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FEATURES
High efficiency: 89% @ 5V/ 15A Size: 58.4mm x 22.8mm x 9.2mm (2.30"x0.90"x0.36") Industry standard pin out 18~75V extremely wide 4:1 input range Fixed frequency operation Input UVLO, Output OCP, OVP and OTP 2250V isolation Basic insulation No minimum load required SMD and through-hole versions ISO 9001, TL 9000, ISO 14001, QS 9000, OHSAS 18001 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 E36SR, 75W Eighth Brick Family DC/DC Power Modules: 18~75V in, 5V/15A out
The Delphi Series E36SR Eighth Brick, 18~75V 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 operates from an extremely wide 18~75V input range and provides up to 75 watts of power in an industry standard eighth brick footprint and pinout. With creative design technology and optimization of component placement, these converters possess outstanding electrical and thermal performances, 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.
OPTIONS
Positive On/Off logic Short pin lengths available SMD pin
APPLICATIONS
Telecom/Datacom Wireless Networks Optical Network Equipment Server and Data Storage Industrial/Testing Equipment
DATASHEET DS_E36SR05015_02092007
TECHNICAL SPECIFICATIONS
(TA=25C, 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 DC Current-Limit Inception 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
E36SR05015 (Standard)
Min. 18 Typ. 24/48 Max. 75 100 122 125 2250 75 19 17.5 2 5 15 1 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 20 20 ms ms F % % Vdc M pF kHz 1.8 18 1.8 18 1 50 10% 10 6 2.2 25 127 V V V V mA uA % % V M hours grams C
100ms Refer to Figure 21 for measuring point
-40 -55 18 18 16.5 1 24/48 18.5 17 1.5 70 10 20 60 4.95 5.0 5 5 25 4.9 60 10 0 110 150 150 200 2 10
100% Load, 18Vin No load, 48Vin P-P thru 12H inductor, 5Hz to 20MHz 120 Hz Vin=48V, Io=Io.max, Tc=25C Io=Io,min to Io,max Vin=18V to 75V Tc=-40C to 85C over sample load, line and temperature 5Hz to 20MHz bandwidth Full Load, 1F ceramic, 10F tantalum Full Load, 1F ceramic, 10F tantalum Output Voltage 10% Low 48V, 10F Tan & 1F Ceramic load cap, 0.1A/s 25% Io.max to 50% Io.max 50% Io.max to 25% Io.max
5.05 10 10 50 5.1 30 15 140
Full load; 5% overshoot of Vout at startup
5000 89 90 2250 10 1500 300
Von/off at Ion/off=1.0mA Von/off at Ion/off=0.0 A Von/off at Ion/off=1.0mA Von/off at Ion/off=0.0 A Ion/off at Von/off=0.0V Logic High, Von/off=15V Across Pins 9 & 5, Pout max rated power Pout max rated power Over full temp range; % of nominal Vout Io=80% of Io, max; 300LFM @25 Refer to Figure 21 for measuring point
0 2.4 0 2.4
-10%
DS_E36SR05015_02092007
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ELECTRICAL CHARACTERISTICS CURVES
Figure 1: Efficiency vs. load current for minimum, nominal, and maximum input voltage at 25C
Figure 2: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at 25C.
Figure 3: Typical full load input characteristics at room temperature
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ELECTRICAL CHARACTERISTICS CURVES
Figure 4: Turn-on transient at full rated load current (CC mode) (5ms/div). Vin=48V.Top Trace: Vout, 2V/div; Bottom Trace: ON/OFF input, 5V/div
Figure 5: Turn-on transient at zero load current (5ms/div). Vin=48V.Top Trace: Vout, 2V/div; Bottom Trace: ON/OFF input, 5V/div
Figure 6: Turn-on transient at full rated load current (CC mode) (5ms/div). Vin=48V.Top Trace: Vout, 2V/div; Bottom Trace: input voltage, 20V/div
Figure 7: Turn-on transient at zero load current (5ms/div). Vin=48V.Top Trace: Vout, 2V/div; Bottom Trace: input voltage, 20V/div
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ELECTRICAL CHARACTERISTICS CURVES
Figure 8: Output voltage response to step-change in load current (50%-25% of Io, max; di/dt = 0.1A/s). Load cap: 10F, tantalum capacitor and 1F ceramic capacitor. Top Trace: Vout (100mV/div, 200us/div), Bottom Trace: I out (5A/div).
Figure 9: Output voltage response to step-change in load current (25%-50% of Io, max; di/dt = 0.1A/s). Load cap: 10F, tantalum capacitor and 1F ceramic capacitor. Top Trace: Vout (100mV/div, 200us/div), Bottom Trace: I out (5A/div).
Figure 10: Test set-up diagram showing measurement points for Input Terminal Ripple Current and Input Reflected Ripple Current.
Figure 11: Input Terminal Ripple Current, ic, at 48Vin and 15A output current with 12H source impedance and 33F electrolytic capacitor (500 mA/div, 2us/div).
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ELECTRICAL CHARACTERISTICS CURVES
Copper Strip Vo(+)
10u Vo(-)
1u
SCOPE
RESISTIVE LOAD
Figure 12: Input reflected ripple current, is, through a 12H source inductor at 48Vin and 15A output current (20 mA/div, 2us/div).
