AC-DC Single Output Power Module PFHC (AC-DC Conversion) and DC-DC Conversion Integrated in One Package. Full Function (F type) 2-in-1 Design Concept One module now contains the functions previously only obtainable by combining a front-end module with a high voltage input DC-DC converter. The product is made using a wide range input AC-DC front end function (harmonic current control and power factor correction) and DC-DC back-end (voltage conversion and isolation) in 1 package). ON/OFF Control. ON/OFF control is possible even there is no ON/OFF in input circuit. ON/OFF control circuit is in between primary & secondary isolation. Inverter Operation Good signal Auxiliary Supply available Huge reduction in space old product By utilizing output current balancing function, parallel operation up to 6 units is possible. High Power Density:0.95/ High Efficiency:89%/ Input Voltage:85265VAC PFE Series Enhanced Surge Immunity Level It is possible to clear 6kV surge voltage in normal and common mode (absorber is installed in the input PFHC is provided, primary and secondary isolation for better safety and wide input range. High efficiency with up to 100 base plate temperatures. PFE500S-12, PFE500F-12: Up to 85 filter). Solution to Serve Different Kinds of Market Demands PFE series features offer many reliable solutions Thanks to its compact size and reduction in cost, power distribution is easier to construct than before. More over, high power density and N+1 redundant parallel operation increase the reliability. High base plate temperature and 6kV surge immunity level makes PFE series suitable to be used in harsh outdoor environment. After all, new functions are added to each models to give reliable solution to many market demands. PFE Series Regulated Output AC Input EMI Filter Load 12V,28V,48V Application Example s h PFE-F SERIES AC-DC Single Output Power Module UL60950-1 EN60950-1 CSA C22.2 No.60950-1 ks Features ph F A F A P FHC &DC-DC conversion integrated in one package W ide input voltage range: 85-265VAC F A F A H igh power factor: 0.95, meet PFHC standard k-a hk-a Blank: standard type T: mounting stand3.3 (non-thread,through hole) FG: 1.5kVDC (output-base plate); 48V output only Output voltage Function F: Full Function Output power Series name Power ON signal B uilt-in capacitor: ceramic capacitors only (high reliability) Applications F A F A Conformity to RoHS Directive This means that, in conformity with EU Directive 2002/95/EC, lead, cadmium, mercury, hexavalent chromium, and specific bromine-based flame retardants, PBB and PBDE, have not been used, except for exempted applications. Product Line up phaalpha PFE-F. AC85-265Vin Output Voltage F A 48V 500W Output Current Model 42A PFE500F-12 60A PFE1000F-12 PFE500F-28 36A PFE1000F-28 PFE500F-48 21A PFE1000F-48 18A 1000W Model 28V F A Output Current 12V dlp ps fps warranty Option High efficiency: max. 86% Wide base plate temperatures: -40 to +100 F A F A Full function model N+1 Redundant parallel operation Current sharing (load current balancing) IOG (Inverter Operation Good signal) Auxiliary supply available ON/OFF control ws hws p 2 Model naming method PFE 500 F-12 / (EN-61000-3-2) f-a pf-a Low Voltage Directive Y E A R S F A F A 10.5A All contents are subject to change without notice. PFE500F PFE500F Specifications MODEL ITEMS/UNITS Voltage Range (*2) (*5) Frequency Input Power Factor V 47 - 63 0.95 (*1) (*1) A (*1)(*5) A Nominal Voltage 81 / 83 A Maximum Power W 12 28 48 42 18 10.5 504 Voltage Setting Accuracy Maximum Line Regulation mV 48 56 Maximum Load Regulation mV 48 56 96 Maximum Ripple & Noise (*5) mVp-p 120 280 480 +/-2 Remote Sensing 105% - 140% (Automatic recovery method) 125% - 145% (Inverter shutdown method) (*6) Possible Remote ON/OFF Control (*6) Possible Parallel Operation (*6) Possible Series Operation (*6) Possible Operating Temperature (*3)(*7) -40 - +85(Baseplate) -40 - +100(Baseplate) -40 - +100 Operating Humidity RH 20 - 95 (No Dewdrop) Storage Humidity RH 10 - 95 (No Dewdrop) At no operating, 10-55Hz (Sweep for 1min.) Storage Temperature Vibration Amplitude 0.825mm constant (Maximum 49.0m/s) X,Y,Z 1 hour each 196.1m/s Shock Cooling (*4) Conduction Cooled Standards Safety Standards Approved by UL60950-1, CSA C22.2 No.60950-1, EN60950-1 Input-Baseplate : 2.5kVAC, Input-Output : 3.0kVAC for 1min. Withstand Voltage Output-Baseplate : 500VDC for 1min. Output-Baseplate 500VDC more than 100M (25 C,70%RH) Isolation Resistance Mechanical 96 -20 / +20 Over Voltage Protection (*8) Isolation 6.4 / 3.2 20 / 40 peak Over Current Protection Environment 84 / 86 6.8 / 3.4 (*1) VDC Maximum Current Voltage Adjustable Range Function PFE500F-48 85 - 265 VAC (*1)(*5) Current Output PFE500F-28 (*2) Hz Efficiency (Typ) Inrush Current (Typ) PFE500F-12 Weight (Typ) Size (W x H x D) g 300 mm 70 x 12.7 x 122 (Refer to Outline Drawing) (*1) At 100VAC/200VAC and maximum output power. (Baseplate Temperature = +25 C.) (*2) For cases where conformance to various safety specs (UL, CSA, EN) are required, input voltage range will be 100 - 240VAC(50/60Hz). (*3) Ratings - refer to Derating Curve on the right. (*4) Heatsink has to be chosen according to Instruction manual. (*5) External components are needed for operation. (Refer to basic connection and instruction manual.) (*6) Refer to Instruction manual. (*7) Ambient Temperature min=-40 C (*8) OVP reset : Line off or Control off. (Refer to instruction manual.) Derating Curve Load 100 80 60 40 PFE500F-12 PFE500F-2848 20 0 -40 -20 0 20 40 60 85 80 100 Baseplate Temperature All contents are subject to change without notice. PFE500F PFE500F Outline Drawing 5.00.5 +0.7 12.7 -0.3 C L see note D see note A -V +V +V R +BC -BC R +BC -BC -S +S PC TRIM +ON/OFF IOG -ON/OFF ENA AUX COM MADE IN JAPAN -S PC +ON/OFF -ON/OFF AUX 2.54 9.93 +S TRIM IOG ENA COM 2.54 EN6 0 9 50 BAR CODE 2.54 AC-DC 2.54 AC (L) 5.78 12.0 -V INPUT:100-240VAC 8A 50/60Hz OUTPUT:48V 10.5A 2.54 70.00.5 59.70.5 5.78 AC(L) PFE500F-48 AC (N) 29.73 CL 12.0 AC(N) see note C 3.7 see note E 5.26 15.0 see note B 15.0 54.12 111.80.5 122.00.5 Lot No. seal NOTES: A: Model name, input voltage range, Nominal output voltage, Maximum output current, country of manufacture and safety marking (C-UL-US, BSI & CE marking) are shown here in accordance with the specifications. B: M3 tapped holes 4 for customer chassis mounting (FG). C: Output terminal : 2-2 D: Input and Intermediate terminal : 5-1 E: Signal pin (+S, -S, TRIM, ENA, IOG, AUX, +ON/OFF, -ON/OFF, PC, COM) : 10-0.64 F: Unless otherwise specified dimensional tolerance : 0.3 All contents are subject to change without notice. PFE500F Basic Connection L=50mm L1 1 +v AC(L) C2 C6 C5 C4 C1 INPUT +s L2 C3 R1 2,3 5 C7 PFE500F C13 + C15 C14 6 C16 + 6 C17 OUTPUT F1 -v AC(N) -s TRIM AUX IOG PC ENA +ON/OFF -ON/OFF COM +BC -BC BASEPLATE R C8 C9 2,3 Input Filter For VCCI-classA 2,3 TFR1 5 + 4 + F1 AC250V 15A C12 2200pF R1 0.5W 470k C13 0.033uF C1 AC250V 1uF (Film) C14 0.033uF C2 2200pF C3 2200pF C4 AC250V 1uF (Film) C5 AC250V 1uF (Film) C6 2200pF C7 2200pF C8 450V 1uF (Film) C12 C10 C11 12V: 25V 1000uF (Elec.) C15 28V: 50V 470uF (Elec.) 48V: 100V 220uF (Elec.) C16 100V 2.2uF (Ceramic) 12V: 25V 1000uF (Elec.) C17 28V: 50V 470uF (Elec.) 48V: 100V 220uF (Elec.) C9 450V 1uF (Film) C10 450V 390uF (Elec.) TFR1 L1 10 139 C (Res., Thermal fuse) 6mH C11 450V 390uF (Elec.) L2 6mH (*1) Use an external fuse of fast blow type for each unit. (*2) The allowable ripple current of capacitor must be more than 3A(rms). (*3) Put this capacitor near the terminal as close as possible. (*4) The maximum capacitance that can be used is less than 1200uF(Rated capacitance). Avoid the connection of capacitance which is more than above, else it will lead to module to damage. (*5) The inrush current at AC throw in can be suppressed by the external Resistor (Built-in thermal fuse) connected between the R and +BC terminals. (*6) If the ambient temperature is less than -20C, use twice the recommended capacitor above. (*7) Refer to instruction manual for further details. All contents are subject to change without notice. PFHC circuit (fixed) : All contents are subject to change without notice. Output voltage detector OCP Iutput voltage detector(DC-DC) OCP OVP Output filter Rectifier Switching circuit +BC -BC Secondary Control DC-DC Control circuit OTP(DC-DC) Inrush current limiting circuit AC(L) OTP(PFHC) Filter PFHC Bias power supply OVP PFHC circuit Boost voltage detector PFHC & BPS Control circuit Rectifier AC(N) Iutput current detector OCP Iutput voltage detector PFE500F Block Diagram DC/DC Converter +V -V IOG TRIM +S -S COM PC ENA +ON/OFF -ON/OFF AUX Switching Frequency DC/DC converter (fixed) : 230kHz (primary),460kHz (secondary) 100kHz PFE500F Sequence Time Chart Input Voltage (AC) 390VDC (typ) BC Terminal Voltage (Boost Voltage) H L H L H Control ON Control OFF OTP Trip Input Line ON Input Line OFF OCP Release OCP Active Control ON L Input Line ON AUX L OVP Trip ENA H Control OFF IOG L Control ON ON/OFF Comtrol H Control OFF Output Voltage V* voltage level: Refer to Application Notes"13.Power ON Signal"section. All contents are subject to change without notice. PFE1000F PFE1000F Specifications MODEL ITEMS/UNITS Voltage Range (*2)(*3) Frequency Inrush Current (Typ) 47 - 63 0.95 80 / 82 (*1) A 9.8 / 4.8 (*1)(*3) A Nominal Voltage 84 / 86 13.6 / 6.6 (*1) VDC 12 28 A 60 36 Maximum Power W 720 21 Voltage Setting Accuracy Maximum Line Regulation mV 48 56 Maximum Load Regulation mV 48 56 96 Maximum Ripple & Noise (*3) mVp-p 120 280 480 +/-2 96 -20 / +20 Over Current Protection (*4)(*5) 105% - 140% Over Voltage Protection (*5) 125% - 145% (Inverter shutdown method) Remote Sensing (*6) Possible Remote ON/OFF Control (*6) Possible Parallel Operation (*6) Possible Series Operation (*6) Possible -40 - +100(Baseplate) -40 - +100 Operating Humidity RH 20 - 95 (No Dewdrop) Storage Humidity RH 10 - 95 (No Dewdrop) At no operating, 10-55Hz (Sweep for 1min.) Storage Temperature Vibration Amplitude 0.825mm constant (Maximum 49.0m/s) X,Y,Z 1 hour each 196.1m/s Shock Cooling (*9) Conduction Cooled Input-Baseplate : 2.5kVAC, Input-Output : 3.0kVAC for 1min. Withstand Voltage Output-Baseplate : 500VDC for 1min. Output to Baseplate 500VDC more than 100M (25 C,70%RH) Isolation Resistance Standards Safety Standards Mechanical 48 1008 Operating Temperature (*7)(*8) Isolation 13.4 / 6.5 20 / 40 peak Maximum Current Voltage Adjustable Range Environment PFE1000F-48 85 - 265 VAC (*1) Current Function V (*1)(*3) Efficiency (Typ) Output PFE1000F-28 (*2) Hz Power Factor Input PFE1000F-12 Weight (Typ) Size (W x H x D) Approved by UL60950-1, CSA60950-1, EN60950-1 g 500 mm 100 x 13.4 x 160 (Refer to Outline Drawing) (*1) At 100VAC/200VAC and maximum output power. (Baseplate Temperature = +25 C.) (*2) For cases where conformance to various safety specs (UL, CSA, EN) are required, input voltage range will be 100 - 240VAC(50/60Hz). (*3) External components are needed for operation. (Refer to basic connection and instruction manual.) (*4) Constant current limiting. (The unit automatically shutdown when left in OCP condition, with the output voltageless than the LVP level. Refer to instruction manual.) (*5) Reset : Line off or Control off. (Refer to instruction manual.) (*6) Refer to Instruction manual. (*7) Ambient Temperature min=-40 C (*8) Ratings - refer to Derating Curve. (*9) Heatsink has to be chosen according to Instruction manual. Derating Curve PFE1000F-12 PFE1000F-28,48 1008W 100 80 Load Load 720W 100 60 40 80 60 40 85VACVin<170VAC 170VACVin<265VAC 20 20 0 0 -40 -20 0 20 40 60 80 Baseplate Temperature All contents are subject to change without notice. 100 -40 -20 0 20 40 60 80 85 100 Baseplate Temperature PFE1000F PFE1000F Outline Drawing 13.40.5 C L 5.00.5 73.7 147.70.5 see note D 2.54 see note E 2.54 see note A PFE1000F-48 AC (N) INPUT : 100-240VAC 16A 50/60Hz OUTPUT : 48V 21A 88.50.5 100.00.5 AC(L) -S +S PC TRIM +ON/OFF -ON/OFF AUX AC (L) IOG ENA COM -V -V -V AC-DC +V +V +V 43.7 BAR CODE EN6 0 9 50 R R +BC 15.0 +BC -BC 3.7 -V -V -V +V +V +V MADE IN JAPAN see note C -BC 15.0 +S TRIM IOG ENA COM 2.54 10.420.5 2.54 2.54 6.35 6.35 10.15 6.35 6.35 8.75 12.0 19.0 C L -S PC +ON/OFF -ON/OFF AUX AC(N) 16.2 71.7 see note B 148.50.5 160.00.5 Lot No. seal NOTES: NOTES Maximum : A: Model name, input voltage range, Nominal output voltage, output current, country of manufacture and safety marking A: Model name, input voltage range, Nominal (C-UL-US, BSI & CE marking) are shown here in accordance with the specifications. output voltage, Maximum output current, B: M3 tapped holes 4 for customer chassis mounting (FG).country of manufacture and safety marking (C-UL-US, BSI & CE marking) are shown C: Output terminal : 6-2 here in accordance with the specifications. D: Input and Intermediate terminal : 5-2 B: M3 tapped holes 4 for customer chassis mounting (FG). E: Signal pin (+S, -S, TRIM, ENA, IOG, AUX, +ON/OFF, -ON/OFF, PC, COM) : 10-0.64 C: Output terminal : 6-O2 F: Unless otherwise specified dimensional tolerance : 0.3 D: Input and Intermediate terminal : 5-O2 E: Signal pin (+S, -S, TRIM, ENA, IOG, AUX, +ON/OFF, -ON/OFF, PC, COM) : 10- 0.64 F: Unless otherwise specified dimensional tolerance : 0.3 10 All contents are subject to change without notice. PFE1000F Basic Connection L=50mm L1 1 L2 C2 +v AC(L) C6 C4 C1 INPUT +s L3 R1 C5 C7 C3 C8 3 2,3 PFE1000F C15 + C17 C16 6 C18 + 6 C19 OUTPUT F1 -v AC(N) -s TRIM AUX IOG PC ENA +ON/OFF -ON/OFF COM +BC -BC BASEPLATE R C9 2,3 C10 2,3 Input Filter For VCCI-classA TFR2 5 TFR1 5 + C11 4 + C12 4 + C13 4 + C14 4 F1 F25AH250V C15 0.033uF C1 AC250V 1uF (Film) C16 0.033uF C2 470pF C3 470pF C4 AC250V 1uF (Film) 12V25V 1000uF (Elec.) C17 28V50V 470uF (Elec.) 48V100V 220uF (Elec.) C5 AC250V 1uF (Film) C6 4700pF C18 100V 2.2uF (Ceramic) C7 4700pF C8 AC250V 1uF (Film) C9 450V 1uF (Film) C10 450V 1uF (Film) TFR1 5.1139 (Res., Thermal fuse) C11 450V 390uF (Elec.) TFR2 5.1139 (Res., Thermal fuse) C12 450V 390uF (Elec.) L1 2mH C13 450V 390uF (Elec.) L2 2mH C14 450V 390uF (Elec.) L3 2mH 12V25V 1000uF (Elec.) C19 28V50V 470uF (Elec.) 48V100V 220uF (Elec.) R1 0.5W470k (*1) Use an external fuse of fast blow type for each unit. (*2) The allowable ripple current of capacitor must be more than 3A(rms). (*3) Put this capacitor near the terminal as close as possible. (*4) The maximum capacitance that can be used is less than 2300uF(Rated capacitance). Avoid the connection of capacitance which is more than above of else it will lead to module damage. (*5) The inrush current at AC throw in can be suppressed by the external Resistor (Built-in thermal fuse) connected between the R and +BC terminals. (*6) If the ambient temperature is less than -20 C, use twice the recommended capacitor above. (*7) Refer to instruction manual for further details. All contents are subject to change without notice. 