Applications Manual for TUNS300/500

Size: px

Start display at page:

Download "Applications Manual for TUNS300/500"

Archibald Hubbard
5 years ago
Views:

1 fr ev. 1.E 214/1/23

2 fr Cntents 1. Pin Assignment A Pin Assignment A-1 2. Cnnectin fr Standard Use Cnnectin fr standard use Input fuse : F11 Input capacitr : C11 Y capacitrs and nise filters : CY,CX,L1 Output capacitrs : C,C4 Smthing capacitr fr bst vltage : Cbc Capacitr fr bst vltage : C2,C3 Inrush current limiting resistr : TF1 Discharging resistr : A A A-7 3. Derating 3.1 Output current derating 4. Operatin under lw temperature cnditins 4.1 ipple vltage f bst vltage Page 5. Hldup time A Hldup time A-1 6. Bard layut A Cnsideratin fr bard layut eference PCB layut A-11 A-15 A-2 A-2 A-3 A-3 A-4 A-4 A-5 A-8 A-8 A-9 A-9 Nte: Infrmatin cntained in this dcument is subject t change withut ntice fr imprvement. The materials are intended as a reference design, cmpnent values and circuit examples described in this dcument varies depending n perating cnditins and cmpnent variatins. Please select the cmpnents and design under cnsideratin f usage cnditin etc.

3 2.11 Pin cnfiguratin Assignment 1.1 Pin Assignment Fig.1.1 Pin Assignment 1AC1 2AC2 7-VOUT 6+VOUT 8-S 9+S 1TM 11IOG 3 4+BC 5-BC 4-FG Bttm view Table 1.1 Pin cnfiguratin and functin N Pin Cnnectin AC1 AC2 +BC -BC +VOUT -VOUT -S +S TM IOG FG AC input Functin External resistr fr inrush current prtectin +BC utput -BC utput +DC utput -DC utput emte sensing(-) emte sensing(+) Adjustment f utput vltage Inverter peratin mnitr Munting hle(fg) A-1

