FEATURES High efficiency: 96.6% @11V/49A Size: open frame 57.9 x 36.8 x 11.7mm (2.28"x1.45"x0.46") with heat spreader 57.9 x 36.8 x 13.2mm (2.28"x1.45"x0.52") Industry standard pin out Input OVP, UVLO; output OCP and OTP 2250V Isolation and basic insulation Monotonic startup into normal and Pre-biased loads No minimum load required Provide optional trim pin for active current sharing of parallel application Double output pin for better thermal and high current/power handling ISO 9001, TL 9000, ISO 14001, QS 9000, OHSAS 18001 certified manufacturing facility UL/cUL 60950-1 (US & Canada) Recognized. Delphi Series Q48SK11049 Quarter Brick Family DC/DC Power Modules: 48V In, 11V/49A Out OPTIONS The Delphi Series Q48SK11049, Quarter Brick, single output, isolated DC/DC converters are the latest offering from a world leader in power systems technology and manufacturing Delta Electronics, Inc. The Q48SK11049 series product is a regulated Bus converter at a certain Vin, and the Vo will be regulated along with Vin with a fixed proportion; It can operate with 49A max output current from 38V to 58V Vin in an industry standard quarter brick footprint. At 58V input, the module provides up to 660W output power. Typical efficiency for the 48V Vin, 11V/49A output is 96.6%. 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. All models are fully protected from abnormal input/output voltage, current, and temperature conditions. The Delphi Series converters meet all safety requirements with basic insulation. DATASHEET DS_Q48SK11049_ 12132012 Positive On/Off logic Short pin lengths Heat spreader available for extended operation. Additional trim pin for current sharing of parallel application APPLICATIONS Telecom/DataCom Wireless Networks Optical Network Equipment Server and Data Storage Industrial/Test Equipment TECHNICAL SPECIFICATIONS (TA=25C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER NOTES and CONDITIONS Q48SK11049 (Standard) Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Operating Ambient Temperature Storage Temperature Input/Output Isolation Voltage INPUT CHARACTERISTICS Operating Input Voltage Input Under-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Hysteresis Voltage Input Over-Voltage Lockout Turn-Off Voltage Threshold Turn-On Voltage Threshold Lockout Hysteresis Voltage Maximum Input Current No-Load Input Current Off Converter Input Current Inrush Current(I2t) Start up Current Input Terminal Ripple Current Input Reflected-Ripple Current OUTPUT CHARACTERISTICS Output Voltage Set Point Vo equation By calculation Output Voltage Regulation Over Load Over Line Over Temperature Total Output Voltage Range Output Voltage Ripple and Noise Peak-to-Peak RMS Operating Output Current Range Output Over Current Protection Threshold Operating Time of Hiccup Mode Over Current Protection DYNAMIC CHARACTERISTICS Output Voltage Current Transient Positive Step Change in Output Current Negative Step Change in Output Current Setting Time (within 1% Vout nominal) Turn-On Transient Start-Up Time, From On/Off Control Start-Up Time, From Input Maximum Output Capacitance EFFICIENCY 100% Load 60% Load ISOLATION CHARACTERISTICS Input to Output Isolation Resistance Isolation Capacitance FEATURE CHARACTERISTICS Switching Frequency ON/OFF Control, Negative Remote On/Off logic Logic Low (Module On) Logic High (Module Off) ON/OFF Control, Positive Remote On/Off logic Logic Low (Module Off) Logic High (Module On) ON/OFF Current (for both remote on/off logic) ON/OFF Current (for both remote on/off logic) Leakage