11 12 PFHC circuit (fixed) : Output voltage detector OCP Iutput voltage detector(DC-DC) OCP LVP OVP Output filter Rectifier Switching circuit +BC -BC Secondary Control DC-DC Control circuit OTP(DC-DC) Inrush current limiting circuit AC(L) OTP(PFHC) Filter PFHC Bias power supply OVP PFHC circuit Boost voltage detector PFHC & BPS Control circuit Rectifier AC(N) Iutput current detector OCP Iutput voltage detector PFE1000F Block Diagram DC/DC Converter +V -V IOG TRIM +S -S COM PC ENA +ON/OFF -ON/OFF AUX Switching Frequency DC/DC converter (fixed) : 230kHz (primary),460kHz (secondary) 100kHz All contents are subject to change without notice. PFE1000F Sequence Time Chart Input Voltage (AC) 390VDC (typ) BC Terminal Voltage (Boost Voltage) OCP Trip Point LVP Trip Point OVP Trip Point H L H L H L H Control ON Control OFF OTP Trip Input Line ON Input Line OFF OCP Active LVP Trip Control OFF Control ON Control ON L Input Line ON AUX V** L OVP Trip ENA V* Control OFF IOG V* Control ON ON/OFF Comtrol H Control OFF Output Voltage V* voltage level: Refer to Application Notes"13.Power ON Signal"section. V** voltage level: Refer to Application Notes"6.Over Current Protection"section. All contents are subject to change without notice. 13 PFE500F1000F SERIES PFE500F, 1000F SERIES Instruction Manual BEFORE USING THE POWER SUPPLY UNIT Be sure to read this instruction manual thoroughly before using this product. Pay attention to all cautions and warnings before using this product. Incorrect usage could lead to an electrical shock, damage to the unit or a fire hazard DANGER Never use this product in locations where flammable gas or ignitable substances are present. WARNING Do not make unauthorized changes to power supply unit, otherwise you might have electric shock and void your warranty. Do not touch this unit and the internal components in operation or shortly after shut down. They might have high voltage or high temperature and as the unit dissipates its heat so the surface of the unit is hot. You might receive electric shock or burn. When the unit is operating, keep your hands and face away from it; you might be injured by an accident. Do not use unit under unusual condition such as emission of smoke or abnormal smell and sound etc. It might cause fire and electric shock. In such case, please contact us; do not repair by yourself, as it is dangerous for the user. Do not drop or insert anything into unit. It might cause failure and fire. Do not operate these units under condensation condition. It might cause fire and electric shock. CAUTION As a component part, compliance with the standard will be based upon installation in the final application. This product must be installed in a restricted access location, accessible to authorized competent personnel only. These AC to DC converters have reinforced insulation between the input and the output. The outputs of these products are energy hazards. All models with an output greater than 48V model are considered to be non-SELV. As such, the instructions for use must refer to these energy hazardous outputs and Non-SELV outputs in that the outputs must not be accessible to the operator. The installer must also provide protection against inadvertent contact by a service engineer. The equipment has been evaluated for use in a Pollution Degree 2 environment. This power supply is primarily designed and manufactured to be used and enclosed in other equipment. Confirm connections to input/output terminals and signal terminals are correct as indicated in the instruction manual. Attach a fast acting external fuse to each module to ensure safety operation and compliance to each safety standard approval. The recommended input fuse rating within the instructions manual. The breaking capacity and voltage rating of this fuse might be subject to the end use application. 14 Input voltage, Output current, Output power, ambient temperature and ambient humidity should be used within specifications, otherwise the unit will be damaged. For application equipment, which requires very high reliability (Nuclear related equipment, traffic control equipment, medical equipment, etc.), please provide fail safety function in the equipment. Do not use the product in environment with strong electromagnetic field, corrosive gas and conductive substance. Do not operate and store this unit at an environment where condensation occurs. In such case, waterproof treatment is necessary Never operate the unit under over current or shorted conditions for 30 seconds or more and out of Input Voltage Range as specification. Insulation failure, smoking, burning or other damage might occur to the unit. The output voltage of this power supply unit is considered to be a hazardous energy level (The voltage is 2V or more and the electric power is 240VA or more). Prevention from direct contact with output terminal is highly necessary. While installing or servicing this power supply unit, avoid dropping tools by mistake or direct contact with output terminal. This might cause an electrical shock. While repairing this power supply unit, the AC input power must be switched off and the input and output voltage should be level. To maintain the SELV output for outputs less than 28VDC, under fault conditions, the output must be connected to earth in the final application. The application circuits and their parameter are for reference only. Be sure to verify effectiveness of application circuits and their parameters before finalizing circuit design. Do not inject abnormal voltage to output terminal and signal terminal from the outside. The injection of reverse voltage or over voltage exceeding nominal output voltage to output terminals might cause damage to internal components. This information in this document is subject to change without prior notice. For actual design-in, please refer to the latest publications of data sheet, etc., for the most up-to date specifications of the unit. Design the board of an application circuit implementing this product in consideration of components layout, pattern layout and pattern width. No part of this document might be copied or reproduced in any form without prior written consent of TDK-Lambda. Note : CE MARKING CE Marking when applied to a product covered by this handbook indicates compliance with the low voltage directive (2006/95/ EC) in that it complies with EN60950-1. All contents are subject to change without notice. PFE500F1000F SERIES 1. Terminal Explanation PFE500F Series AC(N) -V AC(L) +V Name Plate -S PC +ON/OFF R +BC +S TRIM IOG -ON/OFF ENA AUX COM -BC [Input side terminals] [Output side terminals] AC(L) : Input terminal live line AC(N) : Input terminal neutral line +V : -V : +BC : -BC : R: +S : +Remote sensing terminal -S : -Remote sensing terminal PC : Output current balance terminal TRIM : Output voltage trimming terminal IOG : Inverter operation good terminal ENA : Power on signal terminal +ON/OFF : +ON/OFF control terminal -ON/OFF : -ON/OFF control terminal AUX : Auxiliary power supply terminal for external circuits COM : Common ground terminal +Boost voltage terminal -Boost voltage terminal External inrush current limiting resistor terminal +Output terminal -Output terminal Baseplate can be connected to FG through M3 mounting tapped holes. Consider contact resistance when connecting AC (L), AC (N), R, +BC, -BC, +V, -V. Note that +BC and -BC terminals is a primary voltage with high voltage (390VDC). Do not connect load to these terminals. It might result in power module damage. All contents are subject to change without notice. 15 PFE500F1000F SERIES PFE1000F Series -S PC AC(N) +ON/OFF AC(L) Name Plate +S TRIM IOG -ON/OFF ENA AUX COM -V -V -V +V +V +V R +BC -BC [Input side terminals] [Output side terminals] AC(L) : Input terminal live line AC(N) : Input terminal neutral line +V : -V : +BC : -BC : R: +S : +Remote sensing terminal -S : -Remote sensing terminal PC : Output current balance terminal TRIM : Output voltage trimming terminal IOG : Inverter operation good terminal ENA : Power on signal terminal +ON/OFF : +ON/OFF control terminal -ON/OFF : -ON/OFF control terminal AUX : Auxiliary power supply terminal for external circuits COM : Common ground terminal +Boost voltage terminal -Boost voltage terminal External inrush current limiting resistor terminal +Output terminal -Output terminal Baseplate can be connected to FG through M3 mounting tapped holes. Consider contact resistance when connecting AC (L), AC (N), R, +BC, -BC, +V, -V. Note that +BC and -BC terminals is a primary voltage with high voltage (390VDC). Do not connect load to these terminals. It might result in power module damage. 16 All contents are subject to change without notice. PFE500F1000F SERIES 2. Explanations on Specifications should a DC input voltage be applied as this would result Input Voltage Range Input voltage range is indicated below. into power module damage. Take care not to Input Voltage Range : Single Phase 85 to 265VAC apply input voltage which is above this specified range or Line Frequency Range : 47 to 63Hz under this specified range for more than 30 seconds. Nor Basic Connection L=50mm Fuse L1 L2 C2 C6 C4 C1 R1 +S +V AC(L) + C5 C13 + C15 C7 C3 C14 AC(N) + C17 C16 - -V PFE500F Load -S TRIM AUX IOG PC ENA +ON/OFF -ON/OFF COM +BC -BC BASEPLATE R C8 C12 C9 Input Filter (For VCCI-classA) C10 TFR1 + C11 + Fig. 1-1-(1) Basic Connection for PFE500F Series L=50mm Fuse L101 L102 L103 C102 C101 C106 C104 C105 R101 +S +V AC(L) + C117 C108 C107 C103 + C115 C116 AC(N) PFE1000F BASEPLATE R -V C118 + C119 Load - -S TRIM AUX IOG PC ENA +ON/OFF -ON/OFF COM +BC -BC C109 C110 Input Filter (For VCCI-classA) TFR101 TFR102 C111 + C112 + C113 + C114 + Fig. 1-1-(2) Basic Connection for PFE1000F Series Note) To meet the surge immunity, evaluate the addition of the surge protection components. Refer to separate document" PFE500F Series IEC Data"and"PFE1000F Series IEC Data". All contents are subject to change without notice. 17 PFE500F1000F SERIES F1 : External Input Fuse to acquire each Safety Standard and to further improve C2, C3, C6, C7, C12: 2,200pF (Ceramic Capacitor) C102, C103 : 470pF (Ceramic Capacitor) C106, C107 : 4,700pF (Ceramic Capacitor) safety. Further, Fast-Blow type fuse must be used per one Connect ceramic capacitor to conform to EMI/EMS standard. module. Also, in-rush surge current flows during line throw- Be sure to note the leakage current of your equipment when This power module has no internal fuse. Use external fuse in. Be sure to check I 2t capability of external switch and connecting this capacitor. fuse. High withstand voltage are applied across this capacitor deRecommended External Fuse pending on the application. Select capacitors with high with- PFE500F : F15AH, 250V stand voltage rating. PFE1000F : F25AH, 250V R1, R101 : 470kohm Note)Select fuse based on rated voltage, rated current and breaking capacity. nals. 1Voltage Ratings 100VAC line : AC125V C8, C9 : 1uF (Film Capacitor) C109, C110 : 1uF (Film Capacitor) 200VAC line : AC250V 2Current Ratings Rated current is selected by the maximum input current based on operating conditions and can be calculated by the following formula. Iin (max)= Pout VinxEffxPF (Arms) (Formula 1-1) Iin (max)Maximum Input Current Pout : Maximum Output Power Vin : Minimum Input Voltage Eff : Efficiency PF : Power Factor 3Breaking Capacity The breaking capacity may be subject to the end use application. Please select a suitably rated breaking capacity fuse for end use application. For Efficiency and Power Factor values, refer to separate document"PFE500F Series Evaluation Data"and"PFE1000F Series Evaluation Data". C1, C4, C5 : 1uF (Film Capacitor) C101, C104, C105, C108 : 1uF (Film Capacitor) Ripple current flows through this capacitor. When selecting capacitor, be sure to check the allowable maximum ripple current rating of this capacitor. Verify the actual ripple current flowing through this capacitor by doing actual measurement. Recommended Voltage Rating : 250VAC Note)Connect C5, C108 as near as possible towards the input terminals of this power module. Audible noise may occur depending on type of film capacitor. L1, L2 : 6mH L101, L102, L103 : 2mH Add common mode choke coil to conform to EMI/EMS standard. When using multiple modules, connect coil to each module. Note) Depending on the input filter used, noise might increase or power module might malfunction due to filter resonance. 18 Connect bleeder resistor across AC(L) and AC(N) termi- Ripple current flows through this capacitor. When selecting capacitor, be sure to check the allowable maximum ripple current rating of this capacitor. Verify the actual ripple current flowing through this capacitor by doing actual measurement. Recommended Voltage Rating : 450VDC Note) Select Capacitor with more than 3A (rms) rating. Connect C8, C9, C109, C110 as near as possible towards the terminals of this power module. C10, C11: 390uF (Electrolytic Capacitor) C111, C112, C113, C114 : 390uF (Electrolytic Capacitor) Refer to"Selection Method of External Bulk Capacitor for Boost Voltage". Allowable External Capacitance at nominal capacitor value is shown below. Recommended Voltage Rating : 450VDC Recommended Total Capacitor : 390uF to 1,200uF (PFE500F Series) 780uF to 2,300uF (PFE1000F Series) Note)1. Do not connect capacitors with more than the above capacitance value as this might result in power module damage. 2. When using module between 3 9 0 uF - 6 0 0 uF for PFE500F Series, 780uF - 1,200uF for PFE1000F Series total capacitor value, it is necessary to reduce output power as shown in Fig1-3. 3. When using module below -20 deg C ambient temperature, AC ripple of boost voltage, output ripple voltage and start up characteristics might be affected by ESR characteristics of the bulk capacitors. Therefore, be sure to verify characteristics by actual evaluation. C13, C14, C115, C116 : 0.033uF Connect ceramic or film capacitor to conform to EMI/EMS standard and to reduce output spike noise voltage. Note)High Voltage is applied across this capacitor during withstand voltage test depending on the application. Connect C13, C14, C115, C116 as near as possible towards the terminals of this power module. All contents are subject to change without notice. PFE500F1000F SERIES C15, C117 : Refer to Table 1-1 To reduce output ripple voltage and to stabilize operation, connect electrolytic capacitors across +V and -V terminals. Note)Connect C15, C117 as near as possible to the +V and -V terminals of this power module. Vout 12V 28V 48V C15 , C117 25V 1,000uF 50V 470uF 100V 220uF Table 1-1 C15, C117:Recommended external capacitance C16, C118 : 2.2uF (Ceramic Capacitor) Connect ceramic capacitor within 50mm from the output terminals +V and -V of the power module to reduce output spike noise voltage. Also, note that output spike noise voltage might vary depending on the wiring pattern of the printed circuit board. C17, C119 : Refer to Table 1-2 Connect C17, C119 within 50mm from the output terminals +V and -V of the power module to stabilize operation and to reduce output ripple noise voltage. Note that the output ripple and line turn off characteristics of the power module might be affected by the ESR and ESL of the electrolytic capacitor. Also, note that output ripple voltage might vary depending on the wiring pattern of the printed circuit board. Fluctuation in output voltage due to sudden load change or sudden input voltage change can be reduced by increasing external output capacitor value. Vout C17 , C119 (Nippon Chemi-con LXY Series or equivalent) (Nichicon PM Series or equivalent) 2. For module operation at ambient temperature -20 deg C or less, output ripple voltage might be affected by ESR characteristics of the electrolytic capacitors. Increase the capacitor values shown in Table 1-1 and 1-2 according to the table below. Vout C15 , C17 , C117 , C119 12V 25V 1,000uF x 2 parallel 28V 50V 470uF x 2 parallel 48V 100V 220uF x 2 parallel Table 1-3 C15, C17, C117, C119 : Recommended external capacitance (Ambient Temperature < -20 deg C) 3. Take note of the allowable maximum ripple current of the electrolytic capacitor used. Especially, for sudden load current changes, verify actual ripple current and make sure that allowable maximum ripple current is not exceeded. Selection Method of External Bulk Capacitor for Boost Voltage Boost voltage bulk capacitor is selected by ripple voltage, ripple current and output hold-up time. Select capacitor value such that boost voltage ripple voltage does not exceed 15Vp-p. Note) When ambient temperature is -20 deg C or less, ripple voltage of the boost voltage might increase due to ESR characteristics. Therefore, verify above characteristics by actual evaluation. For output hold-up time, refer to separate document "PFE500F Series Evaluation Data"or"PFE1000F Series Evaluation Data"and use appropriate capaci- 12V 25V 1,000uF tor up to 1,200uF maximum for PFE500F Series, 28V 50V 470uF 2,300uF maximum for PFE1000F Series. (It is rec- 48V 100V 220uF ommended that verification should be done through Table 1-2 C17, C119:Recommended external capacitance Note) 1. Use low-impedance electrolytic capacitors with excellent temperature characteristics. All contents are subject to change without notice. actual evaluation). For allowable ripple current value, refer to Fig. 1-2 and select a capacitor with higher ripple current rating. 