4 2. Cnnectin fr Standard Use 2.1 Cnnectin fr standard use T use the series, external cmpnents shuld be cnnected as shwn in Fig The series shuld be cnductin-cled. Use a heatsink r fan t dissipate heat. Fig. 2.1 Cnnectin fr standard use Heatsink AC INPUT F11 SK11 CX1 L11 CX2 L12 1 C11 AC1 +S +VOUT + C C4 Lad AC2 -VOUT CY3 SK21 SK22 FG +BC -S -BC Nise CY2 SA11 C3 TF1 + Cbc C2 CY1 Filter Table 2.1 Cmpnents name TUNS3F TUNS5F N. Symbl Item ating Part name ating Part name 1 F11 Input fuse AC25V/1A AC25V/15A (Littelfuse) (Littelfuse) 2 C11 Input capacitr AC275V/2.2uF ECQUAAF225 ECQUAAF225 AC275V/2.2uF (Panasnic) (Panasnic) 3 CY1 Y capacitr AC25V/22pF DE1E3KX222M AC25V/22pF DE1E3KX222M ADM T ADM T 4 L11 6mH/12A 6mH/12A (Uen) (Uen) Line Filter ADM T ADM T 5 L12 6mH/12A 6mH/12A (Uen) (Uen) ECQUAAF155 ECQUAAF155 6 CX1 AC275V/1.5uF AC275V/1.5uF Nise (Panasnic) (Panasnic) X capacitr filter ECQUAAF155 ECQUAAF155 7 CX2 AC275V/1.5uF AC275V/1.5uF (Panasnic) (Panasnic) 8 CY2 AC25V/22pF DE1E3KX222M AC25V/22pF DE1E3KX222M Y capacitr 9 CY3 AC25V/22pF DE1E3KX222M AC25V/22pF DE1E3KX222M F12 DC25V/22uF ELXZ25ELL222 ELXZ25ELL222 DC25V/22uF (Nippn Chemi-Cn) (Nippn Chemi-Cn) 1 C Output ELXZ5ELL12 ELXZ5ELL12 F28 DC5V/1uF DC5V/1uF capacitr (Nippn Chemi-Cn) (Nippn Chemi-Cn) F48 DC63V/47uF ELXZ63ELL471 ELXZ63ELL471 DC63V/47uF (Nippn Chemi-Cn) (Nippn Chemi-Cn) F12 DC25V/1uF GM31C71E16 GM31C71E16 DC25V/1uF 11 C4 Bypass GM31C71H475 GM31C71H475 F28 DC5V/4.7uF DC5V/4.7uF capacitr F48 DC1V/2.2uF GM31C72A225 GM31C72A225 DC1V/2.2uF 12 Cbc Smthing capacitr ELXM451VSN471 DC45V/39uF ELXM451VSN391 2parallel DC45V/47uF fr bst vltage (Nippn Chemi-Cn) 2parallel (Nippn Chemi-Cn) 13 C2 Capacitr DC45V/.68uF AFS45V684K 2parallel DC45V/.68uF AFS45V684K 2parallel fr bst vltage 2parallel (OKAYA ELECTIC INDUSTIES) 2parallel (OKAYA ELECTIC INDUSTIES) 14 C3 Capacitr DC45V/.68uF AFS45V684K 2parallel DC45V/.68uF AFS45V684K 2parallel fr bst vltage 2parallel (OKAYA ELECTIC INDUSTIES) 2parallel (OKAYA ELECTIC INDUSTIES) 15 TF1 Inrush current F5K-1J14 F5K-1J14 1Ω 1Ω prtectin resistr (TAMUA THEMAL DEVICE) (TAMUA THEMAL DEVICE) 16 1 Discharging resistr 68kΩ 68kΩ CS CS series 3series (HOKUIKU ELECTIC INDUSTY) (HOKUIKU ELECTIC INDUSTY) 2parallel 2parallel 17 SK11 SK21 SK22 Varistr 62V 18 SA11 Surge absrber 4kV TND14V-621K (Nippn Chemi-Cn) DSA-42MA (Mitsubishi Materials) 62V 4kV TND14V-621K (Nippn Chemi-Cn) DSA-42MA (Mitsubishi Materials) Parts name are shwn in Table 2.1 as reference. External parts shuld be changed accrding t the ambient temperature, and input and utput cnditins. Fr details, refer t the selectin methd f individual parts. A-2

5 2.2 Input fuse: F11 N prtective fuse is preinstalled n the input side. T prtect the unit, install a slw-blw type fuse shwn in Table 2.2 in the input circuit. Table 2.2 ecmmended fuse Mdel TUNS3F TUNS5F ated current 1A 15A 2.3 Input capacitr: C11 Cnnect a film capacitr f 2 uf r higher as input capacitr C11. Use a capacitr with a rated vltage f AC25V which cmplies with the safety standards. If C11 is nt cnnected, the pwer supply r external cmpnents culd be damaged. When selecting a capacitr, check the maximum allwable ripple current. ipple current includes lw frequency cmpnent (input frequency) and high frequency cmpnent (1kHz). ipple current values flwing int C11 as listed in Table 2.1 are shwn in Fig The ripple current changes with PCB patterns, external parts, ambient temperature, etc. Check the actual ripple current value flwing thrugh C11. Fig. 2.2 ipple current values C11 s ] 25 2 m r A [m 15 t n e r u c 1 le p ip 5 TUNS3F(1VAC) TUNS3F(2VAC) TUNS5F(1VAC) TUNS5F(2VAC) Output current [%] A-3

