Delta Electronics H48SL User's Manual
Contents
1. Delphi Series H48SL 200W Half Brick Family DC DC Power Modules 48V in 1 5V 60A out The Delphi Series H48SL Half Brick 48V input single output isolated 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 of power 3 3V and above or 60A of output current in an industry standard footprint 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 H48SL1R560 10302006 FEATURES High Efficiency 84 1 5V 60A Size 57 9 x 61 0 x 12 7mm 2 28 x 2 40 x 0 50 Standard footprint Industry standard pin out Fixed frequency operation Metal baseplate Input UVLO Output OCP OVP OTP Basic insulation No minimum load required 2 1 Input voltage range ISO 9001 TL 9000 ISO 14001 QS9000 OHSAS18001 certified manufacturing facility UL cUL 60950 US amp Canada Recognized and TUV EN60950 Certified CE mark meets 73 23 EEC and 93 68 EEC directives OPTIONS Positive Remote On Off logic Negative trim Short pin2. tw Email DCDC delta com tw Fax 978 656 3964 Email DCDC delta corp com 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_H48SL1R560_ 10302006 p 14
3. HES TOLERANCES X Xmm 0 5mm X XX in 0 02 in X XXmm t0 25mm X XXX in 40 010 in Pin No Name Function 1 Vin Negative input voltage 2 Case Case ground 3 ON OFF Remote ON OFF 4 Vin Positive input voltage 5 Vout Positive output voltage 6 SENSE Positive remote sense T TRIM Output voltage trim 8 SENSE Negative remote sense 9 Vout Negative output voltage Pin Specification Pins 1 4 6 8 1 00mm 0 040 diameter Pins 5 amp 9 2 00mm 0 079 diameter All pins are copper with Tin plating DS H48SL1R560 10302006 x 43 PART NUMBERING SYSTEM H 4 S t ans e EH Input Number of Product Output Output ON OFF Pin Length Option Code Voltage Outputs Series Voltage Current Logic H Half Brick 48V L IMS 1R5 1 5V 60 60A N Negative F RoHS 6 6 A Standard positive trim P Positive Lead Free Functions MODEL LIST H48SLO5040NRFA 36V 75V 7 A4A 5V 40A 90 5 H48SL12020NRFA 36V 75V 12V 20A 91 Default remote on off logic is negative and pin length is 0 170 For different remote on off logic and pin length please refer to part numbering system above or contact your local sales office CONTACT www delta com tw dcdc USA Europe Asia amp the rest of world Telephone Telephone 41 31 998 53 11 Telephone 886 3 4526107 x6220 East Coast 888 335 8201 Fax 41 31 998 53 53 Fax 886 3 4513485 West Coast 888 335 8208 Email DCDC delta es
4. M 48 L 40 L Natural 400LFM Convection 32 n O oie oS 100LFM 24 L 200LFM 300LFM 0 10 20 30 40 50 60 70 80 90 100 Ambient Temperature C Figure 17 Output current vs ambient temperature and air velocity Vin lt 60V H48SL1R560 Standard Power Dissipation vs Ambient Temperature and Air Velocity Either Orientation no Heat sink Power Dissipation Watts 600LFM 500LFM 400LFM Natural Convection 200LFM 0 10 20 30 40 50 60 70 80 90 100 Ambient Temperature C Figure 19 Power dissipation vs ambient temperature and air velocity a MES 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 UH we advise adding a 10 to 100 UF electrolytic capacitor ESR 0 7 O 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 des
5. SCRIPTIONS CON 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 Vo 4 Sense R Load Trim Sense Vo Figure 22 Circuit configuration for trim down decrease output voltage If the external resistor is connected between the TRIM and SENSE pins the output voltage set point decreases Fig 22 The external resistor value required to obtain a percentage of output voltage change A is defined as Rtrim down E KQ A J Ex When Trim down 20 1 5Vx0 8 1 2V Vo 1 5 V A t 20 100 2 53 KO DS H48SL1R560 10302006 Vo Sense Trim Sense Vo Figure 23 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 23 The external resistor value required to obtain a percentage output voltage change A is defined as Eus Labs A9 100 zl e 1 225 A A Ex When Trim up 10 1 5Vx1 1 1 65V Vo 1 5V A 10 Vo 100 A 100 2A 1 225 A 1469 KO 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 an