19 2000 100 1600 Output Power% Ripple CurrentmA rms PFE500F1000F SERIES 100VAC 1200 800 200VAC 400 0 0 20 40 60 80 1200uF 80 60 40 20 390uF 0 100 0 200 400 Load Current 800 1000 1200 Fig. 1-3-(1) Output Power v.s. Boost Voltage Bulk Capacitance For PFE500F Series 2000 100 1600 Output Power% Ripple CurrentmA rms 600 Bulk Cap.u Fig. 1-2-(1) Ripple current value for PFE500F Series (A value per one of Fig. 1-1-(1) connection) 100VAC 1200 800 200VAC 400 0 Tbp25 0 20 40 60 80 2300uF 80 60 40 20 780uF 0 100 0 500 Load Current Fig. 1-2-(2) Ripple current value for PFE1000F Series (A value per one of Fig. 1-1-(2) connection) The recommended boost voltage bulk capacitor value range is 390uF-1,200uF for PFE500F Series, 780uF2,300uF for PFE1000F Series. When using with reduced the bulk capacitor value, it is necessary to reduce output power as shown in Fig1-3. Tbp25 1000 1500 2000 2500 Bulk Cap.u Fig. 1-3-(2) Output Power v.s. Boost Voltage Bulk Capacitance For PFE1000F Series Selection Method of External Resistor 1Calculating Resistance Value for External Resistor Resistance can be calculated by the formula below. Vin R= Irush Note that reducing the bulk capacitance affects output (Formula 1-2) hold-up time, dynamic line response and dynamic load re- R sponse characteristics. Vin Input Voltage converted to DC value It is recommended that verification should be done through =Input Votlage (rms)x2 actual evaluation. Resistance Value for External resistor Irush Input surge current value 2Required Surge Current Rating TFR1 : 10 to 100 ohm TFR101, TFR102 : 10 to 50 ohm (Total value) Sufficient surge current withstand capability is required for external resistor. By connecting resistor across R and +BC terminals as shown Required Surge Current Rating can be selected by in Fig. 1-1, in-rush current during line throw-in can be sup- I 2t. (Current squared multiplied by time) pressed. Failures due to in-rush current such as melting of external fuse, welding of relay or switch connecting joints or I2t= shutdown of No-Fuse Breakers (NFB) might occur. Therefore, CoxVin2 2xR (A2s) (Formula 1-3) select TFR1, TFR101, TFR102 in consideration of the surge I 2t : Current-squared multiplied by time current capability of the external components. (TFR1, TFR101, Co : Boost Voltage Bulk Capacitance TFR102 are recommended to use the Thermal Fuse Resistor.) Vin : Input Voltage converted to DC value =Input Voltage (rms)x2 Note) 1.Do not connect resistors that is out of range from the values shown above as this might result in power module damage. 2.Note that this module will not operate without this external resistor. R : Resistance Value for External Resistor Output Voltage Adjustment Range(TRIM terminal) Output voltage can be adjusted within the range below by connecting fixed and variable resistors or applying external 20 All contents are subject to change without notice. PFE500F1000F SERIES voltage. However, take care not to exceed the output voltage range Output Voltage = TRIM Terminal Voltage x Nominal Output shown below because OVP function will activate. Voltage In the PFE1000F Series, be careful not to drop from the following range, because a Low Voltage Protection (LVP) function will be activate. + + Output Voltage Adjustment Range : +/-20% of the typical voltage rating + + + Load When increasing or decreasing output voltage, it must not exceed maximum output current and power. - - Even if the output voltage is adjusted using external circuit - shown in Fig. 2-1, remote sensing can be done. For details on Remote Sensing function, refer to"9. Remote Sensing". - TRIM + Output Voltage Adjustment using Fixed and Variable Resistors External resistor (R1) and variable resistor (VR) values, as Fig. 2-2 Output Voltage Adjustment by applying external voltage well as, circuit connection is shown below. For this case, remote programming of the output voltage can be done through the remote programming resistor VR. Be sure to connect the remote programming resistor between +S and +V terminals For applications other than the above, refer to the TRIM circuit as shown in fig.2-3 and determine external circuit and components values. 12V 28V 48V R1 18k 18k 18k VR 10k 20k 50k Error amplifier +S unit[ohm] External Resistor : Tolerance +/-5% or less Variable Resistor : Total Tolerance +/-20% or less Remain Resistance 1% or less 7.32k TRIM 1.225V Reference voltage Table 2-1 External Resistor and Variable Resistor Value (For +/-20% Output Adjustment) 1k -S Fig.2-3 Internal TRIM Circuit (For the Reference) VR + Maximum Ripple and Noise + + + 32.4k + This value is measured according to the description below Load - - in accordance with JEITA-9131B(Section 7.16, 7.17 and 7.18). In the basic connection shown in Fig. 1-1, additional connection shown in Fig. 3-1 is done for measurement. - R1 TRIM Fig. 2-1 External Resistor Connection Example Capacitor (Ceramic Capacitor : 2.2F and Electrolytic Capacitor : Refer to Table 1-2) must be connected within 50mm from the output terminals. Then, connect coaxial cable with JEITA attachment across the ceramic capacitor electrodes. Use 100MHz bandwidth oscilloscope or Output Voltage Adjustment by applying external voltage equivalent. By applying external voltage at the TRIM terminal, output voltage might vary depending on the wiring pattern of the voltage can be adjusted within the same output voltage printed circuit board. adjustment range as the output voltage adjustment by In general, output ripple voltage and output spike noise external resistor or variable resistor. For this case, output voltage can be reduced by increasing external capaci- voltage can be determined by the formula shown below. tance All contents are subject to change without notice. Also, note that output ripple voltage and output spike noise 21 PFE500F1000F SERIES Wires must be as short as possible + +V + + This module is equipped with OTP function. This func- Load tion activates and shuts down the output when ambient - -V Over Temperature Protection (OTP) temperature or internal temperature abnormal rises. OTP activates at following baseplate temperature. 50mm 1.5m 50 Coaxial Cable JEITA Attachment R50 C4700pF R Oscilloscope PFE500F-12 C Fig. 3-1 Output Ripple Voltage (including Spike Noise) Measurement Method : 90 to 115 deg C PFE500F-28, 48 : 105 to 130 deg C PFE1000F-* : 105 to 130 deg C When OTP function operates, output can be recovered by cooling down the baseplate sufficiently and letting the boost voltage drop down to 20V or less before recycling Maximum Line Regulation Maximum line regulation is defined as the maximum output the input line. In other method, reset to ON/OFF control. voltage change when input voltage is gradually changed Remote Sensing (+S, -S terminals) (Steady-State) within specification range. This module has remote sensing terminals to compensate for voltage line drop from the output terminals to the output Maximum Load Regulation load. When remote sensing is not required, (local sensing) short +S to +V and -S to -V terminals respectively. Maximum load regulation is defined as the maximum out- Note that line drop (voltage drop due to wiring ) compen- put voltage change when output load current is gradually sation voltage range must be such that the output voltage changed (Steady-State) within specification range. is within the output voltage adjustment range and that the When using power module in dynamic load mode, audible voltage between -V and -S must be within 0.5V. sound could be heard from the power module or large Consider power loss due to line drop and use power mod- output voltage change might occur. Make prior evaluation ule within the maximum allowable output power. Reduce thoroughly before using this power module. the effect of noise to the remote sensing line by using a shield line, a twist pair, or a parallel pattern, etc. Over Current Protection (OCP) When remote sensing line is long, add the electrolytic capacitor as shown in Fig 9-1. This module is equipped with OCP function. Constant current limiting with automatic recovery for PFE500F Series. Output will automatically recover when short circuit or overload condition is released. Constant current limiting with delay shutdown for + + + PFE1000F Series. Output will be shutdown when output about under 70 Stabilize the output voltage at load terminal + + + + Twist pair % by short circuit or overload condition that continue about 0.5s. When the shutdown function ac- - tivates, first cut off input line and verify that boost voltage - Load - + has dropped down to 20V or less. Then, recover output by recycling input line. In other method, reset to ON/OFF Fig. 9-1 Remote Sensing is used control. OCP value is fixed and cannot be adjusted externally. Stabilize the output voltage at output terminal Note that continuous short circuit or overload condition more than 30s, might result in power module damage. + + Over Voltage Protection (OVP) This module is equipped with OVP function. This value is set between 125% to 145% of nominal output voltage. When the OVP function activates, first cut off input line + + - + Load - - and verify that boost voltage has dropped down to 20V or less. Then, recover output by recycling input line. In other method, reset to ON/OFF control. OVP value is fixed and Fig. 9-2 Remote Sensing is not used (Local Sensing) cannot be set externally. 22 All contents are subject to change without notice. PFE500F1000F SERIES ON/OFF Control (+ON/OFF, -ON/OFF terminal) AUX This module is equipped with ON/OFF control function. 11V Without turning the input supply on and off, the output can be enabled and disabled using this function. COM The ON/OFF control circuit is isolated from input circuit of the power supply by photo-coupler. Fig. 10-1 and Fig. 10-2 is connection example of ON/ +ON/OFF OFF control. When the ON/OFF control is not used, short +ON/OFF to AUX and -ON/OFF to COM terminals re- 4.7k spectively. -ON/OFF AUX Fig. 10-3 ON/OFF Control Connection Example 3 ON/OFF Control is not used 11V COM Series Operation External voltage R +ON/OFF Series operation is possible for PFE500F Series and PFE1000F Series. Connections shown in Fig. 11-1 and Fig. 11-2 are possible. 4.7k -ON/OFF OFF +S +V ON Fig. 10-1 ON/OFF Control Connection Example 1 ON/OFF Control by External Voltage Select the external voltage and external resistance, as the ON/OFF terminals current is shown below. ON/OFF terminal current 2.5mA (+/-0.5mA) Less than 0.15mA -S Load +S + - -V -S Table 10-1 Recommended ON/OFF Terminal Current Fig. 11-1 Series Operation for High Output Voltage Applications +S AUX +V + 11V + Load - -V -S COM OFF +ON/OFF 4.7k + -V +V Output Voltage ON OFF + +S +V + + ON -ON/OFF -V Load - -S Fig. 11-2 +/-Output Series Applications Fig. 10-2 ON/OFF Control Connection Example 2 ON/OFF Control by Built-in AUX Parallel Operation (PC terminal) By connecting the PC terminal of each power module, output current can be equally drawn from each module. A maximum of 6 units of the same model can be connected. All contents are subject to change without notice. 23 PFE500F1000F SERIES However, maximum output current is derated by parallel PFE500F1000F-12 : 6V (TYP) operation units as shown in Table 12-1. PFE500F1000F-28 : 15V (TYP) Note that usage of power module at out-of-rated condition PFE500F1000F-48 : 28V (TYP) might result in power module temperature abnormal rise or damage. I.O.G signal (IOG terminal) Parallel units 3 units 4 6 units Maximum output current 90% of nominal output current 85% of nominal output current Table 12-1 Condition for Parallel Operation Set the accuracy of the output voltage within +/-1% when adjust the output voltage for parallel operation. When adjust the output voltage by applying external voltage at the TRIM terminal, insert a about 10k ohm resistor between TRIM terminal and external source. Moreover, external circuits are necessary for TRIM terminal at each individual module. Normal or abnormal operation of the power module can be monitored by using the IOG terminal. Output of this signal monitor is located at secondary side (output side) and is an open collector output. This signal is LOW when inverter is normally operating and HIGH when inverter stops or when inverter is operating abnormally. (maximum sink current is 5mA, maximum applied voltage is 35V) Ground for the IOG terminal is the COM terminal. Also note that IOG becomes unstable for following conditions: Operation of Over Current Protection (OCP) Light load conditions at parallel operation + + Dynamic load operation + + + Load - - - TRIM + PC Auxiliary power supply for external circuits (AUX terminal) For AUX terminal, output voltage value is within 10 14VDC range, maximum output current is 20mA. Ground for the AUX terminal is COM terminal. Avoid short circuit of AUX terminal with other terminals as this would lead to power module damage. Fig. 12-1 Output Voltage Adjustment by applying external voltage (For parallel operation) Operating Temperature Range These products can be used in any mounting direction but At parallel operation, +BC, -BC and R terminals must not be sure to consider enough airflow to avoid heat accumu- be connected in parallel with other modules. It might result lation around the module. in power module damage. Consider surrounding components layout and set the PCB Refer to"Parallel Operation"of the PH-Series Application mounting direction such that air can flow through the heat- Notes for details. sink by forced or convection cooling . This product can operate at actual mounting condition Power ON Signal (ENA terminal) This signal is located at the secondary side (output side) and it is an open collector output. (Maximum sink current is 10mA and maximum applied voltage is 75V.) Return line for ENA terminal is the COM terminal. When output voltage goes over a specified voltage level at start up, Power ON signal is LOW. Output voltage threshold level is as follows. PFE500F1000F-12 : 8V (TYP) PFE500F1000F-28 : 19V (TYP) PFE500F1000F-48 : 33V (TYP) when baseplate temperature is maintained at or below the following baseplate temperature. PFE500F-1285 PFE500F-28,48100 PFE1000F-12100 PFE1000F-28,488585VACVin170VAC 100170VACVin 265VAC Verify baseplate temperature at worst case operating condition at the measuring point as shown in Fig. 16-1. For Thermal Design details, refer to Power Module Application Notes"Thermal Design"section. On the other hand, output voltage threshold level for Power ON signal to turn HIGH is as follows. 