6 2.4 Y Capacitrs and nise filters: CY, CX, L1 The series has n internal nise filter. Cnnect external nise filters and capacitrs (CY) t reduce cnductin nise and stabilize the peratin f the pwer supply. Nise filters shuld be prperly designed when the unit must cnfrm t the EMI/EMS standards r when surge vltage may be applied t the unit. Install the primary Y capacitr (CY1) as clse as pssible t the input pins (within 5 mm frm the pins). A capacitance f 47 pf r mre is required. When the ttal capacitance f CYs exceeds 8,8 pf, input-utput withstanding vltage may be drpped. In this case, either reduce the capacitance f Y capacitrs r install a grunding capacitr between utput and FG. Use capacitrs with a rated vltage f AC25V which cmply with the safety standards as CY. 2.5 Output capacitrs: C, C4 Install an external capacitr, C, between +VOUT and -VOUT pins fr stable peratin f the pwer supply. ecmmended capacitance f C is shwn in Table 2.3. Use lw impedance electrlytic capacitrs with excellent temperature characteristics. When used at ambient temperatures belw ºC, the utput ripple vltage increases due t the characteristics f equivalent series resistr (ES). In this case, cnnect three capacitrs, C, f recmmended capacitance in parallel cnnectin. Specificatins, utput ripple and ripple nise as evaluatin data values are measured accrding t Fig Table 2.3 ecmmended capacitance C Output Vltage 12V TUNS3F 2,2uF TUNS5F 2,2uF 28V 1,uF 1,uF 48V 47uF 47uF Fig. 2.3 Measuring envirnment 5mm +S +VOUT + C C4 Lad C4: 12V 1µF 28V 4.7µF 48V 2.2µF -VOUT -S 1.5m 5Ω Caxial Cable C Oscillscpe BW:1MHz =5Ω C=.1uF A-4

7 2.6 Smthing capacitr fr bst vltage: Cbc In rder t smth bst vltage, cnnect Cbc between +BC and -BC. ecmmended capacitance f Cbc is shwn in Table 2.4. Install a capacitr Cbc with a rated vltage f DC42 V r higher within the allwable capacitance. When perated belw ºC, peratin may becme unstable as bst ripple vltage increases due t ES characteristics. Chse a capacitr which has higher capacitance than recmmended. Select a capacitr s that the ripple vltage f the bst vltage is 3 Vp-p r belw. If the ripple vltage f the bst vltage increases, the ripple current rating f the smthing capacitr may be exceeded. Check the maximum allwable ripple current f the capacitr. The ripple current changes with PCB patterns, external parts, ambient temperature, etc. Check the actual ripple current value flwing thrugh Cbc. Table 2.4 ecmmended capacitance Cbc Mdel ecmmended capacitance Allwable capacitance range TUNS3F 47uF 39uF ~ 2,2uF TUNS5F 39uF 2 parallel 39uF ~ 2,2uF efer t item 4 and 5 fr selectin methd f Cbc. 2.7 Capacitr fr bst vltage :C2,C3 Install film capacitrs with a rating f 1uF/DC45V r higher as C2 and C3. If C2 and C3 are nt cnnected, the pwer supply r external cmpnents culd be damaged. The ripple current flws int these capacitrs. Check the maximum allwable ripple current f the capacitr while selecting. The frequency f the ripple current is 1 khz t 2 khz. ipple current values flwing int C2 and C3 as listed in Table 2.1 are shwn in Fig. 2.4 and Fig The ripple current changes with PCB patterns, external parts, ambient temperature, etc. Check the actual ripple current values flwing thrugh C2 and C3. Fig. 2.4 ipple current values C2 25 ] 2 s m r A [m 15 t n r e u c 1 le p ip 5 TUNS3F(1VAC) TUNS3F(2VAC) TUNS5F(1VAC) TUNS5F(2VAC) Output current [%] ipple current value is ttal f 2 paralleled capacitrs. A-5