Current (for both remote on/off logic) Output Voltage Trim Range GENERAL SPECIFICATIONS MTBF (with heat spreader) Weight (without heat spreader) Weight (with heat spreader) -40 -55 ( Without heat spreader) DS_Q48SK11049_12132012 Vdc C C Vdc Vdc 34.5 32.5 1 36 34 2 37.5 35.5 3 Vdc Vdc Vdc 60.5 58.5 1 62 60 2 16 0.22 63.5 61.5 3 12.4 170 15 1 20 0.44 Vdc Vdc Vdc A mA mA A2s A A 20 40 mA 10.7 0.89*(Vin/4) 11 0.91*(Vin/4) Vdc Vdc 10.4 0.87*(Vin/4) Io=Io,min to Io,max Vin=38V to 58V Tc=-40C to 125C 120 4.4 +/-120 7.8 80 20 0 59 Full Load, 10F Tan & 1F Ceramic cap, 0.1A/s 50% Io.max to 75% Io.max 75% Io.max to 50% Io.max 15 15 20 20 95.8 95.8 96.6 96.6 Full load; no overshoot of Vout at startup Vin=48V, Io=49A Vin=48V, Io=30A 60 85 125 2250 58 FullA Load, With 100uF external input capacitor Peak, Vin=38V, Full Load, With 5000uF Co RMS, Vin=48V, Full Load, With 100uF input cap. P-P thru 12H inductor, 5Hz to 20MHz, Vin=48V, Full Load, over sample load, and temperature 5Hz to 20MHz bandwidth Full Load, 1F ceramic, 10F tantalum Full Load, 1F ceramic, 10F tantalum Full input voltage range Output Voltage 10% Low Units 48 110 12 Vin=48V, Full Load, Tc=25C Vin Max. 38 Vin=38V, Full Load, mV V mV 14.5 V 150 60 49 64 40 mV mV A A ms 300 300 200 mV mV s 40 40 5000 ms ms F % % 2250 1500 Vdc M pF 160 kHz 10 Von/off Von/off -0.7 2.0 0.8 50 V V Von/off Von/off Ion/off at Von/off=0.0V Ion/off at Von/off=2.0V Logic High, Von/off=15V -0.7 2.0 0.8 50 1 V V mA A A % 10 50 0 -5 Io=80% of Io, max; 300LFM; Ta=25C Refer to Figure 18 for Hot spot 1 location (48Vin,80% Io, 200LFM,Airflow from Vin+ to Vin-) Refer to Figure 20 for Hot spot 2 location Over-Temperature Shutdown (With heat spreader) (48Vin,80% Io, 200LFM,Airflow from Vin+ to Vin-) Over-Temperature Shutdown ( NTC resistor ) Refer to Figure 18 for NTC resistor location Note: Please attach thermocouple on NTC resistor to test OTP function, the hot spots' temperature is just for reference. Over-Temperature Shutdown Typ. 1.75 53 67 M hours grams grams 125 C 116 C 125 C 2 ELECTRICAL CHARACTERISTICS CURVES W % 22 98 20 97 18 16 96 48Vin 14 38Vin 12 95 58Vin 10 58Vin 8 94 48Vin 6 4 93 2 92 38Vin 0 10 20 30 40 50 10 20 30 40 50 A Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25C A Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25C V V 14 15 13 12 12 9 11 58Vin 50A 6 0A 10 48Vin 38Vin 3 9 8 0 10 20 30 40 50 60 70 A 38 48 58 V Figure 3: Output voltage regulation vs load current showing typical Figure 4: Output voltage regulation vs input Voltage, for minmum current current limit curves and converter shutdown points for minimum, and maximum current nominal, and maximum input voltage at room temperature. DS_Q48SK11049_12132012 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Logic 0 0 0 0 Figure 5: Turn-on transient at zero load current (10ms/div). Vin=48V.Top Trace: Vout, 5V/div; Bottom Trace: ON/OFF input, 5V/div Figure 6: Turn-on transient at full rated load current (constant current load) (10 ms/div). Vin=48V.Top Trace: Vout, 5V/div; Bottom Trace: ON/OFF input, 5V/div For Input Voltage Start up 0 0 0 0 Figure 7: Turn-on transient at zero load current (10 ms/div). Vin=48V.Top Trace: Vout, 5V/div, Bottom Trace: input voltage, 30V/div Figure 8: Turn-on transient at full rated load current (constant current load) (10 ms/div). Vin=48V.Top Trace: Vout, 5V/div; Bottom Trace: input voltage, 30V/div DS_Q48SK11049_12132012 4 ELECTRICAL CHARACTERISTICS CURVES 0 0 0 0 Figure 9: Output voltage response to step-change in load current (50%-75%-50% of Io, max; di/dt = 0.1A/s). Load cap: 10F, tantalum capacitor and 1F ceramic capacitor. Top Trace: Vout (100mV/div, 200us/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 10: Output voltage response to step-change in load current (50%-75%-50% of Io,max; di/dt=1A/s). Load cap: 10uF, tantalum capacitor and 1F ceramic capacitor. Top Trace: Vout (500mV/div, 200us/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. is ic Vin+ + 0 + Vin- Cs: 220uF 100uF, ESR=0.2 ohm @ 25oC 100KHz Figure 11: 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 H. Capacitor Cs offset possible battery impedance. Measure current as shown below DS_Q48SK11049_12132012 Figure 12: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 12H source impedance and 100F electrolytic capacitor (100 mA/div, 2us/div). 5 ELECTRICAL CHARACTERISTICS CURVES Copper Strip 0 Vo(+) 10u 1u SCOPE RESISTIVE LOAD Vo(-) Figure 13: Input reflected ripple current, is, through a 12H source inductor at nominal input voltage and rated load current (20 mA/div, 2us/div). Figure 14: Output voltage noise and ripple measurement test setup 0 Figure 15: Output voltage ripple at nominal input voltage and rated full load current (20 mV/div, 2us/div) Load capacitance: 1F ceramic capacitor and 10F 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. DS_Q48SK11049_12132012 6 DESIGN CONSIDERATIONS Safety Considerations Input Source Impedance The power module must be installed in compliance with the spacing and separation requirements of the end-user's safety agency standard, i.e., UL60950-1, CSA C22.2 NO. 60950-1 2nd and IEC 60950-1 2nd : 2005 and EN 60950-1 2nd: 2006+A11+A1: 2010. 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. 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 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 H, we advise adding a 33 to 100 F electrolytic capacitor (ESR < 0.7 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 Q48SK11049XXXX to meet class B in CISSPR 22. Schematic and Components List Vin(+) CY1 Vin CX Cin L1 - Vo(+) DC/DC Module CY2 Vin(-) Vo(-) CY Cin is 100uF*2 low ESR Aluminum cap; CX is 2.2uF ceramic cap; CY1 are 10nF ceramic caps; CY2 are 10nF ceramic caps; CY is 1nF ceramic cap; L1 is common-mode inductor, L1=0.53mH; Test Result LOAD 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 Fast-acting 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 48V Vin, Full Load Yellow line is quasi peak mode; Blue line is average mode. DS_Q48SK11049_12132012 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. 7 FEATURES DESCRIPTIONS Over-Current Protection Remote On/Off 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, and enter hiccup mode. 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. For the 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. 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. 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. For the auto-restart mode, the module will monitor the module temperature after shutdown. Once the temperature is dropped and within the specification, the module will be auto-restart. 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. Vi(+) Vo(+) R ON/OFF Vi(-) Load Vo(-) Figure 16: Remote on/off implementation DS_Q48SK11049_12132012 8 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''). PWB FANCING PWB MODULE 50.8(2.00") AIR VELOCITY AND AMBIENT TEMPERATURE SURED BELOW THE MODULE AIR F LOW Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) Figure 17: Wind tunnel test setup Thermal Derating Heat can be removed by increasing airflow over the module. 