Delta Electronics H48SL User Manual

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Delphi Series H48SL, 200W Half Brick Family
FEATURES
High Efficiency: 84% @ 1.5V/60A
Size: 57.9 x 61.0 x 12.7mm
(2.28” x 2.40” x 0.50”)
Standard footprint
Industry standard pin out
Fixed frequency operation
Metal baseplate
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 (US & Canada)
Recognized, and TUV (EN60950)
Certified
CE mark meets 73/23/EEC and
93/68/EEC directives
DC/DC Power Modules: 48V in, 1.5V/60A out
The Delphi Series H48SL Half Brick, 48V input, single output, isolated
DC/DC converters are the latest offering from a world leader in powe
product family provides up to 200 watts of power (3.3V and above) o
60A of output current in an industry standard footprint. 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.
voltage, current, and temperature conditions. The Delphi Series
converters meet all safety requirements with basic insulation.
ll models are fully protected from abnormal input/outpu
OPTIONS
Positive Remote On/Off logic
Negative trim
Short pin lengths
APPLICATIONS
Telecom/Datacom
Wireless Networks
Optical Network Equipment Server and Data Storage
Industrial/Test Equipment
DATASHEET DS_H48SL1R560_10302006
TECHNICAL SPECIFICATIONS
(TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted)
PARAMETER NOTES and CONDITIONS H48SL1R560 (Standard)
ABSOLUTE MAXIMUM RATINGS
Input Voltage
Continuous 80 Vdc
Transient (100ms) 100ms 100 Vdc Operating Case Temperature Tc -40 +100 °C Storage Temperature -55 +125 °C Input/Output Isolation Voltage 1 minute 1500 Vdc

INPUT CHARACTERISTICS

Operating Input Voltage 36 48 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 2 3 Vdc
Maximum Input Current 100% Load, 36Vin 3.6 A No-Load Input Current 60 150 mA Off Converter Input Current 3 10 mA Inrush Current(I2t) 0.03 A2s Input Reflected-Ripple Current P-P thru 12µH inductor, 5Hz to 20MHz 25 mA Input Voltage Ripple Rejection 120 Hz 65 dB

OUTPUT CHARACTERISTICS

Output Voltage Set Point Output Voltage Regulation
Over Load Io=Io,min to Io,max ±2 ±5 mV
Over Line Vin=36V to 75V ±2 ±5 mV
Over Temperature
Total Output Voltage Range over sample load, line and temperature 1.43 1.57 V Output Voltage Ripple and Noise 5Hz to 20MHz bandwidth
Peak-to-Peak Full Load, 1µF ceramic, 10µF tantalum 75 150 mV
RMS Full Load, 1µF ceramic, 10µF tantalum 25 40 mV
Operating Output Current Range 0 60 A Output DC Current-Limit Inception Output Voltage 10% Low 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 80 mV
Negative Step Change in Output Current 75% Io.max to 50% Io.max 80 mV
Settling Time (within 1% Vout nominal) 100 us
Turn-On Transient
Start-Up Time, From On/Off Control 10 20 ms
Start-Up Time, From Input 10 20
Maximum Output Capacitance Full load; 5% overshoot of Vout at startup 20000 µF

EFFICIENCY

100% Load 60% Load 87 %

ISOLATION CHARACTERISTICS

Input to Output 1500 Vdc Input to Case Output to Case 500 Vdc Isolation Resistance 10 M Isolation Capacitance 1300 pF

FEATURE CHARACTERISTICS

Switching Frequency 180 kHz ON/OFF Control, Negative Remote On/Off logic
Logic Low (Module On) Von/off at Ion/off=1.0mA 0 0.8 V
Logic High (Module Off) Von/off at Ion/off=0.0 µA 15 V
ON/OFF Control, Positive Remote On/Off logic
Logic Low (Module Off) Von/off at Ion/off=1.0mA 0 0.4 V
Logic High (Module On) Von/off at Ion/off=0.0 µA 15 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 115 122 130 %

GENERAL SPECIFICATIONS

MTBF Io=80% of Io, max; Ta=25°C 2.23 M hours Weight 85 grams Over-Temperature Shutdown Average PCB Temperature 110 °C