8 Fig. 2.5 ipple current values C3 25 ] 2 s r m A [m 15 t n r e c u 1 le p ip 5 TUNS3F(1VAC) TUNS3F(2VAC) TUNS5F(1VAC) TUNS5F(2VAC) Output current [%] ipple current value is ttal f 2 paralleled capacitrs. 2.8 Inrush current limiting resistr: TF1 The must cnnect TF1. If TF1 is nt cnnected, the pwer supply will nt perate. Cnnect TF1 between and +BC. ecmmended resistance f TF1 is shwn in Table 2.5. The surge capacity is required fr TF1. Wirewund resistr with thermal cut-ffs type is required. The inrush current changes by PCB pattern, parts characteristic etc. Check the actual inrush current value flwing thrugh the AC line. Table 2.5 ecmmended resistr TF1 Mdel TUNS3F TUNS5F ecmmended resistance 4.7Ω ~ 22Ω 4.7Ω ~ 22Ω The selectin methd f TF1 is shwn belw. Calculatin f resistance esistance can be calculated using the fllwing frmula. Vin 2 TF1 = L[ Ω] Ip TF1 L Vin Ip : Inrush current limiting resistr : Line impedance : Input vltage (rms) : Inrush current (peak) Calculatin f required surge capacity equired surge capacity can be calculated using the fllwing frmula. I 2 t = Cbc Vin TF1 2 [ A 2 s] I2t TF1 Cbc : Current squared times : Inrush current limiting resistr : Smthing capacitr fr bst vltage Vin : Input vltage (rms) A-6

9 2.9 Discharging resistr: 1 If yu need t meet the safety standards, cnnect a discharging resistr 1 at input interphase. Please select a resistr s that the input interphase vltage decreases in 42.4V r less at 1 secnd after turn ff the input. Fig. 2.6 shws the relatinship between a necessary resistance f 1 and ttal capacitance f input interphase capacitrs. And the data f Fig. 2.6 is the values that assumed the wrst cnditin. Please take margins frm the rated vltage and pwer f 1. Fig. 2.6 TUNS5F elatinship between a necessary resistance f 1 and ttal capacitance f input interphase capacitrs ] Ω [ k Ttal capacitance f input interphase capacitrs [uf] A-7

10 2.1 Pin 3. cnfiguratin Derating 3.1 Output current derating The series shuld be cnductin-cled. Fig. 3.1 and Fig. 3.2 shw the derating curve in relatin t the temperature f the aluminum base plate. Nte that peratin within the shaded area will cause a significant level f ripple and ripple nise. Please measure the temperature f the aluminum base plate at the center. Please measure the temperature n the aluminum base plate edge side when yu cannt measure the temperature f the center part f the aluminum base plate. In this case, please take 5deg temperature margin frm the derating characteristics shwn in Fig. 3.1 and Fig Attentin shuld be paid t thermal fatigue life due t temperature fluctuatins by self-heating. Make the range f temperature fluctuatins as narrw as pssible if temperature ften fluctuates. Fig. 3.1 TUNS3F Output current derating ] % [ r t c a f d a L Aluminum base plate temperature Tc [ ] Fig. 3.2 TUNS5F Output current derating ] % [ r t c a f d a L (75) 5 1TUNS5F12 2TUNS5F28 TUNS5F (75) 8(85) 1 Tc Measuring pint Aluminum base plate temperature Tc [ ] Base plate A-8

11 Pin Operatin cnfiguratin Under Lw Temperature Cnditins 4.1 ipple vltage f bst vltage At lw temperature, ripple vltage f bst vltage increases due t Cbc freezes. Select a capacitr f which ripple vltage f bst vltage des nt exceed 3Vp-p n an actual perating cnditin. And check the maximum allwable ripple current f the capacitr. Fig. 4.1 shws the relatinship between ripple vltage f bst vltage and temperature(vin=ac85v). Fig.4.1 TUNS5F elatinship between ripple vltage f bst vltage and temperature (Vin=AC85V) 9 8 ] [ V 7 C B 6 f e 5 g a l t 4 v l e 3 p i 2 Cbc=39uF Output current [%] 9 8 ] 7 [ V C B 6 f e 5 g a lt 4 v le 3 p i 2 1 Cbc=78uF Output current [%] 9 8 ] 7 [ V C 6 B f e 5 g a l t 4 v l e 3 p i 2 1 Cbc=1,56uF Output current [%] A-9