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. DS_Q48SK11049_12132012 9 THERMAL CURVES (WITHOUT HEAT SPREADER) HOT SPOT 1 THERMAL CURVES (WITH HEAT SPREADER) AIRFLOW HOT SPOT 2 AIRFLOW NTC RESISTOR Figure 18: * Hot spot 1& NTC resistor temperature measured Figure 20: * Hot spot 2 temperature measured point points Output Power(W) Q48SK11049(Standard) Output Power vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation) Output Power(W) 600LFM 550 500 Q48SK11049(Standard) Output Power vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation,With Heatspreader) 600LFM 550 500LFM 450 500LFM 500 450 400 350 Natural Convection 400 Natural Convection 350 300 100LFM 100LFM 250 300 200LFM 250 200LFM 200 200 300LFM 300LFM 150 150 100 100 400LFM 50 400LFM 50 0 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature () Figure 19: Output power vs. ambient temperature and air velocity @Vin=48V(Transverse Orientation, airflow from Vin+ to Vin-, without heat spreader) DS_Q48SK11049_12132012 0 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature () Figure 21: Output power vs. ambient temperature and air velocity @Vin=48V(Transverse Orientation, airflow from Vin+ to Vin-, with heat spreader) 10 MECHANICAL DRAWING (WITH HEAT SPREADER) * For modules with through-hole pins and the optional heatspreader, they are intended for wave soldering assembly onto system boards; please do not subject such modules through reflow temperature profile. DS_Q48SK11049_12132012 11 MECHANICAL DRAWING (WITHOUT HEAT SPREADER) Pin No. 1 2 3 4 5 6 7 8 Name Function +Vin ON/OFF -Vin +Vout -Vout Trim +Vout -Vout Positive input voltage Remote ON/OFF Negative input voltage Positive output voltage (Optional) Negative output voltage Output voltage trim(optional) Positive output voltage Negative output voltage (Optional) Pin Specification: Pins 1,2,3,6 Pins 4,5,7,8 1.00mm (0.040") diameter 1.50mm (0.059") diameter All pins are copper with matte Tin plating over Nickel under plating. DS_Q48SK11049_12132012 12 PART NUMBERING SYSTEM Q 48 S K 110 49 N R Type of Product Input Voltage Number of Outputs Product Series Output Voltage Output Current ON/OFF Logic Pin Length/Type S- Single K - High Power 110 - 11V 49 - 49A N- Negative P- Positive K- 0.110" N- 0.145" R- 0.170" Q - Quarter 48-38V~58V Brick C - 0.181" S - 0.189" T - 0.220" F A Option Code F- RoHS 6/6 T- 8PIN,without heat spreader (Lead Free) A-open frame, without trim pin H-with heat spreader, without trim pin C-open frame, void pin4,6,8 L - 0.248" MODEL LIST MODEL NAME INPUT OUTPUT EFF @ 100% LOAD Q48SK11049NRFA 38V~58V 14A 11V 49A Q48SK11049NRFT 38V~58V 14A 11V 49A 96.6% 96.6% Q48SK11049NRFH 38V~58V 14A 11V 49A 96.6% 1. Default remote on/off logic is negative and pin length is 0.170"; 2. No Trim pin is default; 3. For different remote on/off logic and pin length, please refer to part numbering system above or contact your local sales. * For modules with through-hole pins and the optional heatspreader, they are intended for wave soldering assembly onto system boards; please do not subject such modules through reflow temperature profile. CONTACT: www.delta.com.tw/dcdc USA: Telephone: East Coast: 978-656-3993 West Coast: 510-668-5100 Fax: (978) 656 3964 Email: DCDC@delta-corp.com Europe: Telephone: +41 31 998 53 11 Fax: +41 31 998 53 53 Email: DCDC@delta-es.tw Asia & the rest of world: Telephone: +886 3 4526107 x 6220~6224 Fax: +886 3 4513485 Email: DCDC@delta.com.tw 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. DS_Q48SK11049_12132012 13