6. age Range over sample load line and temperature 1 43 1 57 V Output Voltage Ripple and Noise 5Hz to 20MHz bandwidth Peak to Peak Full Load 1uF ceramic 10uF tantalum 75 150 mV RMS Full Load 1uF ceramic 10uF tantalum 25 40 mV Operating Output Current Range 0 60 A Output DC Current Limit Inception Output Voltage 1096 Low 110 150 SWT ADA Output Voltage Current Transient 48V 10pF Tan amp 1uF Ceramic load cap 0 1A us Positive Step Change in Output Current 5096 lo max to 7596 lo max 80 mV Negative Step Change in Output Current 75 lo max to 50 lo max 80 mV Settling Time within 196 Vout nominal 100 us Turn On Transient Start Up Time From On Off Control 10 20 ms Start Up Time From Input 10 20 ms Maximum Output Capacitance Full load 5 overshoot of Vout at startup 20000 uF 100 Load 84 60 Load 87 Input to Output 1500 Vdc Input to Case 1500 Vdc Output to Case 500 Vdc Isolation Resistance 10 MQ Isolation Capacitance 1300 pF Switching Frequency 180 kHz ON OFF Control Negative Remote On Off logic Logic Low Module On Von off at lon off 1 0mA 0 0 8 V Logic High Module Off Von off at lon off 0 0 pA 15 V ON OFF Control Positive Remote On Off logic Logic Low Module Off Von off at lon off 1 0mA 0 0 4 V Logic High Module On Von off at lon off 0 0 pA 15 V ON OFF Current for Both Remote on off logic lon off at Von off 0 0V 1 mA Leakage Current for Both Remote on off logic Logic High Von off 15V 50 uA Output Voltage Trim Range Acro
7. cally 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 and latch off The over voltage latch is reset by either cycling the input power or by toggling the on off signal 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 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 may be an open collector or open drain For negati
8. cted ripple current with a simulated source Inductance Ltest of 12 uH Capacitor Cs offset possible battery impedance Measure current as shown above DS H48SL1R560 10302006 200us div 700us div AYG SMS s Stopped CH3E100mV CH4 i mV Figure 9 Output voltage response to step change in load current 75 50 75 of lo max di dt 2 5A us Load cap 470uF 35M2 ESR solid electrolytic capacitor and 1uF ceramic capacitor Top Trace Vout 100mV div Bottom Trace lout 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 ELECTRICAL CHARACTERISTICS CURVES NORM TOURS 7S 2us div Stopped 2us div CH4 10mv Figure 11 Input Terminal Ripple Current i at full rated output current and nominal input voltage with 12uH source impedance and 33uF electrolytic capacitor 1A div RESISTIVE LOAD Figure 13 Output voltage noise and ripple measurement test setup DS H48SL1R560 10302006 NORM TOS s 2us div Stopped 2us div f CH4 10m Figure 12 Input reflected ripple current is through a 12uH source inductor at nominal input voltage and rated load current 20 mA div ELECTRICAL CHARACTERISTICS CURVES 2us div 2us div NORM TOURS 7S Stopped CH3 20mv Figure 14 Output voltage ripple at nominal input voltage and rated load current 20 mV
9. d 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 R Load 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 PWB FACING PWB MODULE AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE 50 8 2 0 12 7 0 57 Note Wind Tunnel Test Setup Figure Dimensions are in millimeter
10. div Load capacitance 1uF ceramic capacitor and 10uF 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 H48SL1R560 10302006 OUTPUT VOLTAGE V 0 10 20 30 40 50 60 70 80 90 100 LOAD CURRENT A Figure 15 Output voltage vs load current showing typical current limit curves and converter shutdown points THERMAL CURVES NO HEATSINK EITHER ORIENTATION 26 mm 1 02 i d N CY C E oS E r amp ve Vin Vout e Weary out T c DOl N yw 4 o On Off Sense F lt X Trim 5 Case sense o VIL v out O S 2 Figure 16 Case temperature measurement location Pin locations are for reference only 64 56 48 40 32 24 H48SL1R560 Standard Output Current vs Ambient Temperature and Air Velocity Output Current A Vin 75V Either Orientation no Heat sink 600 LFM gt riri a Natural Convection 400LFM 100LFM 200LFM 300LFM 0 10 20 30 40 50 60 70 80 90 100 Ambient Temperature C Figure 18 Output current vs ambient temperature and air velocity Vin 15 V DS H48SL1R560 10302006 H48SL1R560 Standard Output Current vs Ambient Temperature and Air Velocity i Output Current A Vin lt 60V Either Orientation no Heat sink L 600LFM 56 r 500LF
11. igners 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 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 DS H48SL1R560 10302006 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 v lf 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 o
12. lengths APPLICATIONS Telecom Datacom Wireless Networks Optical Network Equipment Server and Data Storage Industrial Test Equipment Deita Electronics Inc En TECHNICAL SPECIFICATIONS Ta 25 C airflow rate 300 LFM Vin 48Vdc nominal Vout unless otherwise noted NOTES and CONDITIONS H48SL1HR560 Standard Min Typ Max Units ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous 80 Vdc Transient 100ms 100ms 100 Vdc Operating Case Temperature Tc 40 100 C Storage Temperature 55 125 C Input Output Isolation Voltage 1 minute 1500 Vdc Operating Input Voltage 36 48 75 Vdc Input Under Voltage Lockout Turn On Voltage Threshold 33 34 35 Vdc Turn Off Voltage Threshold 31 32 33 Vdc Lockout Hysteresis Voltage 1 2 3 Vdc Maximum Input Current 100 Load 36Vin 3 6 A No Load Input Current 60 150 mA Off Converter Input Current 3 10 mA Inrush Current I t 0 03 As Input Reflected Ripple Current P P thru 12uH inductor 5Hz to 20MHz 25 mA Input Voltage Ripple Rejection 120 Hz 65 dB DUTP ARA Output Voltage Set Point Vin 48V lo lo max Tc 25 C 1 47 19 1 53 Vdc Output Voltage Regulation Over Load lo lo min to lo max t2 5 mV Over Line Vin 36V to 75V 2 5 mV Over Temperature Tc 40 C to 100 C 15 50 mV Total Output Volt
13. s and Inches Figure 24 Wind tunnel test setup DS H48SL1R560 10302006 Thermal Derating Heat may be removed by increasing airflow over the module The modules maximum case temperature is 100 C 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 12 MECHANICAL DRAWING S E x 1 00 0 040 DIA CMM v SOHDBBCSPLATED COPPER ve Xu s E 7X Ps 7 sis i 4 N tol w O O 5 ol Tf roo i d I1 Vin Vout 9o i i Alo SE E T 2 CASE SENSE 8 Y So olol ol l aes o E gt E ER TRIM 7 o Lal olol ol D amp G d CN a cb P Na 3 ON OFF SENSE 6 K M S D T o4 Vin Vout 5 l 2 00 0 079 DIA k i SOLDER PLATED COPPER CRUS 48 3 1 907 oa lt a S MOUNTING INSERTS DTO 228 M3X0 5 THROUGH di MAX SCREW TORQUE 0 48 N m 4 3 Ib in e BOTTOM VIEW 4X ET O N bad e CN Ts gt O Z N e S IL i r O x bog P 5 SIDE VIEW ING TE JMENSIONS ARE IN MILLIM gS AND INC
14. ss Pins 9 amp 5 Pout lt max rated power 20 10 Output Voltage Remote Sense Range Pout lt max rated power 10 Output Over Voltage Protection Over full temp range of nominal Vout 115 122 130 MTBF lo 80 of lo max Ta 25 C 223 M hours Weight 85 grams Over Temperature Shutdown Average PCB Temperature 110 C DS_H48SL1R560_10302006 p 2 ELECTRICAL CHARACTERISTICS CURVES 90 n 75Vin 85 W 80 EFFICIENCY 19 POWER DISSIPATION 70 36Vin 48Vin 75Vin 65 10 20 30 40 50 60 10 20 30 40 50 60 OUTPUT CURRENT A OUTPUT CURRENT A Figure 1 Efficiency vs load current for minimum nominal and Figure 2 Power dissipation vs load current for minimum maximum input voltage at 25 C nominal and maximum input voltage at 25 C 3 5 3 0 2 5 2 0 INPUT CURRENT A 1 5 1 0 0 5 0 0 30 35 40 45 50 55 60 65 TO 15 INPUT VOLTAGE V Figure 3 Typical input characteristics at room temperature DS H48SL1R560 10302006 x 3 ELECTRICAL CHARACTERISTICS CURVES For Negative Remote On Off Logic NORM SOOKS s 2ms div 2ms div CH3 500mv UIT nnne enne need nennen nnne ennt Jenn penpe penpenpespen perpen penere penpe peepee penen ee Figure 4 Turn on transient at full rated load current resistive load 2 ms div Top Trace Vout 500mV di
15. utput When installed into a Class 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 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 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 automati
16. v Bottom Trace ON OFF input 10V div For Positive Remote On Off Logic NORM SO0KS s 2ms div Stopped q 2ms div CH3E5 UmV Figure 6 Turn on transient at full rated load current resistive load 2 ms div Top Trace Vout 500mV div Bottom Trace ON OFF input 2V div DS H48SL1R560 10302006 HORM 5ODES fs 2ms div 2ms div CH3 500mV Figure 5 Turn on transient at zero load current 2 ms div Top Trace Vout 500mV div Bottom Trace ON OFF input 10V div MORHNEBDOKS fs 2ms div 2ms div CH3E500mV S Se es aE ee Figure 7 Turn on transient at zero load current 2 ms div Top Trace Vout 500mV div Bottom Trace ON OFF input 2V div ELECTRICAL CHARACTERISTICS CURVES Bv SMS s 2 fus div Stopped 200us div CH3 100m CH4 10mv Figure 8 Output voltage response to step change in load current 75 50 75 of lo max di dt 0 1A us Load cap T UUE tantalum capacitor and 1uF ceramic capacitor Top Trace Vout 100mV div Bottom Trace lout 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 aa 33uF ESR 0 5 n 820 7 100KHz Cae 2 Our ESRe01 nm B20 100KHz Figure 10 Test set up diagram showing measurement points for Input Terminal Ripple Current and Input Reflected Ripple Current Note Measured input refle
17. ve 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 DS H48SL1R560 10302006 Figure 20 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 lt 10 x Vout This limit includes any increase in voltage due to remote sense compensation and output voltage set point adjustment trim Contact Contact and Distributior Resistance Losses Figure 21 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 may 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 10 FEATURES DE
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