Delta Electronics 33W Family User manual

DATASHEET
DS_S48SA1R812_06012006
Delta Electronics, Inc.
Delphi Series S48SA, 33W Family
DC/DC Power Modules: 48V in, 1.8V/12A out
The Delphi Series S48SA, surface mountable, 48V input, single
output, isolated DC/DC converter is the latest offering from a world
leader in power system and technology and manufacturing – Delta
Electronics, Inc. This product family provides up to 33 watts of powe
r
or up to 12A of output current (for output voltage 1.8V or below). With
creative design technology and optimization of componen
t
placement, these converters possess outstanding electrical and
thermal performance, as well as extremely high reliability unde
r
highly stressful operating conditions. All models are protected from
abnormal input/output voltage and current conditions.
APPLICATIONS
 Telecom/DataCom
 Wireless Networks
 Optical Network Equipment
 Server and Data Storage
 Industrial/Test Equipment
OPTIONS
 Positive on/off logic
 Through hole version
FEATURES
 High efficiency: 88.5% @ 1.8V/ 12A
 Size: 47.2mm x 29.5mm x 8.35mm
(1.86" x 1.16" x 0.33")
 Low profile: 0.33"
 Industry standard footprint and pin out
 Surface mountable
 Fixed frequency operation
 Input UVLO, Output OCP, OVP
 No minimum load required
 2:1 input voltage range
 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 directive

DS_S48SA1R812_06012006
TECHNICAL SPECIFICATIONS
(TA=25°C, airflow rate=300 LFM, Vin=48Vdc, nominal Vout unless otherwise noted.)
PARAMETER NOTES and CONDITIONS S48SA1R812NRFA
Min. Typ. Max. Units
ABSOLUTE MAXIMUM RATINGS
Input Voltage
Continuous 80 Vdc
Transient (100ms) 100ms 100 Vdc
Operating Temperature Refer to Figure 18 for measuring point -40 100 °C
Storage Temperature -55 125 °C
Input/Output Isolation Voltage 1 minute 1500 Vdc
INPUT CHARACTERISTICS
Operating Input Voltage 36 48 75 V
Input Under-Voltage Lockout
Turn-On Voltage Threshold 32.5 34 35.5 V
Turn-Off Voltage Threshold 30.5 32 33.5 V
Lockout Hysteresis Voltage 1 2 3 V
Maximum Input Current 100% Load, 36Vin 0.85 A
No-Load Input Current 30 mA
Off Converter Input Current 7 m
A
Inrush Current(I2t) 0.01 A2s
Input Reflected-Ripple Current P-P thru 12µH inductor, 5Hz to 20MHz 5 mA
Input Voltage Ripple Rejection 120 Hz 50 dB
OUTPUT CHARACTERISTICS
Output Voltage Set Point Vin=48V, Io=50%Io.max, Ta=25℃1.77 1.80 1.83 V
Output Voltage Regulation
Over Load Io=Io,min to Io,max ±2 ±10 mV
Over Line Vin=36V to75V ±2 ±5 mV
Over Temperature Ta=-40C to 85C 100 300
pp
m/℃
Total Output Voltage Range Over sample load, line and temperature 1.73 1.87 V
Output Voltage Ripple and Noise 5Hz to 20MHz bandwidth
Peak-to-Peak Full Load, 1µF ceramic, 10µF tantalum 30 75 mV
RMS Full Load, 1µF ceramic, 10µF tantalum 5 20 mV
Operating Output Current Range 0 12 A
Output DC Current-Limit Inception Output Voltage 10% Low 13.2 15.6 18 A
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 35 100 mV
Negative Step Change in Output Current 75% Io,max to 50% Io.max 35 100 mV
Settling Time to 1% of Final value 200 µs
Turn-On Transient
Start-Up Time, From On/Off Control 6 12 ms
Start-Up Time, From Input 6 12 ms
Maximum Output Capacitance Full load; 5% overshoot of Vout at startup 2200 µF
EFFICIENCY
100% Load 86 88 %
ISOLATION CHARACTERISTICS
Isolation Voltage 1500 V
Isolation Resistance 10 MΩ
Isolation Capacitance 1500 pF
FEATURE CHARACTERISTICS
Switching Frequency 330 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
A
cross Trim Pin & +Vo or
–
Vo, Pout≦max rated -10 +10 %
Output Over-Voltage Protection(Hiccup) Over full temp range; % of nominal Vout 115 125 140 %
GENERAL SPECIFICATIONS
MTBF Io=80% of Io, max; Tc=40°C 6.29 M hours
Weight 18 grams
Over-Temperature Shutdown Refer to Figure 18 for measuring point 115 °C
2

