Delta Electronics H48SA User Manual

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Delphi Series H48SA, Half Brick Family DC/DC Power Modules: 48V in, 12V/25A out

The Delphi Series H48SA Half Brick, 48V input, single output, isolated,

open frame DC/DC converters are the latest offering from a world

leader in power systems technology and manufacturing — Delta

Electronics, Inc. This product family provides up to 300 watts of power

or up to 25A of output current in an industry standard footprint. This

product represents the next generation of design technology required

by today’s leading-edge circuitry. 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. Typical

efficiency of the 12V, 300W module is better than 93.2% and all

modules are fully protected from abnormal input/output voltage, current

and temperature conditions. The Delphi Series converters meet all

safety requirements with basic insulation. A variety of optional

heatsinks are available for extended thermal operation.

FEATURES

 High efficiency: 93.2% @ 12V/ 25A

 Standard footprint: 58.4 x 61.0 x 11.2 mm

(2.30” x2.40”x0.44”)

 Industry standard pin out

 Single board construction

 Fixed frequency operation

 2250V Isolation

 Basic insulation

 Monotonic startup into normal and pre-

bias loads

 Fully protected: input UVLO, output OVP,

OCP, OTP

 No minimum load required

 Wide output trim range: -20%, +10%

 ISO 9001, TL 9000, ISO 14001, QS

9000, OHSAS 18001 certified

manufacturing facility

 UL/cUL 60950-1 (US & Canada)

Recognized, and TUV (EN60950-1)

Certified

 CE mark meets 73/23/EEC and

93/68/EEC directives

OPTIONS

 Positive on/off

 Heatspreader available for extended

operation

APPLICATIONS

 Telecom / DataCom

 Wireless Networks

 Optical Network Equipment  Server and Data Storage

 Industrial / Test Equipment

DATASHEET DS_H48SA12025_05052008

TECHNICAL SPECIFICATIONS

(TA=25°C, airflow rate=300 LFM, V

PARAMETER

ABSOLUTE MAXIMUM RATINGS

Input Voltage

Continuous Transient (100ms) 100ms 100 Vdc

Operating Device Temperature(Openframe) Please refer to fig24. for the measuring point -40 122 °C Operating Device Temperature(Heatspreader) Please refer to fig25. for the measuring point -40 109 °C Storage Temperature Input/Output Isolation Voltage 2250 Vdc

INPUT CHARACTERISTICS

Operating Input Voltage Input Under-Voltage Lockout

Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Hysteresis Voltage

Maximum Input Current Vin=36V, 100% Load 9.5 A No-Load Input Current 170 240 mA Off Converter Input Current 18 mA Inrush Current(I2t) With 100uF external input cap 1 A2S Input Terminal Ripple Current RMS, With 100uF/0.1ohm input cap, 100% Load 0.42 A Input Reflected-Ripple Current Pk-Pk, thru 12µH inductor, 5Hz to 20MHz, 100% Load 7 mA Input Voltage Ripple Rejection 120 Hz 50 dB

OUTPUT CHARACTERISTICS

Output Voltage Set Point Output Voltage Regulation

Over Load Io=Io,min to Io,max ±10 mV Over Line Vin=36V to 75V ±10 mV

Over Temperature Total Output Voltage Range over sample load, line and temperature 11.64 12.36 V Output Voltage Ripple and Noise 5Hz to 20MHz bandwidth

Peak-to-Peak 100% Load, 1µF ceramic, 10µF tantalum 60 120 mV

RMS 100% Load, 1µF ceramic, 10µF tantalum 30 60 mV Operating Output Current Range Full input range 0 25 A Operating Output Power Range Full input range 0 300 W Output DC Current Protection Full input range 110 150 %

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 400 mV

Negative Step Change in Output Current 75% Io,max to 50% Io,max 400 mV

Settling Time (within 1% Vout nominal) 400 uS Turn-On Transient

Start-Up Time, From On/Off Control 12 28 mS

Start-Up Time, From Input 12 28 mS Maximum Output Capacitance 100% Resistor load; 5% overshoot of Vout at startup 10000 µF

EFFICIENCY

100% Load Vin=48V 93.2 % 60% Load Vin=48V 92.5 %

ISOLATION CHARACTERISTICS

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

FEATURE CHARACTERISTICS

Switching Frequency 300 kHz ON/OFF Control, Negative Remote On/Off logic

Logic Low (Module On) Von/off -2 1.2 V

Logic High (Module Off) Von/off 3 18 V ON/OFF Control, Positive Remote On/Off logic Logic Low (Module Off) Von/off -2 1.2 V Logic High (Module On) Von/off 3 18 V

