TDK-Lambda PFE500F Series Manuale utente
INSTRUCTION MANUAL
PFE500F Series
TDK-Lambda
<Page>
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 28V 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.
·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.
1/21 C250-04-11D
PFE500F Series
Instruction Manual
INSTRUCTION MANUAL
PFE500F Series
TDK-Lambda
<Page>
CAUTION
·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 Densei-Lambda.
2/21
INSTRUCTION MANUAL
PFE500F Series
TDK-Lambda
<Page>
Table of Contents
■Block Diagram
■Sequence Time Chart
■Terminal Explanation
■Explanation on Specifications
1. Input Voltage Range
2. Output Voltage Adjustment Range (TRIM terminal)
3. Maximum Output Ripple and Noise
4. Maximum Line Regulation
5. Maximum Load Regulation
6. Over Current Protection (OCP)
7. Over Voltage Protection (OVP)
8. Over Temperature Protection (OTP)
9. Remote Sensing (+S, -S terminals)
10. ON/OFF Control (+ON/OFF, -ON/OFF terminals)
11. Series Operation
12. Parallel Operation (PC terminal)
13. Power ON Signal (ENA terminal)
14. I.O.G Signal (IOG terminal)
15. Auxiliary Power Supply for External Circuits (AUX terminal)
16. Operating Temperature Range
17. Operating Humidity
18. Storage Temperature
19. Storage Humidity
20. Cooling Method
21. Withstand Voltage
22. Insulation Resistance
23. Recommended Soldering Conditions
■Before concluding module damage
■CE MARKING / UKCA MARKING
3/5
INSTRUCTION MANUAL
PFE500F Series
TDK-Lambda
<Page>
■Block Diagram
Switching Frequency
PFHC circuit (fixed) :100kHz
DC/DC converter (fixed) :230kHz (primary), 460kHz (secondary)
■Sequence Time Chart
V* voltage level: Refer to Application Notes “13.Power ON Signal” section.
4/21
Input voltage
detector
Rectifier
Filter
OCP
Rectifier
Output filter
+V
-V
IOG
TRI
M
+S
-S
AC(L)
AC(N)
Inrush current
limiting
circuit
+BC -BCR
PC
ENA
+ON/OFF
-ON/OFF
AUX
COM
PFHC DC/DC Converter
OCP
OVP
OTP
(PFHC)
Input voltage
detector
(DC-DC)
Switching
circuit
PFHC
circuit
PFHC & BPS
Control circuit
Bias power
supply
Secondary
control
Output voltage
detector
DC-DC
Control
circuit
Input current
detector
OCP
Boosted
voltage
detector
OVP
OTP
(DC-DC)
Input Voltage
Output Voltage
BC Terminal Voltage
(Boost Voltage)
L
H
ON/OFF
Control L
H
IOG
L
H
ENA
L
H
Input Line
ON
OVP Trip
OCP Release
OCP Active
Input Line
OFF
Input Line
ON
OTP Trip
AUX
L
H
Control OFF
Control ON
Control OFF
Control ON
Control OFF
Control ON
390VDC (Typ)
V*V*
INSTRUCTION MANUAL
PFE500F Series
TDK-Lambda
<Page>
■Terminal Explanation
[Input side terminals]
AC (L) : Input terminal live line
AC (N) : Input terminal neutral line
+BC : +Boost voltage terminal
-BC : -Boost voltage terminal
R : External inrush current
limiting resistor 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.
5/21
AC(N)
AC(L)
R +BC -BC
+ S- S
TRIMPC
+ ON/OFF IOG
- ON/OFF ENA
COM
AUX
-V
+V
Name Plate
[Output side terminals]
+V : +Output terminal
-V : -Output terminal
+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
INSTRUCTION MANUAL
PFE500F Series
TDK-Lambda
<Page>
■Explanations on Specifications
1. Input Voltage Range
Input voltage range is indicated below. Take care not to apply input voltage which is above this specified
range or under this specified range for more than 30 seconds. Nor should a DC input voltage be applied as
this would result into power module damage.
Input Voltage Range : Single Phase 85 to 265VAC Line Frequency Range : 47 to 63Hz
·Basic Connection
Note) To meet the surge immunity, evaluate the addition of the surge protection components.
Refer to separate document “PFE500F Series IEC Data”.