Min. Typ. Max. Units
Vin=48V, Io=Io.max, Tc=25
Tc =- 4 0 to 100
84 %
1500 Vdc
Across Pins 9 & 5, Pout max rated power
Pout max rated power
1.47 1.5 1.53
±15 ±50 mV
-20 +10 % 10 %
Vdc
ms
DS_H48SL1R560_10302006
2
ELECTRICAL CHARACTERISTICS CURVES
90
85
80
EFFICIENCY (%)
75
70
36Vin 48Vin 75Vin
65
10 20 30 40 50 60
OUTPUT CURRENT (A)
Figure 1: Efficiency vs. load current for minimum, nominal, and
maximum input voltage at 25°C.
3.5 Io=60A Io=36A Io=6A
3.0
2.5
20.0
36Vin 48Vin 75Vin
16.0
12.0
8.0
POWER DISSIPATION (W)
4.0
0.0 10 20 30 40 50 60
OUTPUT CURRENT(A)
Figure 2: Power dissipation vs. load current for minimum,
nominal, and maximum input voltage at 25°C.
2.0
INPUT CURRENT (A)
1.5
1.0
0.5
0.0 30 35 40 45 50 55 60 65 70 75
INPUT VOLTAGE (V)
Figure 3: Typical input characteristics at room temperature
DS_H48SL1R560_10302006
3
ELECTRICAL CHARACTERISTICS CURVES
For Negative Remote On/Off Logic
Figure 4: Turn-on transient at full rated load current (resistive load) (2 ms/div). Top Trace: Vout; 500mV/div; Bottom Trace: ON/OFF input: 10V/div
For Positive Remote On/Off Logic
Figure 5: Turn-on transient at zero load current (2 ms/div). To p
Trace: Vout: 500mV/div; Bottom Trace: ON/OFF input: 10V/div
Figure 6: Turn-on transient at full rated load current (resistive load) (2 ms/div). Top Trace: Vout; 500mV/div; Bottom Trace: ON/OFF input: 2V/div
DS_H48SL1R560_10302006
Figure 7: Turn-on transient at zero load current (2 ms/div). To p
Trace: Vout: 500mV/div; Bottom Trace: ON/OFF input: 2V/div
4
ELECTRICAL CHARACTERISTICS CURVES
A
A
A
)
)
)
Figure 8: Output voltage response to step-change in load
current (75%-50%-75% of Io, max; di/dt = 0.1 10µF, tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (100mV/div), Bottom Trace: Iout (10 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.
/µs). Load cap:
/div). Scope
Figure 9: Output voltage response to step-change in load
current (75%-50%-75% of Io, max; di/dt = 2.5A/µs). Load cap: 470µF, 35m capacitor. Top Trace: Vout (100mV/div), Bottom Trace: Iout (10 cable (length shorter than 20 inches between 51 mm to 76 mm (2 inches to 3 inches
module.
ESR solid electrolytic capacitor and 1µF ceramic
/div). Scope measurement should be made using a BNC
. Position the load
from the
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
DS_H48SL1R560_10302006
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ELECTRICAL CHARACTERISTICS CURVES
E
Figure 11: Input Terminal Ripple Current, i current and nominal input voltage with 12µH source impedance and 33µF electrolytic capacitor (1A/div).
, at full rated output
c
Copper Strip
Vo(+)
10u 1u
SCOPE RESISTIV
LOAD
Vo(-)
Figure 13: Output voltage noise and ripple measurement test setup
Figure 12: Input reflected ripple current, i
source inductor at nominal input voltage and rated load current (20 mA/div).
, through a 12µH
s
DS_H48SL1R560_10302006
6
ELECTRICAL CHARACTERISTICS CURVES
1.6
1.4
1.2
1.0
0.8
0.6
OUTPUT VOLTAGE (V)
0.4
48Vin
0.2
0.0
0 102030405060708090100
LOAD CURRENT (A)
Figure 14: Output voltage ripple at nominal input voltage and rated load current (20 mV/div). Load capacitance: 1µF ceramic
capacitor and 10µF tantalum capacitor. Bandwidth: 20 MHz.
Figure 15: Output voltage vs. load current showing typical
current limit curves and converter shutdown points.
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_H48SL1R560_10302006
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THERMAL CURVES: NO HEATSINK, EITHER ORIENTATION
)
m
" 6
m
0 .
7
1
2
(
26 mm (1.02")
On/Off
Case
out
Sense
Trim
Sense(-)
out
Output Current(A)
64
56
48
40
32
24
16
8
0
0 1020304050607080901
H48SL1R560(Standard) Output Current vs. Ambient Temperature and Air Velocity
Natural
Convection
@ Vin < 60V (Either Orientation, no Heat sink)
100LFM
200LFM
300LFM
600LFM
500LFM
400LFM
Ambient Temperature (℃)
00
Figure 16: Case temperature measurement location.
Pin locations are for reference only.
Output Current(A)
64
56
48
40
32
24
16
8
0
0 10203040506070809010
H48SL1R560(Standard) Output Current vs. Ambient Temperature and Air Velocity
Natural
Convection
Figure 18: Output current vs. ambient temperature and air velocity