ON/OFF Current (for both remote on/off logic) Ion/off at Von/off=0.0V 0.3 mA

ON/OFF Current (for both remote on/off logic) Ion/off at Von/off=3V 10 uA

Leakage Current(for both remote on/off logic) Logic High, Von/off=15V 100 uA Output Voltage Trim Range Pout <= max rated power 9.6 13.2 V Output Voltage Remote Sense Range Pout <= max rated power 10 % Output Over-Voltage Protection Over full input range; Over full temp range 115 140 %

GENERAL SPECIFICATIONS

MTBF Io=80% of Io, max; Ta=25°C,airflow rate=300 LFM 1.5 M hours Weight Open frame 80 grams Over-Temperature Shutdown(Openframe) Please refer to Fig 24. for the measuring point 127 °C Over-Temperature Shutdown(Heatspreader) Please refer to Fig 25. for the measuring point 116 °C

=48Vdc, nominal Vout unless otherwise noted.)

NOTES and CONDITIONS H48SA12025 (Standard)

Vin=48V, Io=Io.max, Tc=25℃

Tc=-40℃ to 100℃

Min. Typ. Max. Units

80 Vdc

-55 125 °C

36 48 75 Vdc

32.5 34 35.5 Vdc

30.5 32 33.5 Vdc

1 2 3 Vdc

11.82 12 12.18 Vdc

±120 mV

DS_H48SA12025_05052008

ELECTRICAL CHARACTERISTICS CURVES

EFFICIENCY (%)

5 10152025

36Vin

OUT PUT CURRENT (A )

48Vin

75Vin

Figure 1: Efficiency vs. load current for minimum, nominal, and

maximum input voltage at 25°C. Vout=12V.

EFFICIENCY (%)

36Vin

48Vin

75Vin

POWER DISSIPATION (W)

0 5 10 15 20 25

48Vin

36Vin

OUT PUT CURRENT (A)

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

nominal, and maximum input voltage at 25°C. Vout=12V.

POWER DISSIPATION (W)

48Vin

36Vin

75Vin

5 10152025

Figure 3: Efficiency vs. load current for minimum, nominal, and

maximum input voltage at 25°C. Vout=9.6V.

DS_H48SA12025_05052008

OUT PUT CURRENT (A )

0 5 10 15 20 25

OUT PUT CURRENT (A)

Figure 4: Power dissipation vs. load current for minimum,

nominal, and maximum input voltage at 25°C. Vout=9.6V.

ELECTRICAL CHARACTERISTICS CURVES

EFFICIENCY (%)

5 10152025

36Vin

OUT P UT CURRENT (A)

48Vin

75Vin

Figure 5: Efficiency vs. output voltage for minimum, nominal,

and maximum input voltage at 25°C, Vout=

.2V.

75Vin

POWER DISS IP ATIO N (W)

0 5 10 15 20 25

48Vin

36Vin

OUT P UT CURRENT (A)

Figure 6: Power dissipation vs. output voltage for minimum,

nominal, and maximum input voltage at 25°C, Vout=13.2V.

Output Voltage (V)

30.0 31.3 33.6 35.0 40.0 45.0 50.0 55.0 60.0 65.0 70. 0 75.0

Output Current (A )

Figure 7: Typical input characteristics at room temperature. Figure 8: Turn-on transient at full rated load current, 4ms/div:

Top Trace: Vout, 5V/div; Bottom Trace: ON/OFF input, 5V/div.

DS_H48SA12025_05052008

ELECTRICAL CHARACTERISTICS CURVES

Figure 9: Turn-on transient at zero load current, 4 ms/div;

Top Trace: Vout, 5V/div; Bottom Trace: ON/OFF input, 5V/div.

Figure 10: Output voltage response to step-change in load

current, 200mV/div, 200us/div. 75%-50%-75% of Io, max, di/dt =

/µs. Load cap: 10µF, tantalum capacitor and 1µF ceramic

0.1 capacitor. 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..

+ +

++ ++

Cs: 220 uF

100uF,

ESR=0.2 ohm @

C 10 0KHz

Vin+

Vin-

Figure 11: Output voltage response to step-change in load

current, 200mV/div, 1ms/div. 75%-50%-75% of Io, max, di/dt = 1A/µs. Load cap: 5000µF tantalum capacitor and 1µF ceramic capacitor. 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..