24 All contents are subject to change without notice. PFE500F1000F SERIES To further improve the reliability, it is recommended to use this module with baseplate temperature derating. Baseplate Tenperature Measuring Point Fig. 16-1 Baseplate Measuring Point Operating Humidity Note that dewdrop might cause power module abnormal operation or damage. Baseplate temperature range is limited according to Fig. 16-2. Storage Temperature Note that rapid temperature change causes dewdrop 100 causing harmful effect on soldering condition of the terminal pins. Load 80 Storage Humidity 60 Storage under high temperature and high humidity causes 40 rust on terminal pins that causes deterioration of soldering conditions. Take enough caution when storing this module. PFE500F-12 20 PFE500F-2848 0 -40 -20 0 20 40 60 85 80 Cooling Method 100 Base-plate temperature For details of thermal design, refer to Power Module Application Notes"Thermal Design"section. Fig. 16-2-(1) PFE500F Series Derating Curve Withstand Voltage 100 This module is designed to withstand applied voltage 2.5kVAC between input and baseplate, 3kVAC between Load 80 input and output for a duration of 1 minute. When doing this test during incoming inspection, set the current limit of 60 test equipment to 20mA. This module is designed to withstand applied voltage 40 500VDC between output and baseplate for 1 minute. When doing this test during incoming inspection, be sure 20 to apply DC voltage only. Avoid applying AC voltage during this test because this will damage the module. 0 -40 -20 0 20 40 60 80 100 Base-plate temperature Refrain from injecting high test voltage suddenly. Be sure to gradually increase the applied voltage during testing and gradually reduce the voltage after the test. Fig. 16-2-(2) PFE1000F-12 Derating Curve Especially, when using timer switch of the test equipment, impulse voltage which is higher than the applied set voltage, is generated when the timer switch is cut off. This 100 causes damage to the power module. minal according to the circuit diagram shown below. 80 Load Connect each ter- For basic connection shown in Fig. 1-1, do the same terminal connections. 60 40 85VACVin<170VAC 20 170VACVin<265VAC 0 -40 -20 0 20 40 60 85 80 100 Base-plate temperature Fig. 16-2-(3) PFE1000F-28,48 Derating Curve All contents are subject to change without notice. 25 PFE500F1000F SERIES Withstand voltage tester BASE-PLATE AC(N) AC(L) PFE500F PFE1000F R +BC -BC +V -V +S -S PC TRIM IOG ENA AUX +ON/OFF -ON/OFF COM 2.5kVAC 1 minute (20mA) Fig. 21-1 Input to Baseplate Withstand Voltage Test Method BASE-PLATE AC(N) AC(L) PFE500F PFE1000F R +BC -BC -V +V -S +S PC TRIM IOG ENA AUX +ON/OFF -ON/OFF COM Insulation Resistance Use DC Insulation Resistance test equipment (MAX.500V) between output and baseplate. Insulation Resistance must be 100Mohm or more at 500VDC. Take caution that some types of test equipment generate high pulse voltage when switching applied voltage. After test, discharge this module using resistor, etc. BASE-PLATE AC(N) AC(L) PFE500F PFE1000F R Withstand voltage tester +BC -BC -V +V -S +S PC TRIM IOG ENA AUX +ON/OFF -ON/OFF COM Isolation tester 100Mohm or more at 500VDC Fig. 22-1 Insulation Resistance Test Method 23 Recommended Soldering Condition 3kVAC 1 minute (20mA) Fig.21-2 Input to Output Withstand Voltage Test Method Recommended soldering temperature is as follows. 1Soldering Dip : 260 , within 10 seconds Preheat : 130 , within 60 seconds 2Soldering iron : 350 , within 3 seconds BASE-PLATE AC(N) AC(L) PFE500F PFE1000F R +BC -BC -V +V -S +S PC TRIM IOG ENA AUX +ON/OFF -ON/OFF COM Withstand voltage tester 500VDC 1 minute Fig.21-3 Output to Baseplate Withstand Voltage Test Method 26 All contents are subject to change without notice. PFE500F1000F SERIES 3. Before Concluding Power Module Damage Verify following items before concluding power module damage. 3) Output voltage is low Is specified input voltage applied? Are the remote sensing terminals (+S, -S) correctly 1) No output voltage connected? Is specified input voltage applied? Is the measurement done at the sensing points? During output voltage adjustment, is the fixed resistor During output voltage adjustment, is the fixed resistor or variable resistor setting correct? Is there no abnormality with the output load? or variable resistor setting correct? Is there no abnormality with the output load? Is the actual baseplate temperature within the specified operating temperature of this module? Are the ON/OFF control terminals (+ON/OFF,-ON/ OFF) correctly connected? 4) Load regulation or line regulation is large Is specified input voltage applied? Are the input or output terminals firmly connected? Is the measurement done at the sensing points? 2) Output voltage is high Are the input and output wires too thin? Are the remote sensing terminals (+S, -S) correctly connected? Is the measurement done at the sensing points? During output voltage adjustment, is the fixed resistor or variable resistor setting correct? 5) Large output ripple Is the measurement done according to methods described Application Notes or is it an equivalent method? All contents are subject to change without notice. 27 PFE500F1000F SERIES Option Standard heat sinks Heat sink forPFE500F HAL-F12T Heat sink forPFE1000F HAM-F10T CL CL 160.0 148.5 100.0 88.5 69.9 59.7 .5 O3 4- 5 3. O 4- 122.0 111.8 R0 .5 P3.5x28=98.0 R0 1.2 .5 33.4 (8.0) R0 .5 ( 4.5 ) .5 R0 35.0 P4x34= 136.0 1.8 Adaptution Model 28 SizeWxHxDmm Standard heat sinks Thermal resistance PFE500F 122x35x69.9 HAL-F12T 0.97 /W PFE1000F 160x33.4x100 HAM-F10T 0.78 /W All contents are subject to change without notice. s h PFE-S SERIES Single Output AC-DC Power Module ks UL60950-1/ CSA C22.2 No.60950-1 ph F A Features F F A A F A package W ide input voltage range: 85-265VAC H igh power factor: 0.95, meeting PFHC standard (EN61000- F 3-2) A F A Output voltage Function Applications AC85-265Vin PFE-S. F A F A Series name This means that, in conformity with EU Directive 2002/95/EC, lead, cadmium, mercury, hexavalent chromium, and specific bromine-based flame retardants, PBB and PBDE, have not been used, except for exempted applications. dlp F A F A 300W Output Voltage 500W 700W Output Current Model Output Current Model Output Current Model 12V 25A PFE300S-12 33A PFE500S-12 - - 28V 10.8A PFE300S-28 18A PFE500S-28 - - PFE300S-48 10.5A PFE500S-48 - - - - - 14A PFE700S-48 48V 50-57V Semi-regulated ps fps Output power Product Line up phaalpha S: Simple Function Conformity to RoHS Directive Built-in capacitor: Ceramic type only (high reliability) p None: Standard type T: Mounting stand 3.3 (Non-thread, Through hole) semi-regulated type (PFE700S) in the line-up P arallel operation supported (PFE700S only) warranty Option Baseplace temperature: -40 to +100 Stable output voltage type (PFE300S,500S) and high power ws hws 2 Model naming method PFE 500 S-12 / High efficiency: 86% max (PFE300S,500S), 89% max (PFE700S) Wide operating temperature k-a hk-a Low Voltage Directive PFHC and DC/DC conversion integrated into a full brick f-a pf-a EN60950 Y E A R S F A 6.3A F A - Note) PFE300S/PFE500S are of the stable output voltage type, and they are constant-voltage power supplies as they are. PFE700S is of the semiregulated type, and a multiple-output power supply can be configured by connecting other multiple DC/DC converters on the back of PFE700S. F A F A All contents are subject to change without notice. 29 PFE300S PFE300S Specifications MODEL ITEMS/UNITS Voltage Range (*2)(*5) Frequency Input Power Factor (min) V 47 - 63 0.95 (*1) 81 / 83 83 / 85 (*1) A 4.0 / 2.0 (*1)(*5) A 20 / 40 peak Nominal Voltage (*1) VDC 12 28 48 A 25 10.8 6.3 Maximum Power W 300 Voltage Setting Accuracy Maximum Line Regulation mV 48 56 Maximum Load Regulation mV 48 56 96 Maximum Ripple Voltage (*5) mVp-p 120 280 480 Maximum Current 302.4 2 Voltage Adjustable Range Function -20% / +20% 105% - 140% (Automatic recovery method) Over Voltage Protection 125% - 145% (Inverter shutdown method) Parallel Operation (*6) Possible Operating Temperature (*3)(*7) -40 to +100 (Baseplate) -40 to +100 Operating Humidity RH 20 - 95 (No dewdrop) Storage Humidity RH Storage Temperature 10 - 95 (No dewdrop) At no operating, 10-55Hz (sweep for 1min.) Vibration Amplitude 0.825mm constant (maximum 49.0m/s) X, Y, Z 1 hour each Shock Cooling Isolation 196.1m/s (*4) Conduction cooled Input-Baseplate : 2.5kVAC, Input-Output : 3.0kVAC for 1min. Withstand Voltage Output-Baseplate : 1.5kVDC for 1min. Isolation Resistance Output to Baseplate 500VDC more than 100M (25, 70%RH) Standards Safety Standards Mechanical 96 Over Current Protection Series Operation Environment PFE300S-48 AC85 - 265 (*1)(*5) Current Output PFE300S-28 (*2) Hz Efficiency (typ) Inrush Current (typ) PFE300S-12 Approved by UL60950-1, CSA C22.2 No.60950-1, EN60950-1 Weight (typ) Size (W x H x D) g 250 mm 61 x 12.7 x 116.8 (Refer to outline drawing.) (*1) At 100VAC/200VAC and maximum output power. (Baseplate temperature = +25.) (*2) For cases where conformance to various safety specs (UL, CSA, EN) are required, input voltage range will be 100 - 240VAC (50/60Hz). (*3) Ratings - refer to derating curve below. (*4) Heatsink has to be chosen according to instruction manual. (*5) External components are needed for operation. (Refer to basic connection and instruction manual.) (*6) Refer to instruction manual. (*7) Ambient temperature min=-40 Derating Curve 100 Load 80 60 40 20 0 -40 30 -20 0 20 40 60 80 Baseplate Temperature 100 All contents are subject to change without notice. PFE500S PFE500S Specifications MODEL ITEMS/UNITS Voltage Range (*2)(*5) Frequency Input Power Factor (min) PFE500S-28 V AC85 - 265 (*2) Hz 47 - 63 (*1)(*5) 0.95 (*1) 82 / 83 84 / 86 Current (*1) A 5.0 / 3.0 6.2 / 3.2 (*1)(*5) A Nominal Voltage 20 / 40 peak (*1) VDC 12 28 48 A 33 18 10.5 Maximum Power W 396 Voltage Setting Accuracy Maximum Line Regulation mV 48 56 Maximum Load Regulation mV 48 56 96 Maximum Ripple & Noise (*5) mVp-p 120 280 480 Maximum Current 504 2 Voltage Adjustable Range Function -20% / +20% 105% - 140% (Automatic recovery method) Over Voltage Protection 125% - 145% (Inverter shutdown method) Parallel Operation (*6) Possible Operating Temperature (*3)(*7) -40 to +85 (Baseplate) -40 to +100 (Baseplate) -40 to +100 Operating Humidity RH 20 - 95 (No dewdrop) Storage Humidity RH Storage Temperature 10 - 95 (No dewdrop) At no operating, 10-55Hz (sweep for 1min.) Amplitude 0.825mm constant (maximum 49.0m/s) X, Y, Z 1 hour each Vibration Shock Cooling Isolation 196.1m/s (*4) Conduction cooled Input-Baseplate : 2.5kVAC, Input-Output : 3.0kVAC for 1min. Output-Baseplate : 1.5kVDC for 1min. Withstand Voltage Isolation Resistance Output to Baseplate 500VDC more than 100M (25, 70%RH) Standards Safety Standards Mechanical 96 Over Current Protection Series Operation Environment PFE500S-48 Efficiency (typ) Inrush Current (typ) Output PFE500S-12 Approved by UL60950-1, CSA C22.2 No.60950-1, EN60950-1 Weight (typ) Size (W x H x D) g 250 mm 61 x 12.7 x 116.8 (Refer to outline drawing.) (*1) At 100VAC/200VAC and maximum output power. (Baseplate temperature = +25.) (*2) For cases where conformance to various safety specs (UL, CSA, EN) are required, input voltage range will be 100 ~ 240VAC (50/60Hz). (*3) Ratings - refer to derating curve on the right. (*4) Heatsink has to be chosen according to instruction manual. (*5) External components are needed for operation. (Refer to basic connection and instruction manual.) (*6) Refer to instruction manual. (*7) Ambient temperature min=-40 Derating Curve 100 Load 80 60 40 20 0 -40 All contents are subject to change without notice. PFE500S-12 PFE500S-28,48 -20 85 0 20 40 60 80 Baseplate Temperature 100 31 PFE300S, 500S Outline Drawing C L See note C AC(L) AC (L) PFE500S-48 INPUT:100-240VAC 8A 50/60Hz OUTPUT:48V 10.5A +V +V 9.0 EN60 95 EN 950 0 BAR CODE R R +BC -BC +BC +S TRIM TRIM ENA ENA NOTES : A: Model name, input voltage range, Nomi output voltage, Maximum output curren MADE IN JAPAN -BC 5.7 15.0 -S +S 4.0 4.0 4.0 61.00.5 50.80.5 5.2 -V -S AC-DC 25.3 C L -V 10.0 AC (N) 10.0 AC(N) 5.2 See note D 5.00.5 12.70.5 (unit : mm) country of manufacture and safety mar (C-UL-US, BSI & CE marking) are show here in accordance with the specificat See note A 15.0 See note B 106.70.5 B: M3 tapped holes 4 for customer chassis mounting (FG). NOTES: A: Model name, input voltageC:range, nominal Output terminal : 2-2 output voltage, maximum D: output current, terminal and signal p Input, Intermediate country of manufacture and safety marking E: Unless otherwise specified dimensional (C-UL-US, BSI & CE marking)tolerance are shown : 0.3 here in accordance with the specifications. B: M3 tapped holes 4 for customer chassis mounting (FG). C: Output terminal : 2-2 D: Input, Intermediate terminal and signal pin: (unit : 9-1 MODEL NAME PFE5 E: Unless otherwise specified dimensional tolerance : 0.3 C212-0 116.80.5 Lot No. Seal Basic Connection L50mm F1 L1 S L2 AC(L) C2 C1 C4 C6 R1 C3 C5 V C12 PFE300S PFE500S C7 C15 C16 C14 Load C13 AC(N) -V -S TRIM ENA R BC -BC BASEPLATE C8 Input Filter For VCCI-classA TFR1 C11 C9 C10 F1 C1 C2 C3 C4 C5 C6 C7 C8 AC250V 15A AC250V 1uF (Film) 4700pF 4700pF AC250V 1uF (Film) AC250V 1uF (Film) 1000pF 1000pF 450V 1uF (Film) C9 450V 1uF (Film) C15 100V 2.2uF (Ceramic) C10 PFE300S:450V 470uF x1 (Elec.) C16 12V: 25V 1000uF (Elec.) PFE500S:450V 390uF x2 (Elec.) 28V: 50V 470uF (Elec.) C11 1000pF 48V: 100V 220uF (Elec.) C12 0.033uF R1 2W 470k C13 0.033uF TFR1 10 139 (Res., Thermal fuse) C14 12V: 25V 1000uF (Elec.) L1 6mH 28V: 50V 470uF (Elec.) L2 6mH 48V: 100V 220uF (Elec.) Note: Except C10, above components list is for both PFE300S and PFE500S Series Please select component standards, withstand voltage, etc based on the application. 