FEATURES High efficiency: 85% @ 5V/2A Standard footprint: 2.0" x1.0" Industry standard pin out Low profile - Open Frame: 9.1mm (0.36") - Encapsulated: 10.7mm (0.42") Fixed frequency operation Input UVLO, Output OCP, OVP 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 Delphi Series S48SR, 15W 2"x1" Family DC/DC Power Modules: 48V in, 5V/2A out The Delphi Series S48SR printed circuit board mounted, 48V input, single output, isolated DC/DC converters are the latest offering from a world leader in power system and technology and manufacturing Delta Electronics, Inc. This product family provides up to 15 watts of power or up to 4.5A of output current (for 3.3V and below) in an industry standard footprint. With creative design technology and optimization of component placement, the Delphi Series Small Power converters possess outstanding electrical and thermal performance, as well as extremely high reliability under highly stressful operating conditions. All models are protected from abnormal input/output voltage and current conditions. An encapsulated version is available for the most robust performance in harsh environments. OPTIONS Short pin length APPLICATIONS Telecom/DataCom Wireless Networks Optical Network Equipment Server and Data Storage Industrial/Test Equipment DATASHEET DS_S48SR05002_07052006 1 Delta Electronics, Inc. Technical Specifications (T =25C, airflow rate=300 LFM, V A PARAMETER in =48Vdc, nominal Vout unless otherwise noted.) NOTES and CONDITIONS S48SR05002ERFA/B/C/D Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Transient (100ms) Operating Case 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 Maximum Input Current No-Load Input Current Inrush Current(I2t) Input Reflected-Ripple Current Input Voltage Ripple Rejection OUTPUT CHARACTERISTICS Output Voltage Set Point 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 DC Current-Limit Inception DYNAMIC CHARACTERISTICS Output Voltage Current Transient Positive Step Change in Output Current Negative Step Change in Output Current Settling Time to 1% of Final value Turn-On Transient Start-Up Time, From Input Maximum Output Capacitance EFFICIENCY 100% Load ISOLATION CHARACTERISTICS Isolation Voltage Isolation Resistance Isolation Capacitance FEATURE CHARACTERISTICS Switching Frequency Output Voltage Trim Range Output Over-Voltage Protection GENERAL SPECIFICATIONS Calculated MTBF Weight (Encapsulated) Weight (Open Frame) Typ. 100ms 1 minute -40 -55 1500 Output Voltage 10% Low 80 100 100 125 Vdc Vdc C C Vdc 48 75 V 33.8 32.0 1 34.5 33.5 2 35.8 34.5 3 0.5 V V V A mA A2s mA dB 5.00 5.10 V 10 5 100 25 15 300 TBD mV mV ppm/ V 50 15 100 25 2 4.4 mV mV A A 75 75 600 100 100 mV mV s 35 50 470 ms F 25 0.01 5 50 P-P thru 12H inductor, 5Hz to 20MHz 120 Hz Io=Io,min to Io,max Vin=36V to 75V Tc=-40C to 100C Over sample load, line and temperature 5Hz to 20MHz bandwidth Full Load, 1F ceramic, 10F tantalum Full Load, 1F ceramic, 10F tantalum Units 36 100% Load, 36Vin Vin=48V, Io=50%Io.max, Tc=25C Max. 4.90 TBD 0 2.4 48V, 10F Tan & 1F Ceramic load cap, 0.1A/s 50% Io.max to 75% Io.max 75% Io.max to 50% Io.max 3.4 Full load; 5% overshoot of Vout at startup 83 85 % 500 V M pF 1500 100 290 Across Trim Pin & +Vo or -Vo, Poutmax rated Over full temp range; % of nominal Vout Io=80% of Io, max; Tc=40C -10 115 125 3 25.5 12.5 +10 140 kHz % % M hours grams grams 2 DS_S48SR05002_07052006 90 36Vin 48Vin POWER DISSIPATION (W) EFFICIENCY (%) ELECTRICAL CHARACTERISTICS CURVES 75Vin 85 80 75 4.0 36Vin 2.5 2.0 65 1.5 60 1.0 55 0.5 0.0 0.5 1 1.5 2 OUTPUT CURRENT (A) Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25C. INPUT CURRENT (A) 75Vin 3.0 70 50 48Vin 3.5 0.5 1 1.5 2 OUTPUT CURRENT (A) Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25C. 0.40 0.35 Io=2A Io=1.2A 0.30 Io=0.2A 0.25 0.20 0.15 0.10 0.05 0.00 30 35 40 45 50 55 60 65 70 75 IN PU T VOLTAGE (V) Figure 3: Typical S48SR05002ER input characteristics at room temperature Figure 4: Turn-on transient at full rated load current (resistive load) (10 ms/div). Top Trace: Vin (20V/div); Bottom Trace: Vout (1V/div) 3 DS_S48SR05002_07052006 ELECTRICAL CHARACTERISTICS CURVES Figure 5: Turn-on transient at zero load current (10 ms/div). Top Trace: Vin (20V/div); Bottom Trace Vout (1V/div) Figure 6: Output voltage response to step-change in load current (50%-75%-50% of Imax; dI/dt = 0.1A/s). Load cap: 10F, 100mESR tantalum capacitor and 1F ceramic capacitor. Top trace: Vout (50mV/div), Bottom trace:I out (1A/div). Figure 7: Test set-up diagram showing measurement points Figure 8:. Input Reflected Ripple Current, i , at full rated c for Input Reflected Ripple Current (Figure 8). output current and nominal input voltage with 12H source Note: Measured input reflected-ripple current with a simulated impedance and 68F electrolytic capacitor (2 mA/div). source Inductance (LTEST) of 12 H. Capacitor Cs offset possible battery impedance. 4 DS_S48SR05002_07052006 ELECTRICAL CHARACTERISTICS CURVES Copper Strip Vo(+) 10u 1u SCOPE RESISTIVE LOAD Vo(-) OUTPUT VOLTAGE (V) Figure 9: Output voltage noise and ripple measurement Figure 10: Output voltage ripple at nominal input voltage and test setup. Scope measurement should be made using a rated load current (50 mV/div). Load capacitance: 1F ceramic BNC cable (length short than 20 inches). Position the load capacitor and 10F tantalum capacitor. Bandwidth: 20 MHz. between 51 mm and 76 mm (2 inches to 3 inches) from the module. 6.0 5.0 4.0 3.0 2.0 1.0 Vin=48V 0.0 0.0 1.0 2.0 3.0 4.0 LOAD CURRENT (A) Figure 11: Output voltage vs. load current showing typical current limit curves and converter shutdown points. 5 DS_S48SR05002_07052006 THERMAL CURVES: ENCAPSULATED VERSION S48SR05002ER A,B Output Current vs. Ambient Temperature and Air Velocity @Vin < 60V 2.1 Output Current(A) 1.8 600LFM 1.5 500LFM Natural Convection 1.2 100LFM 0.9 0.6 400LFM 200LFM 0.3 300LFM Top View 0.0 75 Figure 12: Case Temperature measurement location. Pin locations are for reference only. Output Current(A) 0.9 Power Dissipation (Watts) 2.0 500LFM Natural Convection 1.6 Natural Convection 100 Ambient Temperature () 600LFM 500LFM 1.2 95 2.4 600LFM 1.5 90 S48SR05002ER A,B Power Dissipation vs. Ambient Temperature and Air Velocity 2.8 1.8 85 Figure 13: Output Current vs. Ambient Temperature and Air Velocity @ V<60V S48SR05002ER A,B Output Current vs. Ambient Temperature and Air Velocity @Vin =75V 2.1 80 400LFM 400LFM 100LFM 1.2 100LFM 0.6 200LFM 0.8 200LFM 0.3 300LFM 0.4 300LFM 0.0 0.0 65 70 75 80 85 90 95 Ambient Temperature () Figure 14: Output Current vs. Ambient Temperature and Air Velocity@ V =75V 65 70 75 80 85 90 95 100 105 Ambient Temperature () Figure 15: Power Dissipation vs. Ambient Temperature and Air Velocity 6 DS_S48SR05002_07052006 THERMAL CURVES: OPEN FRAME VERSION S48SR05002ER C,D Output Current vs. Ambient Temperature and Air Velocity @Vin < 60V Output Current(A) 2.1 600LFM 1.8 1.5 500LFM Natural Convection 1.2 400LFM 100LFM 0.9 200LFM 0.6 0.3 300LFM 0.0 70 Figure 16: Hot spot location. Pin locations are for reference only. 75 85 90 95 100 Ambient Temperature () Figure 17: Output Current vs. Ambient Temperature and Air Velocity @ V<60V S48SR05002ER C,D Power Dissipation vs. Ambient Temperature and Air Velocity S48SR05002ER C,D Output Current vs. Ambient Temperature and Air Velocity @Vin =75V 2.1 80 Output Current(A) Power Dissipation (Watts) 2.4 600LFM 1.8 600LFM 2.0 500LFM 1.5 Natural Convection 500LFM 1.6 Natural Convection 400LFM 1.2 100LFM 1.2 100LFM 400LFM 0.9 200LFM 0.8 200LFM 0.6 300LFM 0.4 300LFM 0.3 0.0 0.0 60 65 70 75 80 85 90 95 Ambient Temperature () Figure 18: Output Current vs. Ambient Temperature and Air Velocity @ V=75V 60 65 70 75 80 85 90 95 100 105 Ambient Temperature () Figure 19: Power Dissipation vs. Ambient Temperature and Air Velocity 7 DS_S48SR05002_07052006 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 H, we advise adding a 10 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. 