12 Pin Hldup cnfiguratin Time 5.1 Hldup time Hldup time is determined by the capacitance f Cbc. Fig. 5.1 and Fig. 5.2 shw the relatinship between hldup time and lad within the allwable capacitance f Cbc. Fig. 5.1 TUNS3F elatinship between hldup time and Cbc ] s [m e t im p u ld H 1 1 Cbc=39uF Cbc=47uF Cbc=1,56uF Cbc=2,2uF Output current [%] Fig. 5.2 TUNS5F elatinship between hldup time and Cbc s ] [m e t im p u ld H 1 1 Cbc=39uF Cbc=78uF Cbc=1,56uF Cbc=2,2uF Output current [%] A-1

13 Pin Bard cnfiguratin layut 6.1 Cnsideratin fr bard layut The ptential vltage f each terminal is given belw. External cmpnents that are cnnected t these terminals shuld be at same ptential vltage. Primary (input side) Secndary (utput side) FG (base plate) : AC, BC, pin : VOUT, S, TM, IOG pin : Nut (4 places), Aluminum base plate, Heat sink In rder t meet the breakdwn vltage specificatin f prducts, insulatin distance between cmpnents and between patterns is recmmended t ensure the fllwing. Primary - Secndary Primary -FG Secndary - FG Primary interphase Wiring f AC pin - BC pin : 5mm r mre : 5mm r mre : 1.6mm r mre : 3mm r mre : 3mm r mre Clearance and creepage requirements vary based n different safety standards and cnditins f usage. Please place the cmpnents and wiring pattern accrding t thse safety standards. Fig.6.1 Insulatin distance Aluminum base plate:fg AC1 AC2 -VOUT +VOUT -S +S TM IOG +BC -BC 4-FG Bttm view A-11

14 When installing the electrlytic capacitr and the pwer supply n the same surface f the printed circuit bard, please pay attentin t the distance between the base plate and electrlytic capacitr. Exterir f the electrlytic capacitr is assumed t be the same ptential as the negative electrde. High-frequency nise radiates directly frm the unit t the atmsphere. Therefre, design the shield pattern n the printed circuit bard and cnnect t FG. The shield pattern prevents nise radiatin. Fig. 6.2 Same Surface Munt Peripheral cmpnents Aluminum base plate, Heatsink:FG Electrlytic capacitr There are ntes fr printed circuit bard design at recmmended circuit in this applicatins manual. Please see belw. Fig. 6.3 ecmmended external circuit Heatsink AC INPUT F11 SK11 CX1 L11 CX2 L12 1 C11 AC1 +S +VOUT + C C4 Lad AC2 -VOUT CY3 SK21 SK22 FG +BC -S -BC Nise CY2 SA11 C3 TF1 + Cbc C2 CY1 Filter 1 Input fuse : F11 6 Y Capacitrs : CY1 2 Nise filters 7 Output capacitrs Line filter : L11 L12 Electrlytic capacitr : C Interphase capacitr : CX1 CX2 Ceramic capacitr : C4 Y capacitr : CY2 CY3 8 FG terminals 3 Input capacitr : C11 9 Surge Suppressin 4 Inrush current limiting resistr : TF1 Varistr : SK11 SK21 SK22 5 Capacitr fr bst vltage Surge absrber : SA11 Electrlytic capacitr : Cbc 1 Discharging resistr : 1 Film Capacitrs : C2 C3 A-12

