maximum hot spot temperature is defined at 95
Output Power (W)
750
700
F48SA28025(Standard) Output Power vs. Hot Spot Temperature
(Either Orientation)
AIR VELOCIT AN
D AMBIENT
TEMPERATUR
MEASURED BELOW
THE MODUL
IR FLOW
Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches)
50.8 (2.0”)
12.7 (0.5”)
Figure 19: Wind tunnel test setup
650
600
550
500
450
400
350
25 35 45 55 65 75 85 95
Hot spot Temperature(℃)
Figure 21: Output power vs. hot spot temperature (Either Orientation)
DS_F48SA28025_12072007
11
MECHANICAL DRAWING
Pin No.
1 2 3 4 5 6 7 8 9
10
Pin S ecificatio
p n:
Pins 3-4, 11-16 Pins 1-2, 6-10
All pins are coppe n plating.
DS_F48SA28025_12072007
Name Function
-Vin +Vin
-ON/OFF +ON/OFF +Vout +Vout +Vout
-Vout
-Vout
-Vout
r with Ti
gative input volt
Ne age Po oltage
sitive input v Negative Remote ON/O Positive Remote ON/OFF Positive output voltage Positive output voltage Positive output voltage Negative output voltage Negative output voltage Negative output voltage
1.00mm (0.040”) diameter
2.00mm (0.0
79”) diameter
FF
12
PART NUMBERING SYSTEM
F 48 S A 280 25 P R F A
Form
Factor
F- Full Brick 48V S- Single A- Advanced 280- 28V 25- 25A P- Positive R- 0.170”
Input
Voltage
Number of
Outputs
Product
Series
Output
Voltage
Output
Current
ON/OFF
Logic
Pin
Length
Option Code
F- RoHS 6/6
(Lead Free)
Space - RoHS 5/6
A - Standard
Functions
B - No thread in
heatsink mounting
hole
MODEL LIST
MODEL NAME INPUT OUTPUT EFF @ 100% LOAD
F48SA28025PRFA 36V~75V 21.4A 28V 25A 91.5 %
For different remote on/off logic and pin length options, please contact Delta local sales
CONTACT: www.delta.com.tw/dcdc
USA:
Telephone: East Coast: (888) 335 8201 West Coast: (888) 335 8208 Fax: (978) 656 3964 Email: DCDC@delta-corp.com
Europe:
Phone: +41 31 998 53 11 Fax: +41 31 998 53 53 Email: DCDC@delta-es.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
.
Asia & the rest of world:
Telephone: +886 3 4526107 ext 6220 Fax: +886 3 4513485 Email: DCDC@delta.com.tw
DS_F48SA28025_12072007
13
Loading...