DS_H48SA12025_05052008

Figure 12: 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 (LTEST) of 12 μH. Capacitor Cs offset possible battery impedance. Measured current as shown below.

ELECTRICAL CHARACTERISTICS CURVES

0 0

Figure 13: Input Terminal Ripple Current, i

, at nominal input

voltage and rated load current with 12µH source impedance and 100µF electrolytic capacitor, 500 mA/div, 2us/div.

Copper Strip

Vo(+)

10u 1u

SCOPE RESISTIV

LOAD

Vo(-)

Figure 15: Output voltage noise and ripple measurement

test setup

Figure 14: Input reflected ripple current, i

, through a 12µH

source inductor at nominal input voltage and rated load current,

20 mA/div, 2us/div.

Figure 16: Output voltage ripple at nominal input voltage and

rated load current, 50mV/div, 2us/div. Load capacitance: 1µF

ceramic capacitor and 10µF tantalum 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.

Output Voltage (V)

0 5 10 15 20 25 30 35

Output Current (A)

Figure 17: Output voltage vs. load current showing typical current limit curves and converter shutdown points.

DS_H48SA12025_05052008

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 33 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. Below is the reference design for an input filter tested with H48SA12025NN A to meet class B in CISSPR 22.

Schematic and Components List

Vin

CY1

L1 L2

CX1

CY1

CX is 4.7uF ceramic cap; CX1 is 4.7uF ceramic cap; CY is 3.3nF ceramic cap; CY1 is 4.7nF ceramic cap; L1 is common-mode inductor, L1=0.08mH; L2 is common-mode inductor, L1=0.24mH;

Test Result

Test result is in compliance with CISPR 22 class B, which is shown as below:

Cin

Vin(+)

Vo(+)

H48SA12025

Vin(-)

Vo(-)

LOAD

Safety Considerations

The power module must be installed in compliance with the spacing and separation requirements of the enduser’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. When the input source is 60 Vdc 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.

 If the metal baseplate is grounded the output must

be also grounded.

 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. 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 fuse with 30A 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

Vin=48V, Io=25A, Yellow line is quasi peak mode; Blue line is average mode.

DS_H48SA12025_05052008

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.

FEATURES DESCRIPTIONS

Over-Current Protection

The modules include an internal output over-current protection circuit. If the output current exceeds the OCP set point, the modules will automatically shut down, and enter hiccup mode or latch mode, which is optional.

For hiccup mode, the module 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. Hiccup mode is default mode.

For latch mode, the module will latch off once it shutdown. The latch is reset by either cycling the input power or by toggling the on/off signal for one second.

Over-Voltage Protection

The modules include an internal output over-Voltage protection circuit. If the output voltage exceeds the OVP set point, the modules will automatically shut down, and enter hiccup mode or latch mode, which is optional.

For hiccup mode, the module will try to restart after shutdown. If the over-voltage condition still exists, the module will shut down again. This restart trial will continue until the over-voltage condition is corrected. Hiccup mode is default mode.

For latch mode, the module will latch off once it shutdown. The 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, and enter in auto-restart mode or latch mode, which is optional.

For auto-restart mode, the module will monitor the module temperature after shutdown. Once the temperature is within the specification, the module will be auto-restarted. Auto-restart mode is default mode.

For latch mode, the module will latch off once it shutdown. The latch is reset by either cycling the input power or by toggling the on/off signal for one second.

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.

Vo(+)Vi(+)

Sense(+)

ON/OFF

Vi(-)

Figure 18: Remote on/off implementation

Trim R

Sense(-)

Vo(-)

Distribution resistor

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).

Vo(+)Vi(+)

Sense(+)

Trim R

ON/OFF

Vi(-)

Figure 19: 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.