32 All contents are subject to change without notice. PFE700S PFE700S Specifications MODEL ITEMS/UNITS Voltage Range (*2)(*5) Frequency AC 85 - 265 0.95 (*1) Current Inrush Current (typ) 47 - 63 (*1)(*5) Efficiency (typ) 86 / 89 (*1) A 8.8 / 4.4 (*1)(*5) A 20 / 40 peak Nominal Voltage (*1) VDC Voltage Regulation Range (*7) Output V (*2) Hz Power Factor (min) Input PFE700S-48 51 V 50 - 57 Maximum Current A 14 Maximum Power W 714 Voltage Setting Accuracy (*1) 1 V Maximum Ripple & Noise (*5) 4 Vp-p Over Current Protection Function 105% - 140% (Automatic recovery method) Over Voltage Protection VDC Parallel Operation (*6) Series Operation (*6) Operating Temperature (*3) Possible Possible -40 to +100 (Baseplate), Ambient temperature min=-40 -40 to +100 Operating Humidity RH 20 - 95 (No dewdrop) Storage Humidity RH 10 - 95 (No dewdrop) Storage Temperature Environment 60.0 - 69.6 (Inverter shutdown method) At no operating, 10-55Hz (sweep for 1min.) Vibration Amplitude 0.825mm constant (maximum 49.0m/s) X, Y, Z 1 hour each Shock 196.1m/s Cooling Isolation (*4) Conduction cooled Input-Baseplate : 2.5kVAC, Input-Output : 3.0kVAC for 1min. Withstand Voltage Output-Baseplate : 1.5kVDC for 1min. Isolation Resistance Output to baseplate 500VDC more than 100M (25, 70%RH) Standards Safety Standards Mechanical Weight (typ) Size (W x H x D) Approved by UL60950-1, CSA C22.2 No.60950-1, EN60950-1 g 250 mm 61 x 12.7 x 116.8 (Refer to outline drawing.) (*1) At 100VAC/200VAC and maximum output power. (Baseplate temperature = +25.) (*2) For cases where conformance to various safety specs (UL, CSA, EN) are required, input voltage range will be 100 240VAC (50/60Hz). (*3) Ratings - refer to Derating Curve on the right. (*4) Heatsink has to be chosen according to Instruction manual. (*5) External components are needed for operation. (Refer to basic connection and instruction manual.) (*6) Refer to Instruction manual. (*7) For all input voltage, output load and temperature range. Derating Curve 85 100 Tbp85 100 Load Load 80 60 40 20 0 -40 Tbp100 85% 85% 80 70% 60 40 20 -20 0 20 40 60 80 100 Baseplate Temperature All contents are subject to change without notice. 0 85 80 100 120 140 160 180 200 Input VoltageVAC 265 220 240 260 33 PFE700S Outline Drawing See note C AC(L) AC (L) PFE700S-48 INPUT:100-240VAC 11A 50/60Hz OUTPUT:51V 14A -V +V +V 9.0 -VM AC-DC EN60 95 EN 950 0 25.3 BAR CODE +VM NC ENA R R +BC -BC +BC -VM 4.0 4.0 4.0 61.00.5 50.80.5 5.2 C L -V 10.0 AC (N) 10.0 AC(N) 5.2 See note D 5.00.5 12.70.5 C L +VM NC ENA NOTES : A: Model name, input voltage range, Nominal output voltage, Maximum output current, country of manufacture and safety marking (C-UL-US, BSI & CE marking) are shown here in accordance with the specifications MADE IN JAPAN -BC 5.7 15.0 See note A 15.0 See note B 106.70.5 B: M3 tapped holes 4 for customer chassis mounting (FG). NOTES: A: Model name, input voltageC:range, Nominal outOutput terminal : 2-2 put voltage, Maximum output current, country of D: Input, Intermediate terminal and signal pin : manufacture and safety marking (C-UL-US, BSI & (NU : Make no external connection) CE marking) are shown here in accordance with E: Unless otherwise specified dimensional the specifications. tolerance : 0.3mounting B: M3 tapped holes 4 for customer chassis (FG). C: Output terminal : 2-2 D: Input, Intermediate terminal and signal pin: 9-1 (NC : Make no external connection) E: Unless otherwise specified dimensional tolerance : 0.3 116.80.5 Lot No. Seal Basic Connection L50mm F1 L1 L2 AC(L) C2 C1 C4 C6 R1 C3 C5 VM V C12 PFE700S C15 C7 C14 C16 Load C13 AC(N) -V -VM NC ENA R BC -BC BASEPLATE C8 Input Filter For VCCI-classA TFR1 C11 C9 C10 F1 C1 C2 C3 C4 C5 C6 AC250V 15A AC250V 1uF (Film) 4700pF 4700pF AC250V 1uF (Film) AC250V 1uF (Film) 1000pF C7 C8 C9 C10 C11 C12 C13 1000pF 450V 1uF (Film) 450V 1uF (Film) 450V 390uF x2 Parallel (Elec.) 1000pF 0.033uF 0.033uF C14 C15 C16 R1 TFR1 L1 L2 48V: 100V 220uF (Elec.) 100V 2.2uF (Ceramic) 100V 220uF (Elec.) 2W 470k 10 139 (Res., Thermal fuse) 6mH 6mH Note: Please select component standards, withstand voltage, etc based on the application. 34 All contents are subject to change without notice. PFE300S, 500S Block Diagram Rectifier PFHC circuit Filter AC (N) Input Input voltage current OVP detector detector Inrush current limiting circuit Boosted voltage detector V OCP ENA OVP OTP Control circuit +V Output filter AC (L) DC/DC Converter Circuit +BC BC Rectifier R Switching circuit PFHC Circuit TRIM Control circuit +S Output voltage detector Bias power supply S Switching Frequency PFHC circuit (fixed) : 100kHz DC/DC converter (fixed) : 230kHz (primary),460kHz (secondary) Sequence Time Chart Input Voltage (AC) 385VDC (Typ) BC Terminal Voltage (Boosted Voltage) H Output Voltage L H ENA Signal Input Line Throw-in Input Line Cut-off OTP Circuit Activate Input Line Throw-in Input Line Cut-off OCP Release OCP Activate Input Line Throw-in Input Line Cut-off OVP Activate Input Line Throw-in L Note : This product has no remote ON/OFF function. All contents are subject to change without notice. 35 PFE700S Block Diagram Rectifier PFHC circuit Filter +V Boosted voltage detector OVP Input voltage detector Input current detector AC(N) Inrush current limiting circuit Output filter AC(L) DC/DC Converter +BC BC Rectifier R Switching circuit PFHC Circuit V OCP ENA +VM OVP VM OTP Control circuit Control circuit Output voltage detector Bias power supply Switching Frequency PFHC circuit (fixed) : 100kHz DC/DC converter (fixed) : 180kHz (primary), 360kHz (secondary) Sequence Time Chart Input Voltage (AC) 385VDC (Typ) BC Terminal Voltage (Boosted Voltage) H Output Voltage L H ENA Signal Input Line Throw-in Input Line Cut-off OTP Circuit Activate Input Line Throw-in Input Line Cut-off OCP Release OCP Activate Input Line Throw-in Input Line Cut-off OVP Activate Input Line Throw-in L Note : This product has no remote ON/OFF function. 36 All contents are subject to change without notice. PFE300S, 500S PFE300S, 500S Instruction Manual BEFORE USING THE POWER SUPPLY UNIT Be sure to read this instruction manual thoroughly before using this product. Pay attention to all cautions and warnings before using this product. Incorrect usage could lead to an electrical shock, damage to the unit or a fire hazard. WARNING Do not make unauthorized changes to power supply unit, otherwise you may have electric shock and void your warranty. Do not touch this unit and the internal components in operation or shortly after shut down. They may have high voltage or high temperature and as the unit dissipates its heat so the surface of the unit is hot. You may receive electric shock or burn. When the unit is operating, keep your hands and face away from it; you may be injured by an accident Do not use unit under unusual condition such as emission of smoke or abnormal smell and sound etc. It might cause fire and electric shock. In such case, please contact us; do not repair by yourself, as it is dangerous for the user. Do not drop or insert anything into unit. It might cause failure and fire. Do not operate these units under condensation condition. It may cause fire and electric shock. CAUTION As a component part, compliance with the standard will be based upon installation in the final application. This product must be installed in a restricted access location, accessible to authorized competent personnel only. These AC to DC converters have reinforced insulation between the input and the output. The outputs of these products are energy hazards. All models with an output greater than 48V model are considered to be non-SELV. As such, the instructions for use must refer to these energy hazardous outputs and Non-SELV outputs in that the outputs must not be accessible to the operator. The installer must also provide protection against inadvertent contact by a service engineer. The equipment has been evaluated for use in a Pollution Degree 2 environment. This power supply is primarily designed and manufactured to be used and enclosed in other equipment. Confirm connections to input/output terminals and signal terminals are correct as indicated in the instruction manual. Attach an HBC external fuse to each module to ensure safety operation and compliance to each safety standard approval. The recommended input fuse rating within the instructions is as follows: -15AHBC, 250V fast acting fuse. The breaking capacity and voltage rating of this fuse may be subject to the end use application. All contents are subject to change without notice. Input voltage, output current, output power, ambient temperature and ambient humidity should be used within specifications, otherwise the unit will be damaged. For application equipment, which requires very high reliability (nuclear related equipment, traffic control equipment, medical equipment, etc.), please provide fail safety function in the equipment. Do not use the product in environment with strong electromagnetic field, corrosive gas and conductive substance. Do not operate and store this unit at an environment where condensation occurs. In such case, waterproof treatment is necessary Never operate the unit under over current or shorted conditions for 30 seconds or more and out of Input Voltage Range as specification. Insulation failure, smoking, burning or other damage may occur to the unit. The output voltage of this power supply unit is considered to be a hazardous energy level. (The voltage is 2V or more and the electric power is 240VA or more.) Prevention from direct contact with output terminal is highly necessary. While installing or servicing this power supply unit, avoid dropping tools by mistake or direct contact with output terminal. This might cause an electric shock. While repairing this power supply unit, the AC input power must be switched off and the input and output voltage should be level. To maintain the SELV output for outputs less than 28VDC, under fault conditions, the output must be connected to earth in the final application. The application circuits and their parameter are for reference only. Be sure to verify effectiveness of application circuits and their parameters before finalizing circuit design. Do not inject abnormal voltage to output terminal and signal terminal from the outside. The injection of reverse voltage or over voltage exceeding nominal output voltage to output terminals might cause damage to internal components. This information in this document is subject to change without prior notice. For actual design-in, please refer to the latest publications of data sheet, etc., for the most up-to-date date specifications of the unit. No part of this document may be copied or reproduced in any form without prior written consent of TDK-Lambda. Note : CE MARKING CE Marking when applied to a product covered by this handbook indicates compliance with the low voltage directive (2006/95/ EC) in that it complies with EN60950-1. 37 PFE300S, 500S 1. Terminal Explanation AC(N) -V AC(L) V Name Plate -S S TRIM ENA R BC -BC [Input side terminals] [Output side terminals] AC(L) : Input terminal live line AC(N) : Input terminal neutral line +V : -V : +Output terminal -Output terminal +BC : -BC : R: +S : -S : TRIM : ENA : +Remote sensing terminal -Remote sensing terminal Output voltage trimming terminal Power on signal terminal +Boosted voltage terminal -Boosted voltage terminal External inrush current limiting resistor Baseplate can be connected to FG through M3 mounting tapped holes. Consider contact resistance when connecting AC(L), AC(N), R, +BC, -BC, +V, -V. Note that +BC and -BC terminals is a primary voltage with high voltage (385VDC). Do not connect load from these terminals. 2. Explanations on Specifications This manual explains based on"Fig.1-1 Basic Connection". Please do actual evaluation when changing circuit from Fig.1-1. 1 Input Voltage Range Input voltage range is indicated below. Take care not to Input Voltage Range: apply input voltage which is out of this specified range nor Line Frequency Range: 47 to 63Hz Single Phase 85 to 265VAC should a DC input voltage be applied as this would result into power module damage. L50mm F1 L1 S L2 AC(L) C2 C1 C4 C6 R1 C3 C5 V C12 PFE300S PFE500S C7 C15 C14 C16 Load C13 AC(N) -V -S TRIM ENA R BC -BC BASEPLATE C8 Input Filter For VCCI-classA TFR1 C11 C9 C10 Fig. 1-1 Basic Connection 38 All contents are subject to change without notice. PFE300S, 500S F1: External Input Fuse C6, C7: 1000pF (Ceramic Capacitor) This power module has no internal fuse. Use external fuse Add ceramic capacitor as EMI/EMS countermeasure. Be to acquire each safety standard and to further improve sure to consider leakage current of your equipment when safety. Further, Fast-Blow type fuse must be used per one adding this capacitor. module. Also, in-rush surge current flows during line throw- High withstand voltage are applied across this capacitor in. Be sure to check I t rating of external switch and exter- during withstand voltage test depending on the application. nal fuse. Select capacitors with high withstand voltage rating. Also, connect C6, C7 as close as possible to the termi- 2 Recommended External Fuse: 15A nals. Select fuse based on rated voltage, rated current and surge current capability. 1Voltage Ratings 100VAC line: AC125V 200VAC line: AC250V C8, C9: 1uF (Film Capacitor) 2Current Ratings Rated current is determined by the maximum input current flowing through this capacitor by doing actual mea- Ripple current flows through this capacitor. When selecting capacitor, be sure to check the allowable maximum ripple current rating of this capacitor. Verify the actual ripple current based on operating conditions and can be calculated by the following formula. lin(max) Pout Vin x Eff x PF (Arms) (Formula 1-1) Iin (max): Maximum Input Current Pout: Maximum Output Power Vin: Minimum Input Voltage Eff: Efficiency PF: Power Factor surement. Recommended Voltage Rating : 450VDC NoteSelect Capacitor with more than 3A (rms) rating. Connect C8, C9 as near as possible towards the output terminals of this power module. C10: Electrolytic Capacitor PFE300S: 470Fx1 PFE500S: 390Fx2 pcs in parallel For efficiency and power factor values, refer to separate Refer to "Selection Method of External Bulk Capacitor for "Evaluation Data of each product". Boost Voltage" below. Allowable External Capacitance at nominal capacitor value C1, C4, C5: 1uF (Film Capacitor) Ripple current flows through this capacitor. When selecting capacitor, be sure to check the allowable maximum ripple current rating of this capacitor. Verify the actual ripple current flowing through this capacitor by doing actual mea- is shown below. Recommended Voltage Rating: 450VDC Recommended Total Capacitor: 390uF to 1,200uF Add common mode choke coil as EMI/EMS counter-mea- Note1. Do not connect capacitors with more than the above capacitance value as this would result into power module damage. 2. When using module below -20 ambient temperature, AC ripple of boost voltage, output ripple voltage and stand up characteristics might be affected by ESR characteristics of the bulk capacitor. Therefore, be sure to verify characteristics by actual evaluation. sure. When using multiple modules, connect coil to each C11: 1000pF (Ceramic Capacitor) module. Add ceramic capacitor as EMI/EMS countermeasure. NoteDepending on the input filter used, noise might increase or power module might malfunction due to filter resonance. High withstand voltage are applied across this capacitor surement. Recommended Voltage Rating: 250VAC NoteConnect C5 as near as possible towards the input terminals of this power module. L1, L2: 6mH during withstand voltage test depending on the application. Select capacitors with high withstand voltage rating. Also, connect C11 as close as possible to the terminals. C2, C3: 4,700pF (Ceramic Capacitor) Add ceramic capacitor as EMI/EMS countermeasure. Be C12, C13: 0.033uF sure to consider leakage current of your equipment when Connect ceramic or film capacitor as EMI/EMS counter- adding this capacitor. measure and to reduce spike noise. High withstand voltage are applied across this capacitor NoteHigh Voltage is applied across this capacitor during withstand voltage test depending on the application. Connect C12, C13 as near as possible towards the output terminals of this power module. depending on the application. Select capacitors with high withstand voltage rating. R1: 470k Connect bleeder resistor across AC(L) and AC(N) terminals. All contents are subject to change without notice. 