Delta Electronics H48SR User Manual

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Page 1

FEATURES

 High Efficiency 89% @ 1.8V/80A

 Standard footprint: 58.4 x 61.0 x 11.7mm

(2.30” x2.40” x0.46”)

 Industry standard pin out

 Startup into pre-biased load

 Fixed frequency operation

 Fully protected: OTP, OVP, OCP, UVLO

 No minimum load required

 Wide output trim range

 Fast transient response

 Basic insulation

 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

Delphi Series H48SR, 200W Half Brick Family DC/DC Power Modules: 48V in, 1.8V/80A out

The Delphi Series H48SR Half Brick, 48V input, adjustable 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 200 watts o

power or up to 80A of output current in an industry standard footprint.

This product represents the next generation of design technology which

may be utilized to provide high levels of current at very low output

voltages required by today’s leading-edge circuitry. Utilizing an

advanced patented thermal and electrical design technology, the Delphi

Series H48SR converters are capable of providing much higher output

current capability with excellent transient response and lower common

mode noise. Featuring a wide operating output voltage range and high

current at low output voltages, these units offer more useable powe

over a wide range of ambient operating conditions. The wide range

trimmable output feature allows the user to both reduce and

standardize part numbers across different and/or migrating voltage

requirements.

OPTIONS

 Short lead lengths

 Latching/non-latching over voltage

protection

 Positive/negative trim

 Positive/negative remote on/off

 100V/100ms transient capability or

80V input OVLO

APPLICATIONS

 Telecom/DataCom

 Wireless Networks

 Optical Network Equipment  Server and Data Storage

 Industrial/Test Equipment

DATASHEET DS_H48SR1R880_06272006

Delta Electronics, Inc.

Page 2

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 Tc -40 115 °C Storage Temperature Input/Output Isolation Voltage 1 minute 1500 Vdc

INPUT CHARACTERISTICS

Operating Input Voltage Input Under-Voltage Lockout

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

Maximum Input Current 100% Load, 36Vin 5 A No-Load Input Current 100 140 mA Off Converter Input Current 15 25 mA Inrush Current(I2t) 0.03 A2S Input Reflected-Ripple Current Input Voltage Ripple Rejection 120 Hz 60 dB

OUTPUT CHARACTERISTICS

Output Voltage Set Point Vin=48V, Io=Io.max, Tc=25°C 1.75 1.8 1.85 Output Voltage Regulation

Over Load Io=Io,min to Io,max ±2 ±7 mV Over Line Vin=36V to 75V ±2 ±5 mV

Over Temperature Tc=-40°C to 100°C ±20 ±50 mV Total Output Voltage Range over sample load, line and temperature TBD TBD V Output Voltage Ripple and Noise 5Hz to 20MHz bandwidth

Peak-to-Peak Full Load, 1µF ceramic, 10µF tantalum 70 120 mV

RMS Full Load, 1µF ceramic, 10µF tantalum 20 40 mV Operating Output Current Range 0 80 A Output DC Current-Limit Inception Output Voltage 10% Low 105 130 %

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 50 100 mV

Negative Step Change in Output Current 75% Io,max to 50% Io,max 50 100 mV

Settling Time (within 1% Vout nominal) 200 uS Turn-On Transient

Start-Up Time, From On/Off Control 10 20 mS

Start-Up Time, From Input -40°C to +125°C 20 40

Maximum Output Capacitance Full load; 5% overshoot of Vout at startup 20000 µF

EFFICIENCY

100% Load 60% Load 90 %

ISOLATION CHARACTERISTICS

Input to Output 1500 Vdc Isolation Resistance 10 MΩ Isolation Capacitance 3000 pF

FEATURE CHARACTERISTICS

Switching Frequency 240 kHz ON/OFF Control, (Logic Low-Module ON)

Logic Low Von/off at Ion/off=1.0mA 0 0.8 V

Logic High Von/off at Ion/off=0.0 µA 15 V

ON/OFF Current Ion/off at Von/off=0.0V 1 mA

Leakage Current Logic High, Von/off=15V 50 uA Output Voltage Trim Range Across Pins 9 & 5, Pout <= max rated powe Output Voltage Remote Sense Range Pout <= max rated power 10 % Output Over-Voltage Protection Over full temp range; % of nominal Vout 115 130 155 %

GENERAL SPECIFICATIONS

MTBF Io=80% of Io, max; Ta=25°C,airflow rate=300 LFM 1.41 M hours

Weight 66 grams Over-Temperature Shutdown Power Region Temperature 130 °C

=48Vdc, nominal Vout unless otherwise noted.)