Figure 13: Output voltage noise and ripple measurement test setup
Figure 14: Output voltage ripple at 48Vin and rated load current (Io=15A)(20 mV/div, 2us/div) Load capacitance: 1F ceramic capacitor and 10F tantalum capacitor. Bandwidth: 20 MHz.
Figure 15: Output voltage vs. load current showing typical current limit curves and converter shutdown points.
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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. 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 10A 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.
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FEATURES DESCRIPTIONS
Vi(+) Vo(+)
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.
Sense(+) ON/OFF Sense(-) Vi(-)
Vo(-)
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% x Vout
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.
This limit includes any increase in voltage due to remote sense compensation and output voltage set point adjustment (trim).
Vi(+) Vo(+) Sense(+)
Sense(-) Contact Resistance Vi(-) Vo(-) Contact and Distribution Losses
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.
Figure 17: 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.
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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 19: Circuit configuration for trim-up (increase output voltage)
Figure 18: Circuit configuration for trim-down (decrease 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 . 11 Vo (100 + ) 511 - - 10 . 2 (K ) 1.225
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:
Rtrim - down = 511 - 10 .2 (K )
Ex. When Trim-up +10%(5Vx1.1=5.5V)
Rtrim - up = 5 .11 x 5 x (100 + 10 ) 511 - - 10 .2 = 168 (K ) 1.225 x 10 10
Ex. When Trim-down -10%(5Vx0.9=4.5V)
Rtrim - down = 511 - 10 .2 = 40 .9 (K ) 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. 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.
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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. The hottest point temperature of the module is +122C. 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'').
Figure 21: Hot spot temperature measured point. The allowed maximum hot spot temperature is defined at 122
Output Current(A)
16
E36SR05015(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 24V (Transverse Orientation)
14
12
FACING PWB
PWB
MODULE
Natural Convection
10
100LFM
200LFM
300LFM
8
400LFM
6
500LFM
600LFM
4
AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE
AIR FLOW
2
0 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature ()
50.8 (2.0")
Figure 22: Output current vs. ambient temperature and air velocity @ Vin=24V(Transverse Orientation)
16 Output Current(A)
E36SR05015(Standard) Output Current vs. Ambient Temperature and Air Velocity @Vin = 48V (Transverse Orientation)
12.7 (0.5")
Note: Wind Tunnel Test Setup Figure Dimensions are in millimeters and (Inches)
14
12
Natural Convection
100LFM
10
Figure 20: Wind tunnel test setup
200LFM
300LFM
8
400LFM
500LFM
6
600LFM
4
2
0 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature ()
Figure 23: Output current vs. ambient temperature and air velocity @ Vin=48V(Transverse Orientation)
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PICK AND PLACE LOCATION
SURFACE-MOUNT TAPE & REEL
RECOMMENDED PAD LAYOUT (SMD)
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LEADED (Sn/Pb) PROCESS RECOMMEND TEMP. PROFILE
250 Temperature (C ) 200 150 100 50 2nd Ramp-up temp. Peak temp. 1.0~3.0C /sec. 210~230C 5sec. Pre-heat temp. 140~180C 60~120 sec. Cooling down rate <3C /sec.
Ramp-up temp. 0.5~3.0C /sec.
Over 200C 40~50sec.
0
60
120 Time ( sec. )
180
240
300
Note: The temperature refers to the pin of E36SR, measured on the pin +Vout joint.
LEAD FREE (SAC) PROCESS RECOMMEND TEMP. PROFILE
Temp.
Peak Temp. 240 ~ 245
217 200
Ramp down max. 4/sec.
150
Preheat time 100~140 sec. Ramp up max. 3/sec.
Time Limited 90 sec. above 217
25
Time
Note: The temperature refers to the pin of E36SR, measured on the pin +Vout joint.
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MECHANICAL DRAWING
Surface-mount module Through-hole module
Pin No.
1 2 3 4 5 6 7 8
Name
-Vin ON/OFF +Vin +Vout +SENSE TRIM -SENSE -Vout
Function
Negative input voltage Remote ON/OFF Positive input voltage Positive output voltage Positive remote sense Output voltage trim Negative remote sense Negative output voltage
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PART NUMBERING SYSTEM
E
Type of Product
E- Eighth Brick
36
S
R
Product Series
R- Regular
050
Output Voltage
050- 5.0V
15
Output Current
15-15A
N
ON/OFF Logic
N- Negative
R
Pin Length/Type
R- 0.170"
F
A
Option Code
Input Number of Voltage Outputs
36-18~75V S- Single
F- RoHS 6/6 A- Standard Functions (Lead Free)
MODEL LIST
MODEL NAME
E36SR3R320NRFA E36SR05015NRFA 18V~75V 18V~75V
INPUT
4.5A 5A 3.3V 5.0V
OUTPUT
20A 15A
EFF @ 100% LOAD
88% 89%
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: Telephone: East Coast: (888) 335 8201 West Coast: (888) 335 8208 Fax: (978) 656 3964 Email: DCDC@delta-corp.com Europe: Telephone: +41 31 998 53 11 Fax: +41 31 998 53 53 Email: DCDC@delta-es.tw Asia & the rest of world: Telephone: +886 3 4526107 x 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. DS_E36SR05015_02092007
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