39 PFE300S, 500S C14: Refer to Table 1-1 load current changes, verify actual ripple current and make sure that allowable maximum ripple current is not be exceeded. To reduce output ripple noise voltage, connect electrolytic capacitors across +V and -V. NoteConnect C14 as near as possible to the +V and -V output terminals of this power module. Vout C14 12V 25V 1,000uF 28V 50V 470uF 48V 100V 220uF Table 1-1 C14 : Recommended external capacitance C15: 2.2uF Selection Method of External Bulk Capacitor for Boost Voltage Boost voltage bulk capacitor is determined by boost voltage ripple voltage, ripple current and hold-up time. Select capacitor value such that boost voltage ripple voltage does not exceed 15Vp-p. NoteWhen ambient temperature is -20 or less, Boost voltage might increase due to ESR characteristics. Therefore, verify above characteristics by actual evaluation. Connect chip ceramic capacitor within 50mm from the For output hold-up time, refer to separate document "PFE output terminals +V and -V of the power module to reduce output spike noise. 300S Series Evaluation Data" or "PFE500S Series Evaluation Data" and use appropriate capacitor up to 1,200uF Also, note that output spike voltage may vary depending on maximum. (It is recommended that verification should be the wiring pattern of the printed circuit board. done through actual evaluation). For allowable ripple current value, refer to Fig. 1-2 and se- C16 : Refer to Table 1-2 lect a capacitor with higher ripple current rating. and -V of the power module to stabilize operation. Note that the output ripple and line turn off characteristics of the power module might be affected by the ESR and ESL of the electrolytic capacitor. Also, note that output ripple voltage may vary depending on the wiring pattern of the printed circuit board. Sudden change in output voltage due to sudden load change or sudden input voltage change can be reduced by Ripple CurrentmA rms Connect C16 within 50mm from the output terminals +V 2500 2000 100VAC 1500 1000 increasing external output capacitor value. Vout C16 12V 25V 1,000uF 28V 50V 470uF 48V 100V 220uF Table 1-2 C16 : Recommended external capacitance 200VAC 500 0 0 20 40 60 80 Load current% 100 Fig. 1-2 Allowable ripple current value TFR1 : 10 to 100 By connecting thermal fuse resistor across R and +BC terminals as shown in Fig.1-1, in-rush current during line throw-in can be suppressed. Failures due to in-rush current such as melting of external fuse, welding of relay or switch Note1. Use low-impedance electrolytic capacitors with excellent temperature characteristics. (Nihon Chemi-con LXY Series or equivalent) (Nichicon PM Series or equivalent) 2. For module operation at ambient temperature -20 or less, output ripple voltage might be affected by ESR characteristics of the electrolytic capacitors. Increase the capacitor values shown in Table 1-1 and 1-2 according to the table below. connecting joints or shutdown of No-Fuse Breakers (NFB) can occur. Therefore, be sure to connect this external thermal fuse resistor. Note that this module will not operate without this external resistor. Selection Method of External Resistor 1Calculating Resistance Value for TFR1 Resistance can be calculated by the formula below. Vout C14C16 12V 25V 1,000uF x 2parallel 28V 50V 470uF x 2parallel 48V 100V 220uF x 2parallel Table 1-3 C14, C16 : Recommended external capacitance (Ambient Temperature < -20 deg C) R Vin lrush () (Formula 1-2) R: Resistance Value for External TFR1 Vin: Input Voltage converted to DC value =Input Votlage (rms) x 2 Irush: Input surge current value 2Required Surge Current Rating Sufficient surge current withstand capability is required for external TFR1. 3. Take note of the maximum allowable ripple current of the electrolytic capacitor used. Especially, for sudden 40 Required Surge Current Rating can be selected by I2t. (Current squared multiplied by time). All contents are subject to change without notice. PFE300S, 500S l2t Co x Vin2 2 (A s) (Formula 1-3) 2xR Capacitor: Refer to Table 1-2) must be connected within 50mm from the output terminals. Then, connect coaxial I2t: Current-squared multiplied by time Co: Booster Voltage Bulk Capacitance Vin: Input Voltage converted to DC value = Input Voltage (rms) x 2 R: Resistance Value for External TFR1 cable with JEITA attachment across the ceramic capacitor electrodes. Use 100MHz bandwidth oscilloscope or equivalent. Also, note that output ripple voltage and output spike noise may vary depending on the wiring pattern of the printed circuit board. 2 Output Voltage Adjustment Range Output Voltage can be adjusted within the range below by connecting fixed and variable resistors. However, take care not to exceed the output voltage range shown below be- In general, output ripple voltage and output spike noise can be reduced by increasing external capacitor value. Wires must be as short as possible V Load cause OVP function will activate. Output Voltage Adjustment Range : 20% of the typical voltage rating -V - When increasing output voltage, reduce output current so as not to exceed maximum output power. 50mm Even if the output voltage is adjusted using external circuit 1.5m 50 Coaxial Cable JEITA Attachment R50 C4700pF shown in Fig.2-1, remote sensing can be done. For details on remote sensing function, refer to "9. Remote Sensing". R Oscilloscope C Fig. 3-1 Output Ripple Voltage (including Spike Noise) Output Voltage Adjustment using Fixed and Variable Resistors Measurement Method External resistor (R1) and variable resistor (VR) values, as well as, circuit connection is shown below. 4 Maximum Line Regulation For this case, remote programming of the output voltage Maximum line regulation is defined as the maximum output can be done through the remote programming resistor VR. voltage change when input voltage is gradually changed Be sure to connect the remote programming resistor be- (Steady-State) within specification range. tween +S and +V terminals. 12V 28V 48V R1 10k 47k 100k VR 10k 20k 30k unit: [] External Resistor: Tolerance 5% or less Variable Resistor: Total Tolerance 20% or less End Resistance 1% or less Table 2-1 External Resistor and Variable Resistor Value (For 20% Output Adjustment) VR V + -V -S Maximum load regulation is defined as the maximum output voltage change when output load current is gradually changed (Steady-State) within specification range. When using power module in dynamic load mode, audible sound could be heard from the power module or large output voltage change can occur. Make prior evaluation thoroughly before using this power module. 6 Over Current Protection (OCP) S + 5 Maximum Load Regulation This module is equipped with OCP function. Load Output will automatically recover when short circuit or - R1 TRIM Fig. 2-1 External Resistor Connection Example overload condition is removed. OCP value is fixed and cannot be adjusted externally. Note that continuous short circuit or overload condition might result in power module damage. 7 Over Voltage Protection (OVP) 3 Maximum Ripple and Noise This module is equipped with OVP function. This value is This value is measured according to the description below When the OVP function activates, first cut off input line in accordance with JEITA-9131A (Section 7.12 and Sec- and verify that boost voltage has dropped down to 20V or tion 7.13). less. Then, recover output by recycling input line. In the basic connection shown in Fig.1-1, additional OVP value is fixed and cannot be set externally. set between 125% to 145% of nominal output voltage. connection shown in Fig.3-1 is done for measurement. Capacitor (Ceramic Capacitor: 2.2F and Electrolytic All contents are subject to change without notice. 41 PFE300S, 500S 8 Over Temperature Protection (OTP) S V This module is equipped with OTP function. This function will activate and shutdown the output when ambient -V temperature or internal temperature abnormally rises. OTP -S activates at following baseplate temperature. PFE300S-12, 28, 48: PFE500S-12: PFE500S-28, 48: Load S V 105 to 130 90 to 115 105 to 130 -V - -S When OTP function operates, output can be recovered by cooling down the baseplate sufficiently and letting the boost voltage drop down to 20V or less before recycling Fig. 10-1 Series Operation for High Output Voltage Applications the input line. S 9 Remote Sensing (+S, -S Terminals) V -V - Load This module has remote sensing terminals to compensate for voltage line drop from the output terminals to the output -S load. When remote sensing is not required (local sensing) short +S to +V and -S to -V terminals respectively. S Note that line drop (voltage drop due to wiring ) compen- V is within the output voltage adjustment range and that the -V - voltage between -V and -S must be within 2V. -S sation voltage range must be such that the output voltage Load Consider power loss due to line drop and use power module within the maximum allowable output power. Reduce Fig. 10-2 Output Series Applications the effect of noise to the remote sensing line by using a shield line, a twist pair, or a parallel pattern, etc. Power ON Signal (ENA Terminal) This signal is located at the secondary side (output side) and is an open collector output. Output Voltage stable at Load Terminal S V (Maximum sink current is 10mA and maximum applied volt Twisted Pair (Example) -V Load - age is 75V.) Return line for ENA terminal is the -V terminal. When output voltage goes over a specified voltage level at start up, Power ON signal is "Low level". Output voltage threshold level is as follows. PFE300S or PFE500-129V TYP -S PFE300S or PFE500-2821VTYP PFE300S or PFE500-4837VTYP Fig. 9-1 Remote Sensing is used On the other hand, output voltage threshold level for Power ON signal to turn high level at shutdown varies according to output condition. Therefore, be sure to do actual verifi- Output Voltage stable at Power Module Output Terminals S V + + -V cation. Operating Ambient Temperature Range Load These products can be used in any orientation but be sure - -S Fig. 9-2 Remote Sensing is not used (Local Sensing) to consider enough airflow to avoid heat accumulation around the module. Consider surrounding components layout and set the PCB mounting direction such that air can flow through the heatsink by forced or convection cooling. This product can operate at actual mounting condition when baseplate temperature is maintained at or below the Series Operation Series operation is possible for PFE300S, 500S Series. Connections shown in Fig.10-1 and Fig.10-2 are possible. 42 following baseplate temperature: PFE300S-12, 28, 48: 100 PFE500S-12: 85 PFE500S-28, 48: 100 All contents are subject to change without notice. PFE300S, 500S Verify baseplate temperature at worst case operating con- input and output for a duration of 1 minute. When doing dition at the measuring point shown in Fig. 12-1. this test during incoming inspection, set the current limit of For Thermal Design details, refer to Application Notes "Thermal Design" section. test equipment to 20mA. This module is designed to withstand applied voltage 1.5kVDC between output and baseplate for 1 minute. When doing this test during incoming inspection, be sure Baseplate Temperature Measuring Point to apply DC voltage only. Avoid applying AC voltage during this test because this will damage the module. Refrain from injecting high test voltage suddenly. Be sure Fig. 12-1 Baseplate Measuring Point to gradually increase the applied withstand voltage during Baseplate temperature range is limited according to Fig. Especially, when using timer switch of the test equipment, 12-2. impulse voltage which is higher than the applied set volt- testing and gradually reduce the voltage after the test. age, is generated when the timer switch is cut off. This causes damage to the power module. Connect each termi- Load Current () 100 nal according to the circuit diagram shown below. For basic connection shown in Fig.1-1, do the same termi- 80 nal connections. 60 Withstand Voltage Tester 40 20 -20 0 20 40 60 -V PFE300S, PFE500S (Top View) AC(L) 0 -40 BASE-PLATE AC(N) PFE 500S-12 PFE 500S-28, 48 PFE 300S-12, 28, 48 85 80 V -S S TRIM 100 Baseplate Temperature () R Fig. 12-2 Derating Curve To further improve the reliability, it is recommended to use this module with baseplate temperature derating. BC 2.5kVAC 1 minute (20mA) Fig. 17-1 Input to Baseplate Withstand Voltage Test Method BASE-PLATE Operating Ambient Humidity AC(N) Note that dewdrop might cause power module abnormal -V PFE300S, PFE500S (Top View) AC(L) operation or damage. Storage Ambient Temperature R BC V -S S TRIM ENA -BC Note that rapid temperature change causes dewdrop. caus- Withstand Voltage Tester ing harmful effect on soldering condition of the terminal pins. 3kVAC 1 minute (20mA) Fig.17-2 Input to Output Withstand Voltage Test Method Storage Ambient Humidity Withstand Voltage Tester Storage under high temperature and high humidity causes rust on terminal pins that causes deterioration of soldering conditions. Take enough caution when storing this module. Cooling Method BASE-PLATE AC(N) AC(L) -V PFE300S, PFE500S (Top View) For details of thermal design, refer to Application Notes "Thermal Design" section. Withstand Voltage This module is designed to withstand applied voltage ENA -BC R BC -BC V -S S TRIM ENA 1.5kVDC 1 minute Fig.17-3 Output to Baseplate Withstand Voltage Test Method 2.5kVAC between input and baseplate, 3kVAC between All contents are subject to change without notice. 43 PFE300S, 500S Insulation Resistance Use DC Insulation Resistance test equipment (MAX.500V) between output and baseplate. Insulation Resistance must be 100M or more at 500VDC. Take caution that some types of test equipment generate Recommended Soldering Condition Recommended soldering temperature is as follows. 1Soldering Dip : 260, within 10 seconds Preheat : 130, within 60 seconds 2Soldering iron : 350, within 3 seconds high pulse voltage when switching applied voltage. After test, discharge this module using resistor, etc. Insulation Resistance Tester BASE-PLATE AC(N) AC(L) -V PFE300S, PFE500S (Top View) R BC -BC V -S S TRIM ENA 100M or more at 500VDC Fig. 18-1 Insulation Resistance Test Method 3. Before Concluding Power Module Damage Verify following items before concluding power module damage. 1No output voltage Is specified input voltage applied? During output voltage adjustment, is the fixed resistor or variable resistor setting correct? Is there no abnormality with the output load? Is the actual baseplate temperature within the specified operating temperature of this module? 