V48SR1R225PRFA

FEATURES High efficiency: 84.0% @ 1.2V/25A Size: 33.0 x 22.9 x 9.5 mm (1.30”x0.90”x0.37”) Industry standard footprint and pinout Fixed frequency operation SMD and through-hole versions Input UVLO and OVP OTP and output OCP, OVP Output voltage trim: -20%, +10% Monotonic startup into normal and pre-biased loads 2250V isolation and basic insulation No minimum load required No negative current during power or enable on/off ISO 9001, TL 9000, ISO 14001, QS 9000, OHSAS18001 certified manufacturing facility UL/cUL 60950 (US & Canada), TUV (EN60950) and CE mark pending Delphi Series V48SR, 1/16th Brick 66W DC/DC Power Modules: 48V in, 1.2V, 25A out The Delphi Series V48SR, 1/16th Brick, 48V input, single output, isolated DC/DC converter, is the latest offering from a world leader in power systems technology and manufacturing ― Delta Electronics, Inc. This product family provides up to 66 watts of power or 25A of output current (1.8V and below) in an industry standard 1/16th brick form factor (1.30” x 0.90”). The 1.2V output offers one of the highest output currents available and provides up to 84.0% efficiency at full load. 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 modules are protected from abnormal input/output voltage, current, and temperature conditions. For lower power needs with the 1.2V output, but in a similar small form factor, please check out Delta S48SP (36W or 1.2V/10A) and S48SE (17W or 1.2V/5A) series standard DC/DC modules. OPTIONS SMD pins Positive remote On/Off OTP and output OVP, OCP mode (auto-restart or latch) APPLICATIONS Optical Transport Data Networking Communications Servers DATASHEET DS_V48SR1R225_01312007 TECHNICAL SPECIFICATIONS (TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.) PARAMETER ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Transient (100ms) Operating 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 Off Converter 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 Over Current Protection DYNAMIC CHARACTERISTICS Output Voltage Current Transient Positive Step Change in Output Current Negative Step Change in Output Current Settling 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) Leakage Current (for both remote on/off logic) Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection GENERAL SPECIFICATIONS MTBF Weight Over-Temperature Shutdown NOTES and CONDITIONS V48SR1R225 (Standard) Min. Typ. Max. 80 100 127 125 2250 75 34 32 2 50 10 1 35 33 3 1.2 Units Vdc Vdc °C °C Vdc Vdc Vdc Vdc Vdc A mA mA A2s mA dB Vdc mV mV mV V mV mV A % mV mV us 30 30 30000 84.0 84.0 2250 10 1100 420 ms ms µF % % Vdc MΩ pF kHz 0.7 18 0.7 18 1 50 10 10 160 V V V V mA uA % % % M hours grams °C 100ms Refer to figure 21 for measuring point -40 -55 36 33 31 1 100% Load, 36Vin P-P thru 12µH inductor, 5Hz to 20MHz 120 Hz Vin=48V, Io=Io.max, Tc=25°C Io=Io, min to Io, max Vin=36V to 75V Tc=-40°C to125°C Over sample load, line and temperature 5Hz to 20MHz bandwidth Full Load, 1µF ceramic, 10µF tantalum Full Load, 1µF ceramic, 10µF tantalum Output Voltage 10% Low 48V, 10µF Tan & 1µF Ceramic load cap, 0.1A/µs 50% Io.max to 75% Io.max 75% Io.max to 50% Io.max 1.188 20 60 1.200 ±3 ±3 ±12 1.20 40 15 0 110 50 50 200 1.212 ±10 ±10 1.236 30 25 140 1.164 Full load; 5% overshoot of Vout at startup Von/off Von/off Von/off Von/off Ion/off at Von/off=0.0V Logic High, Von/off=15V Pout ≦ max rated power Pout ≦ max rated power Over full temp range; % of nominal Vout Io=80% of Io, max; Ta=25°C, airflow rate=300FLM Refer to figure 21 for measuring point 2 2 -20 120 130 2.22 16 130 DS_V48SR1R225_01312007 2 ELECTRICAL CHARACTERISTICS CURVES Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25°C Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25°C. Figure 3: Typical full load input characteristics at room temperature DS_V48SR1R225_01312007 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On/Off Logic Figure 4: Turn-on transient at full rated load current (resistive load) (5 ms/div). Vin=48V. Top Trace: Vout, 0.5V/div; Bottom Trace: ON/OFF input, 5V/div Figure 5: Turn-on transient at zero load current (5 ms/div). Vin=48V. Top Trace: Vout: 0.5V/div, Bottom Trace: ON/OFF input,5V/div For Positive Remote On/Off Logic Figure 6: Turn-on transient at full rated load current (resistive load) (5 ms/div). Vin=48V. Top Trace: Vout, 0.5V/div; Bottom Trace: ON/OFF input, 2V/div Figure 7: Turn-on transient at zero load current (5 ms/div). Vin=48V. Top Trace: Vout, 0.5V/div; Bottom Trace: ON/OFF input, 2V/div DS_V48SR1R225_01312007 4 ELECTRICAL CHARACTERISTICS CURVES Figure 8: 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 (50mV/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 9: Output voltage response to step-change in load current (75%-50%-75% of Io, max; di/dt = 1.0A/µs). Load cap: 100µF tantalum capacitor and 1µF ceramic capacitor. Top Trace: Vout (50mV/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: 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. Measure