NOTES and CONDITIONS H48SR1R880NRFA

P-P thru 12µH inductor, 5Hz to 20MHz 10 mA

89 %

Min. Typ. Max. Units

80 Vdc

-55 125 °C

36 48 75 Vdc

32.5 34 35 Vdc 31 32 33.5 Vdc

1 2 3 Vdc

0.8 1.9 V

Vdc

DS_H48SR1R880_06272006

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ELECTRICAL CHARACTERISTICS CURVES

36Vin 48Vin 75Vin

EFFICIENT (%)

10 20 30 40 50 60 70 80

OUTPUT CURRENT (A)

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

maximum input voltage at 25°C. (Vout=1.8V)

24.0

36Vin 48Vin 75Vin

20.0

16.0

POWER DISSIPATION (W)

12.0

8.0

4.0

0.0

10 20 30 40 50 60 70 80

OUTPUT CURRENT(A)

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

nominal, and maximum input voltage at 25°C. (Vout=1,8V)

24.0

36Vin 48Vin 75Vin

20.0

EFFICIENT (%)

36Vin 48Vin 75Vin

10 20 30 40 50 60 70 80

OUTPUT CURRENT (A)

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

maximum input voltage at 25°C. (Vout=0.8V)

16.0

POWER DISSIPATION (W)

12.0

8.0

4.0

0.0

10 20 30 40 50 60 70 80

OUTPUT CURRENT(A)

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

nominal, and maximum input voltage at 25°C. (Vout=0.8V)

DS_H48SR1R880_06272006

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ELECTRICAL CHARACTERISTICS CURVES

EFFICIENCY (%)

36Vin 48Vin 75Vin

0.8 1.0 1.2 1.4 1.6 1.8

OUTPUT VOLTAGE (V)

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

and maximum input voltage at 25°C. (Iout=80A)

6.0

Io=80A Io=48A Io=8A

5.0

24.0

22.0

20.0

POWER DISSIPATION (W)

18.0

16.0

14.0

12.0

36Vin 48Vin 75Vin

10.0

0.8 1.0 1.2 1.4 1.6 1.8

OUTPUT VOLTAGE (V)

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

nominal, and maximum input voltage at 25°C. (Iout=80A)

4.0

INPUT CURREN (A)

3.0

2.0

1.0

0.0

30 35 40 45 50 55 60 65 70 75

INPUT VOLTAGE (V)

Figure 7: Typical input characteristics at room temperature Figure 8: Turn-on transient at full rated load current (resistive

load) (1 ms/div). Top Trace: Vout; 1V/div; Bottom Trace:

ON/OFF input: 2V/div

DS_H48SR1R880_06272006

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ELECTRICAL CHARACTERISTICS CURVES



)

Figure 9: Turn-on transient at zero load current (2 ms/div).

Top Trace: Vout: 1V/div; Bottom Trace: ON/OFF input: 2V/div

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

current (75%-50%-75% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF, tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (20 mV/div), Bottom Trace: Iout (20 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). Scope

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

current (75%-50%-75% of Io, max: di/dt = 2.5A/µs). Load cap: 470µF, 35m ceramic capacitor. Top Trace: Vout (100mV/div), Bottom Trace: Iout (20 using a BNC cable (length shorter than 20 inches the load between 51 mm to 76 mm (2 inches to 3 inches from the module.

Ω

/div). Scope measurement should be made

DS_H48SR1R880_06272006

ESR solid electrolytic capacitor and 1µF

. Position

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 (L battery impedance. Measure current as shown above.

) of 12 µH. Capacitor Cs offset possible

TEST

Page 6

ELECTRICAL CHARACTERISTICS CURVES

Figure 13: Input Terminal Ripple Current, i

, at full rated

output current and nominal input voltage with 12µH source

impedance and 33µF electrolytic capacitor (500 mA/div).

Copper Strip

Vo(+)

10u 1u

SCOPE RESISTIV

LOAD

Vo(-)

Figure 15: Output voltage noise and ripple measurement

test setup

2.0

1.8

1.6

1.4

1.2

OUTPUT VOLTAGE (V)

1.0

0.8

0.6

0.4

0.2

0.0

Vin= 48V

0 10 203040 5060708090100

LOAD CURRENT (A)

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

Figure 14: Input reflected ripple current, i

, through a 12µH

source inductor at nominal input voltage and rated load current

(5 mA/div).

Figure 16: Output voltage ripple at nominal input voltage and

rated load current (50 mV/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.

DS_H48SR1R880_06272006

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THERMAL CURVES

Output Current(A)

0 10203040506070809010011

Figure 18: Hot spot location (unit in mm) Figure 19: Output current vs. ambient temperature and air

velocity (Vin=48V / 75V, V

H48SR1R880(Standard) Output Current vs. Ambient Temperature and Ai r Velocity

Natural

Convection

@ Output Voltage 0.8V (Eit her Orientation)

100LFM

200LFM

=0.8V )

out

300LFM

600LFM

Ambient Temperature (℃)

500LFM

400LFM

Output Current(A)

0 1020304050607080 90100

H48SR1R880(Standard) Output Current vs. Ambient Temperature and Ai r Velocity

Natural

Convection

Figure 20: Output current vs. ambient temperature and air

velocity (Vin=48V / 75V, V

@ Output Voltage 1.8V (Eit her Orientation)