2Output voltage is high Are the remote sensing terminals (+S, -S) correctly 4Load regulation or line regulation is large Is specified input voltage applied? A re the input or output terminals firmly connected? Is the measurement done at the sensing points? Are the input and output wires too thin? 5Large output ripple Is the measurement done according to methods described Application Notes or is it an equivalent method? connected? Is the measurement done at the sensing points? During output voltage adjustment, is the fixed resistor or variable resistor setting correct? 3Output voltage is low Is specified input voltage applied? Are the remote sensing terminals (+S, -S) correctly connected? Is the measurement done at the sensing points? During output voltage adjustment, is the fixed resistor or variable resistor setting correct? Is there no abnormality with the output load? 44 All contents are subject to change without notice. PFE700S PFE700S Instruction Manual BEFORE USING THE POWER SUPPLY UNIT Be sure to read this instruction manual thoroughly before using this product. Pay attention to all cautions and warnings before using this product. Incorrect usage could lead to an electric shock, damage to the unit or a fire hazard. WARNING Do not make unauthorized changes to power supply unit, otherwise you may have electric shock and void your warranty. Do not touch this unit and the internal components in operation or shortly after shut down. They may have high voltage or high temperature and as the unit dissipates its heat so the surface of the unit is hot. You may receive electric shock or burn. When the unit is operating, keep your hands and face away from it; you may be injured by an accident. Do not use unit under unusual condition such as emission of smoke or abnormal smell and sound etc. It might cause fire and electric shock. In such case, please contact us; do not repair by yourself, as it is dangerous for the user. Do not drop or insert anything into unit. It might cause failure and fire. Do not operate these units under condensation condition. It may cause fire and electric shock. CAUTION As a component part, compliance with the standard will be based upon installation in the final application. This product must be installed in a restricted access location, accessible to authorized competent personnel only. These AC to DC converters have reinforced insulation between the input and the output. The outputs of these products are energy hazards. This model is considered to be non-SELV. As such, the instructions for use must refer to these energy hazardous outputs and Non-SELV outputs in that the outputs must not be accessible to the operator. The installer must also provide protection against inadvertent contact by a service engineer. The equipment has been evaluated for use in a Pollution Degree 2 environment. This power supply is primarily designed and manufactured to be used and enclosed in other equipment. Confirm connections to input/output terminals and signal terminals are correct as indicated in the instruction manual. Attach an HBC external fuse to each module to ensure safety operation and compliance to each safety standard approval. The recommended input fuse rating within the instructions is as follows: -15AHBC, 250V fast acting fuse. The breaking capacity and voltage rating of this fuse may be subject to the end use application. All contents are subject to change without notice. Input voltage, output current, output power, ambient temperature and ambient humidity should be used within specifications, otherwise the unit will be damaged. For application equipment, which requires very high reliability (nuclear related equipment, traffic control equipment, medical equipment, etc.), please provide fail safety function in the equipment. Do not use the product in environment with strong electromagnetic field, corrosive gas and conductive substance. Do not operate and store this unit at an environment where condensation occurs. In such case, waterproof treatment is necessary. Never operate the unit under over current or shorted conditions for 30 seconds or more and out of input voltage range as specification. Insulation failure, smoking, burning or other damage may occur to the unit. The output voltage of this power supply unit is considered to be a hazardous energy level. (The voltage is 2V or more and the electric power is 240VA or more.) Prevention from direct contact with output terminal is highly necessary. While installing or servicing this power supply unit, avoid dropping tools by mistake or direct contact with output terminal. This might cause an electric shock. While repairing this power supply unit, the AC input power must be switched off and the input and output voltage should be level. To maintain the SELV output for outputs less than 28VDC, under fault conditions, the output must be connected to earth in the final application. The application circuits and their parameter are for reference only. Be sure to verify effectiveness of application circuits and their parameters before finalizing circuit design. Do not inject abnormal voltage to output terminal and signal terminal from the outside. The injection of reverse voltage or over voltage exceeding nominal output voltage to output terminals might cause damage to internal components. This information in this document is subject to change without prior notice. For actual design-in, please refer to the latest publications of data sheet, etc., for the most up-to-date specifications of the unit. No part of this document may be copied or reproduced in any form without prior written consent of TDK-Lambda. NoteCE MARKING CE Marking when applied to a product covered by this handbook indicates compliance with the low voltage directive (2006/95/ EC) in that it complies with EN60950-1. 45 PFE700S 1. Terminal Explanation AC(N) -V AC(L) +V Name Plate -VM +VM NC ENA R +BC -BC Input side terminals Output side terminals ACL: Input terminal live line ACN:Input terminal neutral line V : V : Output terminal Output terminal BC : Boost voltage terminal BC : Boost voltage terminal R: External inrush current limiting resistor VM : VOutput monitor terminal -VM :-VOutput monitor terminal NC : Make no external connection ENA : Power on signal terminal Baseplate can be connected to FG through M3 mounting tapped holes. Consider contact resistance when connecting AC(L), AC(N), R, BC, -BC, +V, -V. Note that BC and -BC terminals are primary voltage with high voltage (385VDC). Do not connect load from these terminals. Do not make external connection to NC terminal. 2. Explanations on Specifications This manual explains based on "Fig. 1-1 Basic Connection." Please do actual evaluation when changing circuit from Fig.1-1. 1 Input Voltage Range Input voltage range is indicated below. Take care not to Input Voltage Range: Single Phase 85 to 265VAC apply input voltage which is out of this specified range nor Line Frequency Range : 47 to 63Hz should a DC input voltage be applied as this would result into power module damage. L50mm F1 L1 L2 AC(L) C2 C1 C4 C6 R1 C3 C5 VM V C12 PFE700S C15 C7 C14 C16 Load C13 AC(N) -V -VM NC ENA R BC -BC BASEPLATE C8 Imput Filter For VCCI-classA TFR1 C11 C9 C10 Fig. 1-1 Basic Connection 46 All contents are subject to change without notice. PFE700S F1: External Input Fuse C6, C7: 1000pFCeramic Capacitor This power module has no internal fuse. Use external fuse Add ceramic capacitor as EMI/EMS countermeasure. Be to acquire each safety standard and to further improve sure to consider leakage current of your equipment when safety. Further, Fast-Blow type fuse must be used per one adding this capacitor. module. Also, in-rush surge current flows during line throw- High withstand voltage are applied across this capacitor in. Be sure to check I t rating of external switch and exter- during withstand voltage test depending on the application. nal fuse. Select capacitors with high withstand voltage rating. Also, connect C6, C7 as close as possible to the termi- 2 Recommended External Fuse15A nals. Select fuse based on rated voltage, rated current and C8, C91FFilm Capacitor surge current capability. 1Voltage Ratings Ripple current flows through this capacitor. When selecting 100VAC lineAC125V capacitor, be sure to check the allowable maximum ripple 200VAC lineAC250V current rating of this capacitor. Verify the actual ripple 2Current Ratings current flowing through this capacitor by doing actual mea- Rated current is determined by the maximum input current based on operating conditions and can be calculated by the following formula. linmax Pout VinxEffxPF Arms Formula 1-1 Iinmax Maximum Input Current Pout Maximum Output Power Vin Minimum Input Voltage Eff Efficiency surement. Recommended Voltage Rating450VDC Note Select Capacitor with more than 3A (rms) rating. Connect C8, C9 as near as possible towards the output terminals of this power module. C10780F390Fx2 pcs. in parallel Electrolytic Capacitor PF Power Factor or efficiency and power factor values, refer to sepaF Refer to "Selection Method of External Bulk Capacitor for rate document "PFE700S Series Evaluation Data". Allowable external capacitance at nominal capacitor value Boost Voltage" below. is shown below. C1, C4, C51FFilm Capacitor Ripple current flows through this capacitor. When selecting capacitor, be sure to check the allowable maximum ripple current rating of this capacitor. Verify the actual ripple current flowing through this capacitor by doing actual measurement. Recommended Voltage Rating: 250VAC NoteConnect C5 as near as possible towards the input terminals of this power module. Recommended Voltage Rating 450VDC Recommended Total Capacitor 390uF to 1,200uF Note1. Do not connect capacitors with more than the above capacitance value as this would result into power module damage. 2. When using module below -20 deg C ambient temperature, AC ripple of boost voltage, output ripple voltage and start up characteristics might be affected by ESR characteristics of the bulk capacitors. Therefore, be sure to verify characteristics by actual evaluation. L1, L26mH C11: 1000pFCeramic Capacitor Add common mode choke coil as EMI/EMS counter-mea- Add ceramic capacitor as EMI/EMS countermeasure. sure. When using multiple modules, connect coil to each High withstand voltage are applied across this capacitor module. during withstand voltage test depending on the application. NoteDepending on the input filter used, noise might increase or power module might malfunction due to filter resonance. Select capacitors with high withstand voltage rating. C2, C3: 4,700pFCeramic Capacitor Connect ceramic or film capacitor as EMI/EMS counter- Add ceramic capacitor as EMI/EMS countermeasure. Be measure and to reduce spike noise. sure to consider leakage current of your equipment when NoteHigh voltage is applied across this capacitor during withstand voltage test depending on the application. Connect C12, C13 as near as possible towards the output terminals of this power module. Also, connect C11 as close as possible to the terminals. C12, C130.033F adding this capacitor. High withstand voltage are applied across this capacitor depending on the application. Select capacitors with high withstand voltage rating. C14220F R1470k Connect bleeder resistor across AC(L) and AC(N) termi- To reduce output ripple noise voltage, connect electrolytic capacitors across V and -V. nals. NoteConnect C14 as near as possible to the V and -V output terminals of this power module. All contents are subject to change without notice. 47 PFE700S Ripple CurrentmA rms Recommended Voltage Rating100VDC C152.2F Connect chip ceramic capacitor within 50mm from the output terminals V and -V of the power module to reduce output spike noise. Also, note that output spike voltage may vary depending on 2500 2000 100VAC 1500 1000 200VAC 500 0 0 20 40 60 80 100 Load Current% the wiring pattern of the printed circuit board. Fig. 1-2 Allowable ripple current value C16220F Connect C13 within 50mm from the output terminals V and -V of the power module to stabilize operation. Note that the output ripple and line turn off characteristics TFR110 to 100 ohm of the power module might be affected by the ESR and throw-in can be suppressed. Failures due to in-rush current ESL of the electrolytic capacitor. Also, note that output ripple voltage may vary depending such as melting of external fuse, welding of relay or switch connecting joints or shutdown of No-Fuse Breakers (NFB) on the wiring pattern of the printed circuit board. might occur. Therefore, be sure to connect this external Sudden change in output voltage due to sudden load thermal fuse resistor. change or sudden input voltage change can be reduced by Note that this module will not operate without this external increasing external output capacitor value. resistor. Recommended Voltage Rating100VDC Note1. Use low-impedance electrolytic capacitors with excellent temperature characteristics. Nichicon PM Series or equivalent 2. For module operation at ambient temperature -20 deg C or less, output ripple voltage might be affected by ESR characteristics of the electrolytic capacitors. Increase the capacitor values shown below. By connecting thermal fuse resistor across R and BC terminals as shown in Fig.1-1, in-rush current during line Selection Method of External Resistor 1Calculating Resistance Value for TFR1 Resistance can be calculated by the formula below. R R Resistance Value for External TFR1 Vin Input Voltage converted to DC value Input Voltage rmsx 2 C14, C16: 100V 220F x 2 parallel Ambient Temperature<-20 deg C Vin Formula 1-2 lrush IrushInput surge current value 2Required Surge Current Rating Sufficient surge current withstand capability is re- 3. Take note of the maximum allowable ripple current of the electrolytic capacitor used. Especially, for sudden load current changes, verify actual ripple current and make sure that allowable maximum ripple current is not be exceeded. quired for external TFR1. Required surge current rating can be selected by l2t. (Current squared multiplied by time) l2t CoxVin2 2 A s Formula 1-3 2xR Selection Method of External Bulk Capacitor for Boost Voltage I2t Current-squared multiplied by time Boost voltage bulk capacitor is determined by boost volt- Vin Input Voltage converted to DC value Co Boost Voltage Bulk Capacitance age ripple voltage, ripple current and hold-up time. Select capacitor value such that boost voltage ripple volt- Input Voltage rmsx 2 R Resistance Value for External TFR1 age does not exceed 15Vp-p. Note When ambient temperature is -20 deg C or less, Boost voltage might increase due to ESR characteristics. Therefore, verify above characteristics by actual evaluation. 2 Maximum Ripple and Noise For output hold-up time, refer to separate document tion 7.13). "PFE700S Series Evaluation Data" and use appropriate capacitor up to 1,200uF maximum. (It is recommended In the basic connection shown in Fig.1-1, additional connection shown in Fig.2-1 is done for measurement. that verification should be done through actual evaluation). Capacitor (ceramic capacitor 2.2F and electrolytic This value is measured according to the description below in accordance with JEITA-9131A (Section 7.12 and Sec- capacitor: 220F) must be connected within 50mm from For allowable ripple current value, refer to Fig.1-2 and se- the output terminals. Then, connect coaxial cable with lect a capacitor with higher ripple current rating. JEITA attachment across the ceramic capacitor electrodes. Use 100MHz bandwidth oscilloscope or equivalent. Also, note that output ripple voltage and output spike noise may vary depending on the wiring pattern of the printed circuit board. In general, output ripple voltage and output spike noise can be reduced by increasing external capacitor value. 