DS_S48SA1R812_06012006
ELECTRICAL CHARACTERISTICS CURVES
55
60
65
70
75
80
85
90
95
123456789101112
OU TPU T C U RR EN T (A)
EFFICIENCY (%)
36Vin
48Vin
75Vin
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
123456789101112
OUTPUT CURRENT (A)
POWER DISSIPATION (W)
36Vin
48Vin
75Vin
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.
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
30 35 40 45 50 55 60 65 70 75
INPUT VOLTAGE (V)
INPUT CURRENT (A)
Io=12A
Io=7.2A
Io=1.2A
Figure 3: Typical input characteristics at room temperature. Figure 4: Turn-on transient at full rated load current (1 ms/div).
Top Trace: Vout (500mV/div); Bottom Trace: ON/OFF Control
(5V/div).
3

DS_S48SA1R812_06012006 4
ELECTRICAL CHARACTERISTICS CURVES
Figure5: Turn-on transient at zero load current (1 ms/div). Top
Trace: Vout (500mV/div); Bottom Trace: ON/OFF Control
(5V/div).
Figure 6: Output voltage response to step-change in load
current (50%-75% of Io, max; di/dt = 0.1A/µs). Load cap: 10µF,
100 m
Ω

ESR tantalum capacitor and 1µF ceramic capacitor.
Top Trace: Vout (50mV/div), Bottom Trace: Iout (5A/div).
Figure 7: Output voltage response to step-change in load
current (75%-50% of Io, max; di/dt = 0.1A/µs). Load cap:
10µF, 100 m
Ω ESR tantalum capacitor and 1µF ceramic
capacitor. Top Trace: Vout (50mV/div), Bottom Trace: Iout
5A/div).
Figure 8: Test set-up diagram showing measurement points
for Input Reflected Ripple Current (Figure 9).
Note: Measured input reflected-ripple current with a simulated
source Inductance (LTEST
)
of 12 µH. Capacitor Cs offset
possible battery impedance.

DS_S48SA1R812_06012006
ELECTRICAL CHARACTERISTICS CURVES
StripCopper
Vo(-)
Vo(+)
10u 1u SCOPE RESISTIV
E
LOAD
Figure 9:Input Reflected Ripple Current, is, at full rated output
current and nominal input voltage with 12µH source impedance
and 33µF electrolytic capacitor (2 mA/div).
Figure 10: Output voltage noise and ripple measurement test
setup. 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.
0.0
0.3
0.6
0.9
1.2
1.5
1.8
2.1
0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0
LOAD CURRENT (A)
OUTPUT VOLTAGE (V)
Vin=48V
Figure 11: 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 12: Output voltage vs. load current showing typical
current limit curves and converter shutdown points.
5

DS_S48SA1R812_06012006
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 3A 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.
DESIGN CONSIDERATION
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 Ωat 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 if the system in which the
power module is to be used must meet safety agency
requirements.
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.
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.
6

DS_S48SA1R812_06012006
Vo(+)Vi(+)
Vo(-)
Sense(-)
Sense(+)
Vi(-)
ON/OFF
Figure 13: Remote on/off implementation
Remote Sense (Optional)
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(-)
Vi(+)
Vo(-)
Vo(+)
Sense(+)
Sense(-)
Resistance
Contact Contact and Distributio
n
Losses
Figure 14: 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.
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 (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 (Hiccup
mode). The modules will try to restart after shutdown. If
the fault condition still exists, the module will shut down
again. This restart trial will continue until the fault
condition is corrected.
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 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 to floating.

DS_S48SA1R812_06012006
[] ΚΩ−
∆
=− 104
%Vo
up −∆+ 1089%)100(8.23 Vo
Ex. When trim-up +10% (1.8V X 1.1 = 1.98V)
Rtrim
[]
ΚΩ=−=− 9.48104
10
up −+ 1089)10100(8.23
are should be taken to ensure that the maximum
utput Voltage Adjustment (TRIM)
o increase or decrease the output voltage set point, the
Rtrim
C
output power of the module remains at or below the
maximum rated power.
O
T
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.
Figure 15: Circuit configuration for trim-down (decrease output
the external resistor is connected between the TRIM
voltage)
If
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:
[]
ΚΩ−
∆
=− 104
%Vo
down 1089
x. When trim-down –10% (1.8V X 0.9 = 1.62V)
Rtrim
E
[]
ΚΩ=−=− 9.4104
10
down 1089 Rtrim
Figure 16: Circuit configuration for trim-up (increase output
the external resistor is connected between the TRIM
voltage)
If
and Vo+ the output voltage set point increases. The
external resistor value required to obtain a percentage
output voltage change △Vo% is defined as:
8

DS_S48SA1R812_06012006 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 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 or a heat sink is
6.35mm (0.25”).
Thermal Derating
Heat can be removed by increasing airflow over the
module. Figure 18 and 19 show maximum output is a
function of ambient temperature and airflow rate. 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.
Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches)
10 (0.4”)
MODULE
A
IR FLOW
50.8
(
2.0”
)
FACING PWB PWB
AIR VELOCIT
Y
AND AMBIENT
TEMPERATURE
MEASURED BELOW
THE MODULE
Figure 17: Wind tunnel test setup
THERMAL CURVES
Figure 19: Output current vs. ambient temperature and air velocity
@Vin< 60V
S48SA1R812(Standard) Output Current vs. Ambient Temperature and Air Velocity
@ Vin < 60V
0
2
4
6
8
10
12
14
65 70 75 80 85 90 95 100
Ambient Temperature (℃)
Output Current(A)
Natural
Convection
100LFM
200LFM
300LFM
400LFM
500LFM
600LFM
Figure 18: Hot spot temperature measured point
＊ The allowed maximum hot spot temperature is defined at
110
℃

DS_S48SA1R812_06012006
10
PICK AND PLACE LOCATION SURFACE-MOUNT TAPE & REEL
RECOMMENDED PAD LAYOUT (SMD)

DS_S48SA1R812_06012006
Temp.
Time
150℃
200℃
100~140 sec. Time Limited 90 sec.
above 217℃
217℃
Preheat time
Ramp up
max. 3℃/sec.
Ramp down
max. 4℃/sec.
Peak Tem
p
. 240 ~ 245
℃
25℃
Note: The temperature refers to the pin of S48SA, measured on the pin +Vout joint.
11
LEADED (Sn/Pb) PROCESS RECOMMEND TEMP. PROFILE
Time ( sec. )
Pre-heat temp.
140~180°C 60~120 sec.
Peak temp.
210~230°C 5sec.
Ramp-up temp.
0.5~3.0°C /sec.
Temperature (°C )
50
100
150
200
250
300600 120 180 240
2nd Ramp-up temp.
1.0~3.0°C /sec.
Over 200°C
40~50sec.
Cooling down rate <3°C /sec.
Note: The temperature refers to the pin of S48SA, measured on the pin +Vout joint.
LEAD FREE (SAC) PROCESS RECOMMEND TEMP. PROFILE

DS_S48SA1R812_06012006
MECHANICAL DRAWING
SMD Through-Hole
Pin No. Name Function
1 +Vout Positive output voltage
2 -Vout Negative output voltage
6 Trim Output voltage trim
8 ON/OFF ON/OFF logic
11 -Vin Negative input voltage
12 +Vin Positive input voltage
Optional Pin Name Function
4 +Sense (Option) Positive sense pin
5
9
-Sense (Option)
NC
Negative sense pin
No connection
12

DS_S48SA1R812_06012006 14
PART NUMBERING SYSTEM
S 48 S A 1R8 12 N R F A*
Form
Factor Input Voltage Number of Outputs Product Series Output Voltage Output Current ON/OFF Logic Pin Type Option
Code
S- Small
Power
48V S- Single A- Advanced 1R2-1.2V
1R5-1.5V
1R8-1.8V
2R5-2.5V
3R3- 3.3V
050- 5.0V
120- 12V
03- 3.0V
06- 6.6A
10- 10A
12- 12A
N- Negative
P- Positive
R- SMD
T-Through
hole
F- RoHS 6/6
(Lead Free)
A- 9 pin, no sense
B- 6 pin, no sense
C- 9 pins with sense
(12V has option B
only)
* Option code A includes 9 pins. Pins 4, 5, and 9 have no connection.
Option code B excludes pin 4, 5,and 9 (total 6 pins).
Option code C features 9 pins with sense function.
MODEL LIST
MODEL NAME INPUT OUTPUT EFF @ 100% LOAD
S48SA1R212NRFA 36V~75V 0.85A 1.2V 12A 84.0%
S48SA1R512NRFA 36V~75V 0.85A 1.5V 12A 88.0%
S48SA1R812NRFA 36V~75V 0.85A 1.8V 12A 88.0%
S48SA2R510NRFA 36V~75V 1.3A 2.5V 10A 88.5%
S48SA3R310NRFA 36V~75V 1.3A 3.3V 10A 90.5%
S48SA05006NRFA 36V~75V 1.3A 5.0V 6.6A 90.5%
S48SA12003NRFB 36V~75V 1.3A 12V 3.0A 90.0%
CONTACT: www.delta.com.tw/dcdc
USA:
Telephone:
East Coast: [phone]
West Coast: [phone]
Fax: [phone]
Email: [email protected]
Europe:
Phone: [phone]
Fax: [phone]
Email: [email protected]
Asia & the rest of world:
Telephone: [phone] ext 6220
Fax: [phone]
Email: [email protected]
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.
13