100LFM

200LFM

=1.8V )

out

600LFM

500LFM

400LFM

300LFM

Ambient Temperature (℃)

H48SR1R880(Standard) Power Dis sipation vs. Ambient Temperature and Air V elocity

Power Dissipation (Watts)

Natural

Convection

100LFM

0 102030 405060708090100110

Figure 21: Power dissipation vs. ambient temperature and air

velocity (Vin=48V / 75V, V

(Either Orientation)

200LFM

=0.8V~1.8V )

out

600LFM

500LFM

400LFM

300LFM

Ambient Temperature (℃)

DS_H48SR1R880_06272006

Page 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 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 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_H48SR1R880_06272006

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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 overvoltage set point, the module will shut down and latch off. The over-voltage latch is reset by cycling the input power 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 overtemperature 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 floating.

Vo(+)Vi(+)

Sense(+)

ON/OFF

Sense(-)

Vi(-)

Vo(-)

Figure 22: 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 23: 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.

DS_H48SR1R880_06272006

Page 10

FEATURES DESCRIPTIONS (CON.)

Ω

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 24: 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. 24). The external resistor value required to obtain a percentage of output voltage change △% is defined as:

upRtrim 1110

⎢ ⎣

⎡

()

=∆− kk

()

∆

ref

where Vonom = nominal Vout (1.8V) Vref = 1.225V ∆ = trim expressed as decimal fraction, i.e. 10% is written as 0.1

Ex. When trim up to 1.9V from 1.8V Vonom = 1.8V Vref = 1.225V

∆ = (1.9-1.8)/1.8 = 0.05556

()()

[]

=−

Ω=Ω−

18.8811

05556.0*225.1

⎤

−∆+

refonom

V1V

⎥ ⎦

−

225.105556.1*8.1 10

Ω−Ω

Ω×

KupRtrim

Figure 25: 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. 25). The external resistor value required to obtain a percentage output voltage change △% is defined

as:

()

downRtrim 11

where Vonom = nominal Vout (1.8V) ∆ = trim expressed as decimal fraction, i.e. 40% is written as 0.4

=∆− k

∆

Ω−

Ex. When trim down to 0.8V from 1.8V Vonom = 1.8V ∆ = (1.8-0.8)/1.8 = 0.5556

downRtrim 711

Ω=Ω−=− KK

5556.0

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.

Output voltage

1.5V 49.00

1.2V 19.00

1.0V 11.50

0.9V 9.0

0.8V 7.0

Figure 26: Trim resistor value example for popular output

Resistor value (

k )

DS_H48SR1R880_06272006

Page 11

)

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 115 ℃ and the measured location is illustrated in Figure

18. 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 27: Wind Tunnel Test Setup

PWB

MODULE

50.8 (2.0”

IR FLOW

12.7 (0.5”)

DS_H48SR1R880_06272006

Page 12

MECHANICAL DRAWING

Pin No. Name Function

1 2 3 4 5 6 7 8

Notes:

1 2 3

DS_H48SR1R880_06272006

-Vin ON/OFF +Vin +Vout +SENSE TRIM

-SENSE

-Vout

Pins 1-3, 5-7 are 1.00mm (0.039”) diameter Pins 4 and 8 are 2.00mm (0.079”) diameter All pins are copper with Tin plating.

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

Page 13

PART NUMBERING SYSTEM

H 48 S R 1R8 80 N R F A

Form

Factor

H- Half Brick 48-

Input

Voltage

36V~75V

Number of

Outputs

S- Single R- Single

Product

Series

Board

Output

Voltage

1R8- 1.8V 80- 80A N- Negative

Output

Current

ON/OFF

Logic

P- Positive

Length

R- 0.170” N- 0.145” K- 0.110”

Option Code

F- RoHS 6/6

(Lead Free)

A - Standard

Functions

MODEL LIST

Part Number INPUT OUTPUT EFF @ 100% LOAD

H48SR1R860NRFA 36V~75V

H48SR1R880NRFA 36V~75V 5.0A 0.8V – 1.9V 80A 89%

H48SR3R360NRFA 36V~75V 6.4A 1.45V – 3.6V 60A 90%

3.7A

Please contact us for modules with fixed output voltages.

CONTACT:

USA:

Telephone: East Coast: (888) 335 8201 West Coast: (888) 335 8208 Fax: (978) 656 3964

DCDC@delta-corp.com

Email:

www.delta.com.tw/dcdc

Europe:

Telephone: +41 31 998 53 11 Fax: +41 31 998 53 53

DCDC@delta-es.tw

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

0.8V – 1.9V 60A

Asia & the rest of world:

Telephone: +886 3 4526107 x6220 Fax: +886 3 4513485 Email:

88%

DCDC@delta.com.tw

DS_H48SR1R880_06272006