48 All contents are subject to change without notice. PFE700S Wires must be as short as possible V Current share parallel operation is possible for PFE700S Load -V Series by connecting the output terminal of each power - 50mm 1.5m 50 Coaxial Cable JEITA Attachment R50 C4700pF R 8 Parallel Operation module. Verify the allowable maximum total output current Oscilloscope C by actual evaluation such that maximum output current rating of each module is not exceeded. Consult us for details when using PFE700S Series at parallel operation. Fig. 2-1 Output Ripple Voltage (including Spike Noise) Measurement Method 3 Maximum Line Regulation 9 Series Operation Series operation is possible for PFE700S Series. Connections shown in Fig.9-1 and Fig.9-2 are possible. Maximum line regulation is defined as the maximum output voltage change when input voltage is gradually changed V (steady-state) within specification range. -V Load 4 Maximum Load Regulation V Maximum load regulation is defined as the maximum out- -V - put voltage change when output load current is gradually changed (steady-state) within specification range. When using power module in dynamic load mode, audible Fig. 9-1 Series Operation for High Output Voltage Applications sound could be heard from the power module or large output voltage change can occur. Make prior evaluation thoroughly before using this power module. 5 Over Current Protection (OCP) V -V - V -V - Load Load Fig. 9-2 /-Output Series Applications This module is equipped with OCP function. Output will automatically recover when short circuit or overload condition is removed. OCP value is fixed and can- Power ON Signal (ENA Terminal) not be adjusted externally. This signal is located at the secondary side (output side) Note that continuous short circuit or overload condition and is an open collector output. might result in power module damage. (Maximum sink current is 10mA and maximum applied voltage is 75V.) 6 Over Voltage Protection (OVP) When output voltage goes over 46V(TYP) at start up, Pow- This module is equipped with OVP function. This value is On the other hand, output voltage threshold level for Power set between 60.0V to 69.6V. ON signal to turn "High Level" at shutdown varies accord- When the OVP function activates, first cut off input line ing to output condition. and verify that boost voltage has dropped down to 20V or Therefore, be sure to do actual verification. er ON signal is "Low Level". less. Then, recover output by recycling input line. OVP value is fixed and cannot be set externally. Operating Ambient Temperature Range 7 Over Temperature Protection (OTP) These products can be used in any orientation but be sure This module is equipped with OTP function. This func- to consider enough airflow to avoid heat accumulation around the module. Consider surrounding components lay- tion will activate and shut down the output when ambient out and set the PCB mounting direction such that air can temperature or internal temperature abnormally rises. OTP flow through the heatsink by forced or convection cooling. activates at following baseplate temperature. This product can operate at actual mounting condition OTP operating temperature105 to 130 deg C when baseplate temperature is maintained at or below the 100 deg C. When OTP function operates, output can be recovered Verify baseplate temperature at worst case operating con- by cooling down the baseplate sufficiently and letting the dition at the measuring point shown in Fig.11-1. boost voltage drop down to 20V or less before recycling For Thermal Design details, refer to Application Notes the input line. "Thermal Design" section. All contents are subject to change without notice. 49 PFE700S to apply DC voltage only. Avoid applying AC voltage during this test because this will damage the module. Baseplate Temperature Measuring Point Fig.11-1 Baseplate Measuring Point Baseplate temperature range is limited according to Fig. 11-2. testing and gradually reduce the voltage after the test. Especially, when using timer switch of the test equipment, impulse voltage which is higher than the applied set voltage, is generated when the timer switch is cut off. This causes damage to the power module. Connect each termi- 100 Load current () Refrain from injecting high test voltage suddenly. Be sure to gradually increase the applied withstand voltage during nal according to the circuit diagram shown below. 85 80 For basic connection shown in Fig.1-1, do the same termi- 60 nal connections. 40 20 0 -40 -20 0 20 40 60 85 80 Withstand Voltage Tester 100 BASE-PLATE Baseplate temperature () AC(N) -V Load current () 100 85 PFE700S (Top View) AC(L) 80 70 60 V -VM VM NC ENA 40 Tbp85 Tbp100 20 0 80 85 R BC -BC 265 100 120 140 160 180 200 220 240 260 Input Voltage (VAC) Fig. 11-2 Derating Curve 2.5kVAC 1 minute (20mA) Fig. 16-1 Input to Baseplate Withstand Voltage Test Method To further improve the reliability, it is recommended to use BASE-PLATE this module with baseplate temperature derating. AC(N) -V PFE700S (Top View) AC(L) Operating Ambient Humidity V NC ENA Note that dewdrop might cause power module abnormal operation or damage. Storage Ambient Temperature Note that rapid temperature change causes dewdrop causing harmful effect on soldering condition of the terminal R BC -BC Withstand Voltege Tester 3kVAC 1 minute (20mA) Fig.16-2 Input to Output Withstand Voltage Test Method Withstand Voltage Tester pins. BASE-PLATE Storage Ambient Humidity Storage under high temperature and high humidity causes AC(N) -V PFE700S (Top View) AC(L) rust on terminal pins that causes deterioration of soldering conditions. Take enough caution when storing this module. Cooling Method R BC -BC V - NC ENA 1.5kVDC 1 minute Fig.16-3 Output to Baseplate Withstand Voltage Test Method For details of thermal design, refer to Application Notes "Thermal Design" section. Withstand Voltage This module is designed to withstand applied voltage 2.5kVAC between input and baseplate, 3kVAC between input and output for a duration of 1 minute. When doing this test during incoming inspection, set the current limit of test equipment to 20mA. This module is designed to withstand applied voltage 1.5kVDC between output and baseplate for 1 minute. When doing this test during incoming inspection, be sure 50 All contents are subject to change without notice. PFE700S Insulation Resistance Use DC Insulation Resistance test equipment (MAX.500V) between output and baseplate. Insulation Resistance must be 100Mohm or more at 500VDC. Take caution that some types of test equipment Recommended Soldering Condition Recommended soldering temperature is as follows. 1Soldering Dip : 260, within 10 seconds Preheat : 130, within 60 seconds 2Soldering iron : 350, within 3 seconds generate high pulse voltage when switching applied voltage. After test, discharge this module using resistor, etc. Insulation Resistance Tester BASE-PLATE AC(N) -V PFE700S (Top View) AC(L) R BC -BC V VM NC ENA 100M ohm or more at 500VDC Fig. 17-1 Insulation Resistance Test Method 3. Before Concluding Power Module Damage Verify following items before concluding power module damage. 1No output voltage Is specified input voltage applied? Is there no abnormality with the output load? Is the actual baseplate temperature within the specified operating temperature of this module? 3Load regulation or line regulation is large Is specified input voltage applied? A re the input or output terminals firmly connected? Are the input and output wires too thin? 4Large output ripple Is the measurement done according to methods described Application Notes or is it an equivalent method? 2Output voltage is low Is specified input voltage applied? Is there no abnormality with the output load? All contents are subject to change without notice. 51 52 Precautions for Use WARNING Do not modify, disassemble, or open this product. Failure to do so can cause electric shock hazard. TDK-Lambda cannot be held responsible for damage caused by modifications to this product. Internal voltage can be retained inside the product. Do not touch any parts inside the product because there can be high-voltage and high-temperature parts even when the electric current is not applied. This can cause an electric shock hazard or burn injury. There can be high-voltage and high-temperature parts even in products without a cover. Do not touch them. Touching them can cause an electric shock hazard or burn injury. While electric current is being applied, keep your hands and face away from it. This may cause injury or an unexpected accident. CAUTION Be sure to read the catalogue and instruction manual before using this product. For strictly accurate information, request the specifications of the delivered product to check the information. Incorrect usage could lead to an electric shock, damage to the product or a fire hazard. If there are differences between the specific information given for your product and this document, the specific information given for your product has priority. Use this product within the specified input voltage, output power, output voltage, output current, and range of ambient temperature/ambient humidity. Using this product in conditions beyond the specification limits can shorten the lifetime of the product, or can cause, damage to the product, electric shock, or a fire hazard. Also, measure the temperature inside the device to check that there are no problems. Check the direction the product should face and the conditions for ventilation in the specifications of the delivered product, and use the product in the correct manner. Disconnect the power input before connecting inputs and outputs. If an internal fuse becomes burned out, do not use the unit by replacing the fuse. This can cause trouble inside the unit. Be sure to request us to repair the unit. Insert fuses in the input circuit for products in which protection circuits (elements, fuses, etc.) are not installed, to prevent smoking or burning. Also for products with protection circuits installed inside, an appropriate use of protection circuits is recommended as there is possibility that the internal protection circuit may not operate depending on the usage conditions. Use only the fuses specified or recommended by TDK-Lambda for external fuses. This product is designed and manufactured as a component part to be installed in electronic devices. Attach the warning label to the unit and insert the notes in the instruction manual. Malfunction and failure may be caused if this product is used in a strong electromagnetic field. Failure may be caused in the power supply unit due to corrosion if used in environments with corrosive gas (hydrogen sulfide, sulfur dioxide, etc.). Malfunction and failure may be caused if this product is used in environments with conductive substances or dust. Be sure to take protective measures against the surge voltage caused by lightning, etc. Damage to the unit may be caused due to irregular voltage. Connect the frame ground terminal of the power supply unit to the earth terminal of the device, for safety and to reduce noise. If grounding is not made, it may cause an electric shock hazard. It is necessary to exchange consumable parts (built-in fan, electrolytic capacitor) periodically. Set an appropriate overhaul interval period for the performance of maintenance. There may be some cases where overhaul maintenance cannot be conducted due to unavailability of parts due to production discontinuation. This product might fail accidentally or through unexpected conditions. When using this product with application devices, in which an extremely high reliability is required (Nuclear-related devices, traffic control devices, medical devices, etc.), be sure to ensure that the fail-safe function is effective in the devices. * * * As for EMI or immunity, they are measured in the TDK-Lambda standard conditions. It is not guaranteed that this product meets industry standards or regulations when being used in different conditions of mounting and wiring. Assess and evaluate values on the actual device before use. To export this product, follow the necessary procedures of application for the export license by the government of Japan, etc., complying with the regulations of the Foreign Exchange and Foreign Trade Control Law. The information in this catalogue is subject to change without prior notice. All specifications are subject to change without notice. 53 TDK-Lambda Corporation HEAD OFFICE Denpa Bldg. 1-11-15 Higashi-Gotanda, Shinagawa-ku, Tokyo 141-0022, JAPAN Tel: +81-03-3447-4411 Fax: +81-03-3447-7784 http://www.tdk-lambda.com/ TDK-Lambda Sales Network ASIA CHINA Wuxi TDK-Lambda Electronics Co., Ltd. (Shanghai Office) Tel: +86-21-6485-0777 Fax: +86-21-6485-0666 Wuxi TDK-Lambda Electronics Co., Ltd. (Shenzhen Office) Tel: +86-755-83588261 Fax: +86-755-83588260 Wuxi TDK-Lambda Electronics Co., Ltd. (Beijing Office) Tel: +86-10-6310-4872 Fax: +86-10-6310-4874 TDK-Lambda Corporation (Hong Kong Office) Tel: +852-2420-6693 Fax: +852-2420-3362 Wuxi TDK-Lambda Electronics Co., Ltd. (Chengdu Office) Tel: +86-28-85311929 Fax: +86-28-85311150 Wuxi TDK-Lambda Electronics Co., Ltd Tel: +86-510-85281029 Fax: +86-510-85282585 INDIA TDK-Lambda India (Bangalore Office) Tel: +91-80-43550500 Fax: +91-80-43550501 TDK-Lambda India (Hyderabad Office) Tel: +91-40-69996653 Fax: +91-40-23261415 TDK-Lambda India (Pune Office) Tel: +91-20-24475533 TDK-Lambda India (Delhi Office) Tel: +91-120-4357819 Fax: +91-120-4357818 KOREA TDK-Lambda Corporation (Seoul Office) Tel: +82-31-717-7051 Fax: +82-31-726-9137 MALAYSIA TDK-Lambda Malaysia Sdn. Bhd. Tel: +60-3-7957-8800 Fax: +60-3-7958-2400 SINGAPORE TDK-Lambda Singapore Pte.Ltd. Tel: +65-6251-7211 Fax: +65-6250-9171 EMEA GERMANY TDK-Lambda Germany GmbH Tel: +49-7841-666-0 Fax: +49-7841-500-0 U.K. TDK-Lambda UK Ltd. Tel: +44-1271-856666 Fax: +44-1271-864894 FRANCE TDK-Lambda France SAS Tel: +33-1-60-12-71-65 Fax: +33-1-60-12-71-66 ITALY TDK-Lambda Italy S.r.l. Tel: +39-02-61293863 Fax: +39-02-61290900 ISRAEL NEMIC-Lambda LTD. Tel: +972-3-902-4333 Fax: +972-3-902-4777 NORTH AMERICA U.S.A. TDK-Lambda Americas Inc. (San Diego Office) Tel: +1-619-575-4400 Fax: +1-619-575-7185 TDK-Lambda Americas Inc. (Neptune) Tel: +1-732-922-9300 Fax: +1-732-922-8160 TDK-Lambda Americas Inc. (Hauppauge) Tel: +1-631-967-3000 Fax: +1-516-967-3022 Change of Content Specifications or designs in this catalog are subject to change due to improvements without prior notice. Trademarks Company names, product names, service marks and/or logos used, quoted and/ or referenced in this catalog are trademarks or registered trademarks of TDK Corporation or TDK-Lambda Corporation or any of its affiliates in Japan and other countries. Not all trademarks or registered trademarks stated herein are followed by (R) or (TM). TDK logo TDK logo is a trademark or registered trademark of TDK Corporation. PFE-0902E