current as shown above Figure 11: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 12µH source impedance and 33µF electrolytic capacitor (200 mA/div, 1us/div) DS_V48SR1R225_01312007 5 ELECTRICAL CHARACTERISTICS CURVES Copper Strip Vo(+) 10u Vo(-) 1u SCOPE RESISTIV LOAD Figure 12: Input reflected ripple current, is, through a 12µH source inductor at nominal input voltage and rated load current (20 mA/div, 1us/div) Figure 13: Output voltage noise and ripple measurement test setup Figure 14: Output voltage ripple at nominal input voltage and rated load current (Io=25A)(50 mV/div, 1us/div) Load capacitance: 1µF ceramic capacitor and 10µF 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 Figure 15: Output voltage vs. load current showing typical current limit curves and converter shutdown points DS_V48SR1R225_01312007 6 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. 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 5A 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. 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 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: 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_V48SR1R225_01312007 7 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, and enter hiccup mode or latch mode, which is optional. For hiccup mode, the module will try to restart after shutdown. If the over current condition still exists, the module will shut down again. This restart trial will continue until the over current condition is corrected. 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 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. Vi(+) Vo(+) Sense(+) ON/OFF Sense(-) Vi(-) 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 over-voltage threshold, the module will shut down, and enter in 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. 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. Figure 16: 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). 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 hiccup mode or latch mode, which is optional. For hiccup mode, the module will try to restart after shutdown. If the over temperature condition still exists, the module will shut down again. This restart trial will continue until the over temperature condition is corrected. 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. Vi(+) Vo(+) Sense(+) Sense(-) Contact Resistance Vi(-) Vo(-) Contact and Distributio Losses Figure 17: Effective circuit configuration for remote sense operation 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. DS_V48SR1R225_01312007 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. 8 FEATURES DESCRIPTIONS (CON.) 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. 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 19: 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. 19). The external resistor value required to obtain a percentage output voltage change △% is defined as: Rtrim − up = 5 .11Vo (100 + ∆ ) 511 − − 10 .2 (K Ω ) ∆ 0.6 ∆ Ex. When Trim-up +10% (1.2V×1.1=1.32V) Figure 18: Circuit configuration for trim-down (decrease output voltage) Rtrim − up = 5.11× 1.2 × (100 + 10) 511 − − 10.2 = 51.1(KΩ ) 0.6 × 10 10 If the external resistor is connected between the TRIM and SENSE (-) pins, the output voltage set point decreases (Fig. 18). The external resistor value required to obtain a percentage of output voltage change △% is defined as: Trim resistors can also be connected to Vo+ or Vobut connecting this way would introduce a small error voltage than the desired value. 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. ⎡ 511 ⎤ Rtrim − down = ⎢ − 10 .2 ⎥ (K Ω ) ⎣∆ ⎦ Ex. When Trim-down -10% (1.2V×0.9=1.08V) ⎡ 511 ⎤ Rtrim − down = ⎢ − 10 .2 ⎥ (K Ω ) = 40 .9 (K Ω ) ⎣ 10 ⎦ DS_V48SR1R225_01312007 9 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 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. THERMAL CURVES 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’’). FACING PWB PWB 25 Figure 21: Temperature measurement location The allowed maximum hot spot temperature is defined at 127℃. Outpu t Cu rren t (A) V 48S R1R225(standard) O utput Current vs. Am bient Tem perature and Ai r Veloci ty @Vi n = 48V (Either Orientati on) MODULE 20 Natural Convecti on 100LFM 15 200LFM 300LFM AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE AIR FLOW 10 50.8 (2.0”) 5 0 65 70 75 80 85 Ambie nt Te mpera ture (℃) 12.7 (0.5”) Figure 22: Output Current vs. Ambient Temperature and Air Velocity @ Vin=48V (Either Orientation) Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches) Figure 20: Wind tunnel test setup DS_V48SR1R225_01312007 10 PICK AND PLACE LOCATION RECOMMENDED PAD LAYOUT (SMD) SURFACE-MOUNT TAPE & REEL DS_V48SR1R225_01312007 11 LEADED (Sn/Pb) PROCESS RECOMMEND TEMP. PROFILE 250 Temperature (°C ) 200 150 100 50 2nd Ramp-up temp. Peak temp. 1.0~3.0°C /sec. 210~230°C 5sec. Pre-heat temp. 140~180°C 60~120 sec. Cooling down rate