Trim R

Sense(-)

Vo(-)

Distribution resistor

DS_H48SA12025_05052008

⎛⎝⎞

⎠

⎛⎝⎞

⎢

⎥

⎛⎝⎞

⎢

⎥

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 20: Circuit configuration for trim-up (increase output

voltage)

If the external resistor is connected between the TRIM and SENSE (+) pins, the output voltage set point increases (Fig. 20). The external resistor value required to obtain a percentage of output voltage change △% is defined as:

Rtrim_up

⎡

1.225

⎣

()

2−

100 Δ+

⋅ 100+

⎠

Ex. When trim up to 13.2V from 12V Δ = 100*(13.2-12)/12 = 10

⎡

Rtrim_up

1.225

⎣

Rtrim_up = 95.755 kΩ

2−

100 10+()⋅ 100+

⎠

⎤

kΩ

⎦

⎤

kΩ

⎦

Figure 21: Circuit configuration for trim-down (decrease output

voltage)

If the external resistor is connected between the TRIM and SENSE (-) the output voltage set point decreases (Fig. 21). The external resistor value required to obtain a percentage of output voltage change △% is defined as:

Rtrim_down

Ex. When trim down to 9.6V from 12V Δ = 100*(12-9.6)/12 = 20

Rtrim_down =

Rtrim_down = 3 kΩ

The typical resistor value can be seen in below figure22.

Output voltage

13.2V 95.8

12.6V 183.7

10.8V 8.0

9.6V 3.0

Figure 22: Trim resistor value example for popular output

voltages

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.

100

( −

Resistor value (

2−

kΩ

kΩ

Ωk )

DS_H48SA12025_05052008

)

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 is constantly kept at

6.35mm (0.25’’).

Thermal Derating

Heat can be removed by increasing airflow over the module. The module’s maximum device temperature is to be defined and the measured location is illustrated in Figure 24. 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

AIR VELOCIT AND AMBIENT

TEMPERATURE

MEASURED BELOW

THE MODULE

Note: Wind Tunnel Test Se tup Fig u r e Dimensions are in millimeters an d (In che s )

Figure 23: Wind tunnel test setup

PWB

MODULE

50.8 (2.0”

IR FLOW

12.7 (0.5”)

DS_H48SA12025_05052008

THERMAL CURVES

Output Current (A)

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

H48SA12025(Standard) Output Current vs. Ambient Temperature and Air Velocity

Natural

Convection

100LFM

@Vin = 48V (Either Orientation)

200LFM

300LFM

400LFM

Ambient Temperature

600LFM

500LFM

Figure 24: Temperature measurement location for openframe

version - The allowed maximum hot spot temperature is defined at 122

℃

Figure 25: Temperature measurement location for heatspreader

version - The allowed maximum hot spot temperature is defined at 109

℃

Figure 26: Output current vs. ambient temperature and air

velocity @ V

=48V, Vout=12V(Openframe Version, Either

Orientation).

Output Current (A)

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

H48SA12025(standard) O utput Current vs. Ambient Temperature and Air Velo city

Natural

Convection

100LFM

Figure 27: Output current vs. ambient temperature and air

velocity @ V Orientation).

@Vin = 48V (Either Orientation,With Heatspreader)

200LFM

300LFM

400LFM

500LFM

600LFM

Ambient Temperature

=48V, Vout=12V(Heatspreader version, Either

DS_H48SA12025_05052008

MECHANICAL DRAWING (WITHOUT HEATSPREADER)

Pin No. Name Function

1 2 3 4 5 6 7 8 9

Notes:

1 2 3

DS_H48SA12025_05052008

+Vin ON/OFF CASE

-Vin

-Vout

-SENSE TRIM +SENSE +Vout

Pins 1-4, 6-8 are 1.00mm (0.040”) diameter Pins 5 and 9 are 2.00mm (0.079”) diameter All pins are copper with Tin plating.

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

MECHANICAL DRAWING (WITH HEATSPREADER)

DS_H48SA12025_05052008

PART NUMBERING SYSTEM

H 48 S A 120 25 N N F A

Form

Factor

H - Half-

Brick

Input

Voltage

48V S- Single A - Advanced 120- 12V 25- 25A N - Negative

Number of

Outputs

Product

Series

Output

Voltage

Output

Current

ON/OFF

Logic

P - Positive

Length

N - 0.145”

Option Code

F- RoHS 6/6

(Lead Free)

A - Standard Functions H - with Heatspreader

MODEL LIST

Part Number INPUT OUTPUT EFF @ 100% LOAD

H48SA12025NNFA 36V~75V 11A 12V 25A 93.2%

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

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

Europe:

Phone: +41 31 998 53 11 Fax: +41 31 998 53 53 Email: DCDC@delta-es.com

Asia & the rest of world:

Telephone: +886 3 4526107 ext 6220 Fax: +886 3 4513485 Email: DCDC@delta.com.tw

DS_H48SA12025_05052008

Delta Electronics H48SA User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual