Delta Electronics Power Supply Series H48SA User Manual

FEATURES  
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High efficiency: 93.2% @ 12V/ 25A  
Š
Standard footprint: 58.4 x 61.0 x 11.2 mm  
(2.30” x2.40”x0.44”)  
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Š
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Š
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Industry standard pin out  
Single board construction  
Fixed frequency operation  
2250V Isolation  
Basic insulation  
Monotonic startup into normal and pre-  
bias loads  
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Fully protected: input UVLO, output OVP,  
OCP, OTP  
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No minimum load required  
Wide output trim range: -20%, +10%  
ISO 9001, TL 9000, ISO 14001, QS  
9000, OHSAS 18001 certified  
manufacturing facility  
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UL/cUL 60950-1 (US & Canada)  
Recognized, and TUV (EN60950-1)  
Certified  
CE mark meets 73/23/EEC and  
93/68/EEC directives  
Delphi Series H48SA, Half Brick Family  
DC/DC Power Modules: 48V in, 12V/25A out  
The Delphi Series H48SA Half Brick, 48V input, single output, isolated,  
open frame 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 300 watts of power  
or up to 25A of output current in an industry standard footprint. This  
product represents the next generation of design technology required  
by today’s leading-edge circuitry. 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. Typical  
efficiency of the 12V, 300W module is better than 93.2% and all  
modules are fully protected from abnormal input/output voltage, current  
and temperature conditions. The Delphi Series converters meet all  
safety requirements with basic insulation. A variety of optional  
heatsinks are available for extended thermal operation.  
OPTIONS  
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Positive on/off  
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Heatspreader available for extended  
operation  
APPLICATIONS  
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Telecom / DataCom  
Wireless Networks  
Optical Network Equipment  
Server and Data Storage  
Industrial / Test Equipment  
DATASHEET  
DS_H48SA12025_05052008  
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ELECTRICAL CHARACTERISTICS CURVES  
95  
30  
25  
20  
15  
10  
5
90  
75Vin  
75Vin  
85  
48Vin  
48Vin  
36Vin  
80  
36Vin  
75  
70  
65  
60  
0
0
5
10  
15  
20  
25  
5
10  
15  
20  
25  
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. Vout=12V.  
nominal, and maximum input voltage at 25°C. Vout=12V.  
95  
90  
30  
25  
75Vin  
85  
75Vin  
48Vin  
20  
48Vin  
36Vin  
80  
15  
10  
5
36Vin  
75  
70  
65  
60  
0
0
5
10  
15  
20  
25  
5
10  
15  
20  
25  
OUTPUT CURRENT (A)  
OUTPUT CURRENT (A)  
Figure 3: Efficiency vs. load current for minimum, nominal, and  
Figure 4: Power dissipation vs. load current for minimum,  
maximum input voltage at 25°C. Vout=9.6V.  
nominal, and maximum input voltage at 25°C. Vout=9.6V.  
3
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DS_H48SA12025_05052008  
ELECTRICAL CHARACTERISTICS CURVES  
95  
30  
25  
20  
15  
10  
5
90  
75Vin  
75Vin  
85  
80  
75  
70  
65  
60  
48Vin  
48Vin  
36Vin  
36Vin  
0
0
5
10  
15  
20  
25  
5
10  
15  
OUTPUT CURRENT (A)  
20  
25  
OUTPUT CURRENT (A)  
Figure 5: Efficiency vs. output voltage for minimum, nominal,  
and maximum input voltage at 25°C, Vout=13.2V.  
Figure 6: Power dissipation vs. output voltage for minimum,  
nominal, and maximum input voltage at 25°C, Vout=13.2V.  
12  
10  
8
0
0
6
4
2
0
30.0 31.3 33.6 35.0 40.0 45.0 50.0 55.0 60.0 65.0 70.0 75.0  
Output Current (A)  
Figure 7: Typical input characteristics at room temperature.  
Figure 8: Turn-on transient at full rated load current, 4ms/div:  
Top Trace: Vout, 5V/div; Bottom Trace: ON/OFF input, 5V/div.  
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DS_H48SA12025_05052008  
ELECTRICAL CHARACTERISTICS CURVES  
0
0
0
Figure 9: Turn-on transient at zero load current, 4 ms/div;  
Top Trace: Vout, 5V/div; Bottom Trace: ON/OFF input,  
5V/div.  
Figure 10: Output voltage response to step-change in load  
current, 200mV/div, 200us/div. 75%-50%-75% of Io, max, di/dt =  
0.1A/µs. Load cap: 10µF, tantalum capacitor and 1µF ceramic  
capacitor.  
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+  
+
+
Vin-  
Cs: 220uF  
100uF,  
ESR=0.2 ohm @  
25oC 100KHz  
0
Figure 11: Output voltage response to step-change in load  
current, 200mV/div, 1ms/div. 75%-50%-75% of Io, max, di/dt  
= 1A/µs. Load cap: 5000µF tantalum capacitor and 1µF  
ceramic capacitor.  
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 12: 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. Measured current as shown below.  
5
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DS_H48SA12025_05052008  
ELECTRICAL CHARACTERISTICS CURVES  
0
0
Figure 13: Input Terminal Ripple Current, ic, at nominal input  
voltage and rated load current with 12µH source impedance  
and 100µF electrolytic capacitor, 500 mA/div, 2us/div.  
Figure 14: Input reflected ripple current, is, through a 12µH  
source inductor at nominal input voltage and rated load current,  
20 mA/div, 2us/div.  
Copper Strip  
Vo(+)  
SCOPE  
RESISTIVE  
LOAD  
10u  
1u  
0
Vo(-)  
Figure 15: Output voltage noise and ripple measurement  
test setup  
Figure 16: Output voltage ripple at nominal input voltage and  
rated load current, 50mV/div, 2us/div. Load capacitance: 1µF  
ceramic capacitor and 10µF 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.  
12  
10  
8
6
4
2
0
0
5
10  
15  
20  
25  
30  
35  
Output Current (A)  
Figure 17: Output voltage vs. load current showing typical  
current limit curves and converter shutdown points.  
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DS_H48SA12025_05052008  
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,  
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. 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:  
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 33 to 100 μF  
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  
H48SA12025NN A to meet class B in CISSPR 22.  
Š
The input source must be insulated from any  
hazardous voltages, including the ac mains, with  
reinforced insulation.  
Š
Š
Š
Š
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.  
Schematic and Components List  
If the metal baseplate is grounded the output must  
be also grounded.  
+
Vin(+) Vo(+)  
H48SA12025  
Vin(-) Vo(-)  
CY1  
CY1  
CX  
CX1  
Cin  
Vin  
LOAD  
L1  
L2  
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.  
-
CY  
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. 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 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.  
CX is 4.7uF ceramic cap;  
CX1 is 4.7uF ceramic cap;  
CY is 3.3nF ceramic cap;  
CY1 is 4.7nF ceramic cap;  
L1 is common-mode inductor, L1=0.08mH;  
L2 is common-mode inductor, L1=0.24mH;  
Test Result  
Test result is in compliance with CISPR 22 class B, which  
is shown as below:  
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.  
Vin=48V, Io=25A,  
Yellow line is quasi peak mode;  
Blue line is average mode.  
7
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DS_H48SA12025_05052008  
FEATURES DESCRIPTIONS  
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-Current Protection  
The modules include an internal output over-current  
protection circuit. 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.  
Vi(+)  
Vo(+)  
Sense(+)  
Trim  
ON/OFF  
Vi(-)  
R
For 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.  
Hiccup mode is default mode.  
Sense(-)  
Vo(-)  
Distribution resistor  
Figure 18: Remote on/off implementation  
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 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:  
Over-Voltage Protection  
The modules include an internal output over-Voltage  
protection circuit. If the output voltage exceeds the OVP  
set point, the modules will automatically shut down, and  
enter hiccup mode or latch mode, which is optional.  
[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).  
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.  
Hiccup mode is default mode.  
Vi(+)  
Vo(+)  
Sense(+)  
Trim  
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.  
ON/OFF  
Vi(-)  
R
Sense(-)  
Vo(-)  
Over-Temperature Protection  
Distribution resistor  
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 or latch mode, which is optional.  
Figure 19: 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.  
For auto-restart mode, the module will monitor the  
module temperature after shutdown. Once the  
temperature is within the specification, the module will  
be auto-restarted. Auto-restart mode is default mode.  
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.  
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.  
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.  
Remote On/Off  
Care should be taken to ensure that the maximum  
output power does not exceed the maximum rated  
power.  
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.  
8
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DS_H48SA12025_05052008  
FEATURES DESCRIPTIONS (CON.)  
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  
SENSE(+) or SENSE(-). The TRIM pin should be left  
open if this feature is not used.  
Figure 21: Circuit configuration for trim-down (decrease output  
voltage)  
If the external resistor is connected between the TRIM  
and SENSE (-) the output voltage set point decreases  
(Fig. 21). The external resistor value required to obtain a  
percentage of output voltage change % is defined as:  
100  
Rtrim_down  
2 kΩ  
Figure 20: Circuit configuration for trim-up (increase output  
voltage)  
Δ
Ex. When trim down to 9.6V from 12V  
Δ = 100*(12-9.6)/12 = 20  
If the external resistor is connected between the TRIM  
and SENSE (+) pins, the output voltage set point  
increases (Fig. 20). The external resistor value  
required to obtain a percentage of output voltage  
change % is defined as:  
100  
(
2)  
kΩ  
Rtrim_down =  
20  
Rtrim_down = 3 kΩ  
12  
⎡⎛  
(
)
2 100 + Δ + 100  
The typical resistor value can be seen in below figure22.  