6/21
LOAD
C13
C12
AC(L)
AC(N)
+V
-V
+S
-S
ENA
-BC
+BC
R
BASE-
PLATE
C14
C15
L= 50mm
C16
＋
－
C4 C5
C3
C2
Fuse
C1
L1 L2
R1
C9
C8
C10
TFR1
IOG
AUX
COM
+ON/OFF
-ON/OFF
TRIM
PC
C6
C7
C11
C17
Input Filter
(For VCCI-classA)
PFE500F
Fig. 1-1 Basic Connection
INSTRUCTION MANUAL
PFE500F Series
TDK-Lambda
<Page>
External Input Fuse
This power module has no internal fuse. Use external fuse to acquire each Safety Standard and to further
improve safety. Further, Fast-Blow type fuse must be used per one module. Also, in-rush surge current flows
during line throw-in. Be sure to check I2t capability of external switch and fuse.
Recommended External Fuse : F15AH, 250V
Note) Select fuse based on rated voltage, rated current and breaking capacity.
(1) Voltage Ratings
100VAC line : AC125V
200VAC line : AC250V
(2) Current Ratings
Rated current is selected by the maximum input current based on operating conditions and can be
calculated by the following formula.
(Formula 1-1)
Iin (max) : Maximum Input Current
Pout : Maximum Output Power
Vin : Minimum Input Voltage
Eff : Efficiency
PF : Power Factor
(3) Breaking 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”.
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 measurement.
Recommended Voltage Rating : 250VAC
Note) Connect C5 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
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.
C2, C3, C6, C7, C12: 2,200pF (Ceramic Capacitor)
Connect ceramic capacitor to conform to EMI/EMS standard. Be sure to note the leakage current of your
equipment when connecting this capacitor.
High withstand voltage are applied across this capacitor depending on the application. Select capacitors with
high withstand voltage rating.
R1 : 470kohm
Connect bleeder resistor across AC(L) and AC(N) terminals.
7/21
Iin(max)= Pout
Vin × Eff × PF (Arms)
INSTRUCTION MANUAL
PFE500F Series
TDK-Lambda
<Page>
C8, C9 : 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 : 450VDC
Note) Select Capacitor with more than 3A (rms) rating. Connect C8, C9 as near as possible towards the
terminals of this power module.
C10, C11: 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
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 390uF – 600uF for PFE500F 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 : 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 as near as possible towards the terminals of this power module.
C15 : 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 as near as possible to the +V and -V terminals of this power module.
C16 : 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.
8/21
12V
Vout
25V 1,000uF
C15
28V 50V 470uF
48V 100V 220uF
Table 1-1 C15:Recommended external capacitance
INSTRUCTION MANUAL
PFE500F Series
TDK-Lambda
<Page>
C17 : Refer to Table 1-2
Connect C17 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.
Note) 1. Use low-impedance electrolytic capacitors with excellent temperature characteristics.
(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.
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.
9/21
12V
Vout
25V 1,000uF
C17
28V 50V 470uF
48V 100V 220uF
Table 1-2 C17:Recommended external capacitance
12V
Vout
25V 1,000uF x 2 parallel
C15 , C17
28V 50V 470uF x 2 parallel
48V 100V 220uF x 2 parallel
Table 1-3 C15, C17 : Recommended external capacitance (Ambient Temperature < -20 deg C)
INSTRUCTION MANUAL
PFE500F Series
TDK-Lambda
<Page>
· 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” and use
appropriate
capacitor up to 1,200uF maximum. (It is recommended that verification should be done through actual
evaluation).
For allowable ripple current value, refer to Fig. 1-2 and select a capacitor with higher ripple current rating.
The recommended boost voltage bulk capacitance value range is 390uF-1,200uF.
When using with reduced the bulk capacitance value, it is necessary to reduce output power as shown in Fig1-3.
Note that reducing the bulk capacitance affects output hold-up time, dynamic line response and dynamic load
response characteristics.It is recommended that verification should be done through actual evaluation.
TFR1 : 10 to 100 ohm
By connecting 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
connecting joints or shutdown of No-Fuse Breakers (NFB) might occur. Therefore, select TFR1 in consideration
of the surge current capability of the external components. (TFR1 is recommended to use the Thermal Fuse
Resistor.)
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.
10/21
Fig. 1-2 Ripple current value (A value per one of Fig. 1-1 connection)
0
20
40
60
80
100
120
0 200 400 600 800 1000 1200
Bulk Cap.
(uF)
Output Power
(%)
390uF
1200uF
Tbp:25degC
0
400
800
1200
1600
2000
0 20 40 60 80 100
Load Current (%)
Ripple Current (mA rms)
100VAC
200VAC
Fig. 1-3 Output Power v.s. Boost Voltage Bulk Capacitance For PFE500F Series
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