(V
=75V)
in
@ Vin = 75V (Either Orientation, no Heat sink)
100LFM
200LFM
300LFM
600LFM
500LFM
400LFM
Ambient Temperature (℃)
0
Figure 17: Output current vs. ambient temperature and air
velocity (V
Power Dissipation (Watts)
21
18
15
12
9
6
3
0
0 1020304050607080901
<60V)
in
H48SL1R560(Standard) Power Dissipation vs. Ambient Temperature and Air Velocity
Natural
Convection
100LFM
(Either Orientation, no Heat sink)
600LFM
200LFM
300LFM
500LFM
400LFM
Ambient Temperature (℃)
Figure 19: Power dissipation vs. ambient temperature and air
velocity
00
DS_H48SL1R560_10302006
8
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 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 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_H48SL1R560_10302006
9
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
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 may 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.
DS_H48SL1R560_10302006
Vo(+)Vi(+)
Sense(+)
ON/OFF
Sense(-)
Vi(-)
Vo(-)
Figure 20: 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 21: 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 may 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.
10
FEATURES DESCRIPTIONS (CON.)
⎛⎝⎞
(
Output Voltage Adjustment (TRIM)
To increase or decrease the output voltage set point, connect 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 22: 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. 22) The external resistor value required to obtain a percentage of output voltage change % is defined as:
Rtrim down=
Ex. When Trim-down -20%(1.5V×0.8=1.2V)
Vo 1.5:= V 20:=
100
100 %
2 3= K Ω
2
ΚΩ
Figure 23: 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. 23). The external resistor value required to obtain a percentage output voltage change % is defined
as:
Rtrim up=
Vo 100 %+
1.225%
)
100 2%+
%
ΚΩ
Ex. When Trim-up +10%(1.5V×1.1=1.65V)
Vo 1.5:= V 10:=
()
Vo 100 +
1.225 ∆⋅
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 2 ∆⋅+
1.469= K
DS_H48SL1R560_10302006
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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’’).
Thermal Derating
Heat may be removed by increasing airflow over the module. The module’s maximum case temperature is +100°C. 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 Setup Figure Dimensions are in millimeters and (Inches)
Figure 24: Wind tunnel test setup
PWB
MODULE
50.8 (2.0”)
IR FLOW
12.7 (0.5”)
DS_H48SL1R560_10302006
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MECHANICAL DRAWING
Pin No. Name Function
1 2 3 4 5 6 7 8 9
Pin Specification:
Pins 1-4, 6-8 1.00mm (0.040”) diameter Pins 5 & 9 2.00mm (0.079”) diameter
All pins are copper with Tin plating.
DS_H48SL1R560_10302006
-Vin Case ON/OFF +Vin +Vout +SENSE TRIM
-SENSE
-Vout
Negative input voltage Case ground Remote ON/OFF Positive input voltage Positive output voltage Positive remote sense Output voltage trim Negative remote sense Negative output voltage
13
PART NUMBERING SYSTEM
H 48 S L 1R5 60 N R F A
Form Factor Input
Voltage
H – Half-Brick 48V S - Single L - IMS,
Number of
Outputs
Product
Series
positive trim
Output
Voltage
1R5 - 1.5V 60 - 60A N - Negative
Output
Current
ON/OFF
Logic
P - Positive
Pin Length Option Code
R - 0.170” N - 0.145” K - 0.110”
F- RoHS 6/6 Lead Free)
MODEL LIST
MODEL NAME INPUT OUTPUT EFF @ 100% LOAD
H48SL1R560NRFA 36V~75V 3.6A 1.5V 60A 84%
H48SL1R860NRFA 36V~75V 4.3A 1.8V 60A 85%
H48SL2R560NRFA 36V~75V 5.7A 2.5V 60A 88%
H48SL3R360NRFA 36V~75V 7.4A 3.3V 60A 89%
H48SL05040NRFA 36V~75V 7.4A 5V 40A 90.5%
H48SL12020NRFA 36V~75V 8.7A 12V 20A 91%
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.
A - Standard Functions
CONTACT: www.delta.com.tw/dcdc
USA:
Telephone: East Coast: (888) 335 8201 West Coast: (888) 335 8208 Fax: (978) 656 3964
DCDC@delta-corp.com
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
.
Europe:
Telephone: +41 31 998 53 11 Fax: +41 31 998 53 53
DCDC@delta-es.tw
Email:
Asia & the rest of world:
Telephone: +886 3 4526107 x6220 Fax: +886 3 4513485
DCDC@delta.com.tw
Email:
DS_H48SL1R560_10302006
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