15 1 Input fuse : F11 When the fuse is blwn ut, input vltage wuld be applied between the terminals f the fuse F11. Please keep the distance f the pattern between the terminals f the fuse mre than 2.5mm if yu must be cmplied safety apprvals. 2 Nise filter Nise filter is build by Line filters (L11, L12), X capacitr (CX1, CX2) and Y capacitr (CY2,CY3). And the Nise filter is used t reduce cnductin nise frm pwer supply. Off-the-shelf Nise filter is als available. If the Line filter is placed near the cmpnents which is switching at high frequency, the cnductin nise may be increased because the nise ges int the Line filter. Therefre, the Line filter shuld be shielded r keep the distance frm the surce f nise. C11 Pwer supply LF Pwer supply LF Input Output Input Output CX C11 CX Nt gd Gd The effect f nise reductin by Y capacitr depends n the place f the FG cnnectin. ecmmend cnnecting Y capacitr t the FG terminal f the pwer supply as clse as pssible. Please evaluate befre use. 3 Input capacitr : C11 Huge ripple current flws int the X capacitr C11. Place the X capacitr near the pwer supply as clse as pssible. 4 Inrush current limiting resistr : TF1 Inrush current will flw thrugh the Cbc TF1 frm the pin. Please have a pattern width that is nt damaged by the inrush current. 5 Capacitr fr bst vltage : Cbc,C2 pin cnnected capacitr : C3 The high vltage(apprx. 38VDC) is applied between +BC, and -BC terminals. The distance between +BC, and -BC terminals must be 3mm r mre. Huge ripple current flws int the capacitr C2. Place C2 near the pwer supply as clse as pssible. 6 Y Capacitrs : CY1 CY1 shuld be cnnected t the FG terminal f the pwer supply as clse as pssible. A-13

16 7 Output capacitrs : C, C4 Cnnecting the utput capacitr (C,C4) t the pwer mdule as clse as pssible fr stable peratin and radiatin nise reductin. The utput line impedence culd cause unstable utput vltage, which can be reduced by adding the utput capacitr clse t the lad. When the utput ripple and ripple nise must be reduced, ceramic capacitr C4 which has gd characteristics at high frequency shuld be used. If thrugh-hle type ceramic capacitr is used, the effect f the nise reductin wuld be reduced by the impedance f the lead frame f the cmpnents. Please evaluate befre using. 8 FG terminals f the pwer supply Cnnect the FG terminal f the pwer supply t the PWB by screw. If the FG terminals f the pwer supply is nt cnnected prperly, malfunctin r failure culd happen. Expse the slder mask arund the hle f the FG cnnectin n the PWB t cnnect FG terminals by screws. 9 Surge Suppressin : SK11,SK21,SK22, and SA11 In islatin test, test vltage is applied t the SA11. When the test vltage beynd the specificatin f the SA11 is applied, please remve the SA11 during the test, r lwer the test vltage. Nte. When cnducting islatin test between the primary and the secndary, high vltage is applied t SA11,SK11,SK21, and SK22, by the partial pressure f the Y capacitr. 1 Discharging resistr : 1 Please keep distance between electrdes, when using multiple resistrs fr 1 due t lss variance. In the case f apparatus fr btaining safety standards, please keep insulatin distance required by the standard. esistance PWB Pattern A-14

4(b) Example f the pattern and cmpnents layut

17 6.2 eference PCB layut Fig. 6.4 Example f the pattern layut (Tp view) Fig.6.4(a) Example f the pattern and cmpnents layut (Tp layer) Fig.6.4(b) Example f the pattern and cmpnents layut (Bttm layer) Primary (Input Line) Primary (BC Line) FG Secndary Fig.6.4(c) Parts vltage distributin A-15

18 evisin histry N. date page cntent A-16

1. Transformer A transformer is used to obtain the approximate output voltage of the power supply. The output of the transformer is still AC.

1. Transformer A transformer is used to obtain the approximate output voltage of the power supply. The output of the transformer is still AC. PHYSIS 536 Experiment 4: D Pwer Supply I. Intrductin The prcess f changing A t D is investigated in this experiment. An integrated circuit regulatr makes it easy t cnstruct a high-perfrmance vltage surce