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 if the system in which the power module is to be used must meet safety agency requirements. 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. 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 1A 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. When the input source is 60Vdc 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. 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. 8 DS_S48SR05002_07052006 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). EX. When Trim-down -10%(5Vx0.9=4.5V) 35.381 - 47.05 x 0.1 Rtrim - down = - 6.49 = 52.96[] 5 x 0.1 + 0.016 Vo(+) 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. Trim R trim-up Vo(-) 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. 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 Vo+ or Vo -. The TRIM pin should be left open if this feature is not used. Vo(+) Trim R trim-down Figure 21: Circuit configuration for trim-up (increase output voltage) If the external resistor is connected between the TRIM and Vo- the output voltage set point increases. The external resistor value required to obtain a percentage output voltage change Vo% is defined as: Rtrim - up = 11.668 - 6.49[] 5Vo - 0.016 Ex. When Trim-up +10%(5Vx1.1=5.5V) 11.668 Rtrim - up = - 6.49 = 17.62[ ] 5 x 0.1-0.016 Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. Vo(-) Figure 20: Circuit configuration for trim-down (decrease output voltage) If the external resistor is connected between the TRIM and Vo+ pins, the output voltage set point decreases. The external resistor value required to obtain a percentage of output voltage change Vo% is defined as: Rtrim - down = 35.381 - 47.05Vo - 6.49[] 5Vo + 0.016 9 DS_S48SR05002_07052006 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. PWB FACING PWB MODULE AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE 50.8 (2.0") AIR FLOW 10 (0.4") Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) Figure 22: Wind Tunnel Test Setup 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 or a heat sink is 6.35mm (0.25"). Thermal Derating Heat can be removed by increasing airflow over the module. Figure 13, 14, 17, and 18 show maximum output is a function of ambient temperature and airflow rate. The module's maximum case temperature is +100C. 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. 10 DS_S48SR05002_07052006 MECHANICAL DRAWING Open Frame Version Pin No. 1 2 3 4 5 Encapsulated Version Name Function +Vin -Vin +Vout TRIM -Vout Positive input voltage Negative input voltage Positive output voltage Output voltage trim Negative output voltage 11 DS_S48SR05002_07052006 PART NUMBERING SYSTEM S Form Factor 48 S Input Number of Voltage Outputs S- Small Power 48V S- Single R 050 Product Series Output Voltage R- Thru-hole 050-5.0V 02 E R F Output ON/OFF Logic Pin Current Length 02- 2A E-No ON/OFF Control Function A Option Code R- 0.170" Space-RoHS N- 0.145" 5/6 K- 0.110" F- RoHS 6/6 (Lead Free) A- Encapsulated & Trim B- Encapsulated & No Trim C- Open Frame & Trim D- Open Frame & No Trim MODEL LIST MODEL NAME S48SR1R805ER A S48SR2R504ER A S48SR3R303ER A S48SR3R304ER A S48SR05002ER A S48SR05003ER A S48SR12001ER A INPUT 36V~75V 36V~75V 36V~75V 36V~75V 36V~75V 36V~75V 36V~75V OUTPUT 0.5A 0.5A 0.5A 0.6A 0.5A 0.6A 0.6A 1.8V 2.5V 3.3V 3.3V 5.0V 5.0V 12.0V EFF @ 100% LOAD 5.0A 4.5A 3.0A 4.5A 2.0A 3.0A 1.25A 80.0% 83.0% 84.5% 86.0% 85.0% 86.5% 86.5% 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 Asia & the rest of world: Telephone: +886 3 4526107 ext 6220 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. 12 DS_S48SR05002_07052006