1.225  
Rtrim_up  
kΩ  
Δ
Output voltage  
Resistor value ( kΩ )  
13.2V  
12.6V  
10.8V  
9.6V  
95.8  
183.7  
8.0  
Ex. When trim up to 13.2V from 12V  
Δ = 100*(13.2-12)/12 = 10  
3.0  
12  
⎡⎛  
2 (100 + 10) + 100  
Figure 22: Trim resistor value example for popular output  
voltages  
1.225  
Rtrim_up  
kΩ  
10  
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.  
Rtrim_up = 95.755 kΩ  
I
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.  
9
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DS_H48SA12025_05052008  
THERMAL CONSIDERATIONS  
Thermal Derating  
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.  
Heat can be removed by increasing airflow over the  
module. The module’s maximum device temperature is to  
be defined and the measured location is illustrated in  
Figure 24. 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.  
Hence, the choice of equipment to characterize the  
thermal performance of the power module is a wind  
tunnel.  
Thermal Testing Setup  
PWB  
FACING PWB  
MODULE  
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.  
AIR VELOCITY  
AND AMBIENT  
TEMPERATURE  
MEASURED BELOW  
THE MODULE  
50.8 (2.0”)  
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’’).  
AIR FLOW  
12.7 (0.5”)  
Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches)  
Figure 23: Wind tunnel test setup  
10  
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DS_H48SA12025_05052008  
THERMAL CURVES  
H48SA12025(Standard) Output Current vs. Ambient Temperature and Air Velocity  
@Vin = 48V (Either Orientation)  
Output Current (A)  
600LFM  
25  
20  
15  
10  
5
500LFM  
Natural  
Convection  
100LFM  
200LFM  
300LFM  
400LFM  
0
25  
30  
35  
40  
45  
50  
55  
60  
65  
70  
75  
80  
85  
Ambient Temperature  
Figure 26: Output current vs. ambient temperature and air  
velocity @ Vin=48V, Vout=12V(Openframe Version, Either  
Orientation).  
Figure 24: Temperature measurement location for openframe  
version - The allowed maximum hot spot temperature is  
defined at 122.  
H48SA12025(standard) Output Current vs. Ambient Temperature and Air Velocity  
@Vin = 48V (Either Orientation,With Heatspreader)  
Output Current (A)  
25  
20  
15  
10  
5
Natural  
Convection  
100LFM  
200LFM  
300LFM  
400LFM  
500LFM  
600LFM  
0
25  
30  
35  
40  
45  
50  
55  
60  
65  
70  
75  
80  
85  
Ambient Temperature  
Figure 27: Output current vs. ambient temperature and air  
velocity @ Vin=48V, Vout=12V(Heatspreader version, Either  
Orientation).  
Figure 25: Temperature measurement location for heatspreader  
version - The allowed maximum hot spot temperature is defined  
at 109.  
11  
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DS_H48SA12025_05052008  
MECHANICAL DRAWING (WITHOUT HEATSPREADER)  
Pin No. Name  
Function  
1
2
3
4
5
6
7
8
9
+Vin  
Positive input voltage  
Remote ON/OFF  
ON/OFF  
CASE  
-Vin  
-Vout  
-SENSE  
TRIM  
Case pin  
Negative input voltage  
Negative output voltage  
Negative remote sense  
Output voltage trim  
Positive remote sense  
Positive output voltage  
+SENSE  
+Vout  
Notes:  
Pins 1-4, 6-8 are 1.00mm (0.040”) diameter  
Pins 5 and 9 are 2.00mm (0.079”) diameter  
All pins are copper with Tin plating.  
1
2
3
12  
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DS_H48SA12025_05052008  
MECHANICAL DRAWING (WITH HEATSPREADER)  
13  
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DS_H48SA12025_05052008  
PART NUMBERING SYSTEM  
H
48  
S
A
120  
25  
N
N
F
A
Form  
Input Number of Product  
Output  
Output  
ON/OFF  
Pin  
Option Code  
Factor Voltage Outputs  
Series  
Voltage Current  
Logic  
Length  
N - 0.145”  
H - Half-  
Brick  
48V  
S- Single A - Advanced 120- 12V  
25- 25A N - Negative  
P - Positive  
A - Standard Functions  
H - with Heatspreader  
F- RoHS 6/6  
(Lead Free)  
MODEL LIST  
Part Number  
INPUT  
OUTPUT  
EFF @ 100% LOAD  
H48SA12025NNFA  
36V~75V  
11A  
12V  
25A  
93.2%  
USA:  
Telephone:  
East Coast: (888) 335 8201  
West Coast: (888) 335 8208  
Fax: (978) 656 3964  
Asia & the rest of world:  
Telephone: +886 3 4526107 ext 6220  
Fax: +886 3 4513485  
Europe:  
Phone: +41 31 998 53 11  
Fax: +41 31 998 53 53  
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.  
14  
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DS_H48SA12025_05052008  

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