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PFH500F-28-xxx Series
BEFORE USING THE POWER SUPPLY UNIT
Be sure to read and understand 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. There are risks of igniting these
substances and exploding by an arcing
WARNING
 Do not touch this product or its internal components while circuit is live, or shortly after shut down. There may be
high voltage or high temperature present and you may receive an electric shock or burn.
 While this product is operating, keep your hands and face away from it as you may be injured by an unexpected situation.
 Do not make unauthorized changes to this product, otherwise you may receive an electric shock and void your warranty.
 Do not drop or insert anything into the product. It might lead to a failure, fire and electric shock.
 Do not use this product under unusual conditions such as emission of smoke and/or abnormal smell or audible noise, etc.
It might lead to fire and/or electric shock. In such cases, please contact TDK Lambda. Do not attempt repair by yourself, as it
is dangerous for the user.
 Do not operate these products in the presence of condensation. It might lead to fire and electric shock.
CAUTION
 This power supply is designed and manufactured for use within an end product such that it is accessible only to trained
SERVICE ENGINEERS.
 Confirm that the connections to input/output terminals, and signal terminals are correct as specified in this instruction manual
before turning on the power.
 Input voltage, Output current, Output power, ambient temperature, case temperature, and ambient humidity should be kept
within the specifications, otherwise the product may be damaged.
 Do not operate and store this product in an environment where condensation might occur. In such case, waterproof treatment
is necessary.
 The equipment has been evaluated for use in a Pollution Degree 2 environment.
 Do not use this product in environment with a strong electromagnetic field, corrosive gas or conductive substances.
 For applications, which require very high reliability, such as nuclear related equipment, medical equipment, traffic control
equipment, etc., it is necessary to provide a fail-safe mechanism in the end equipment.
 Do not inject abnormal voltages into the output terminal or signal terminal of this product. The injection of reverse voltage or
over voltage exceeding nominal output voltage into the output terminal or signal terminal might cause damage to internal
components.
 Never operate the product under the over-current or short circuit conditions. The failure or other damages may occur.
 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 240W or more). It must not be made accessible to users. Protection must be provided for Service Engineers
against indirect contact with the output terminals and/or to prevent tools being dropped across them. While working on this
product, the AC input power must be switched off, and the input, output, +VBus, and -VBus terminal voltages should be at
safe level.
 The application circuits and their parameters are for reference only. Be sure to verify effectiveness of these circuits and their
parameters before finalizing the circuit design.
 Use a Fast-Blow external fuse to each module to ensure safe operation and compliance with the safety standards to which it is
approved. The recommended input fuse rating within the instructions is as follows: 10A, 250V fast acting fuse. The breaking
capacity and voltage rating of this fuse may be subject to the end use application.
0
Instruction Manual
.
Rev. 2.0
June 11, 2018

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Summary of Contents for TDK-Lambda PFH500F-28 series

  • Page 1 PFH500F-28-xxx Series Instruction Manual BEFORE USING THE POWER SUPPLY UNIT Be sure to read and understand 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.
  • Page 2  This information in this document is subject to change without prior notice. Please refer to the latest version of the data sheet, etc., for the most up-to date specifications of the product.  No part of this document may be copied or reproduced in any form without prior written consent TDK-Lambda. Rev. 2.0...
  • Page 3 1. Model name identification scheme: PFH 500X – YZ – UVW – R ROHS Option Code Rated Output Voltage Feature Set (Full or Simple) Output Power type Series Name 1-1. Ordering Table: Pin Length Parallel Operation Module Output Case (Latch) (Non-Latch) (Non-Latch) (0.240”)
  • Page 4: Table Of Contents

    2. Module Pinout: FUNCTION FUNCTION AC Input (Line) Secondary Signal GND AC Input (Neutral) Aux Power Supply Vout (-) PMBus Clock Vout (-) PMBus Data ON/OFF PMBus Alert Trim PMBus Address 2 Remote Sense (+) PMBus Address 1 Vout (+) Inrush Control Vout (+) - Boost Voltage Bus (-VBUS)
  • Page 5: On/Off

    3. Circuit Block Diagram PFC Circuit DC-DC Circuit Vbus DC-DC Inrush Bridgeless Synchro. Fuse Bridge Circuit PFC Conv. Rectifiers Converter Relay Ipeak Vin Detect Sense DC-DC Vo_sns UVP/OVP Digital Digital Controller Controller ON/OFF Digital (OVP/UVP) Trim Iin Detect Isolators OCP1 Vbus OTP1 OVP1...
  • Page 6 Sequence Timing Diagram Note: PFH series product has a remote ON/OFF pin that is referenced to output return. Rev. 2.0 June 11, 2018...
  • Page 7 5. Terminal connecting method In order to use the PFH500 series, this module must be connected with external components according to Figure 5-1. Pay attention to the wiring details. If PFH module is connected to wrong terminal(s), the power module will be damaged.
  • Page 8 F1 : External Input Fuse PFH500 series module has no internal fuse. Use external fuse to meet Safety Agency requirement. PFH500 series modules were tested for safety agency certifications (UL, cUL, VDE, etc.) using 10A, 250Vac, Fast-Acting line fuse. Furthermore, the Fast-Acting type fuse selected must be used with one fuse per each module.
  • Page 9 L1 and L2 : 6.3mH (Common Mode Choke) Add common mode chokes as EMI noise countermeasure to protect the EMI noise generated by PFH500 series module flowing into the ac mains. When using multiple PFH500 series modules in parallel, it is important to insert the EMI filter stages (including X caps, Y caps, and common mode chokes) for each PFH500 module.
  • Page 10 Notes: 1. Do not connect capacitors with more than the above capacitance value as this could lead to PFH Series power module damage. Consult TDK Lambda for higher bulk capacitance requirement. 2. When using module below -20℃ ambient temperature, AC ripple of boost voltage, output ripple voltage might be affected by ESR characteristics of the bulk capacitors.
  • Page 11 2. For module operation at ambient temperature below -20 ºC, the output ripple voltage will be affected by ESR characteristics of the electrolytic capacitors. Increase the recommended capacitance values as shown in table below. Table 5-2 Recommended external output capacitance (when Ambient Temperature ≦ -20 ºC) Module Output Voltage 470 µF, 50V 470 µF, 50V...
  • Page 12 Note that reduction of the bulk capacitance affects the module output hold-up time, dynamic line transient response, and dynamic load transient response characteristics. It is recommended that the verification test is performed for the entire operating temperature range. R2: 20Ω - 30Ω By inserting a thermal fuse inrush resistor between the line filter and the input terminal, AC(L) as shown in Fig.
  • Page 13 70V, the internal bias circuitry starts to work. After a short delay, the PFC controller starts to enable the PFC converter, which charges the bulk capacitor bank to the regulated voltage level about 385V. The value of the thermal resistor, R2, limits the PFC converter ramp –up time, especially at low line case. RL: Inrush Relay, 10A/277Vac (16A/125Vac), 12V coil The inrush relay is connected in parallel with R2 resistor.
  • Page 14: Trim

           (Formula 5-4)    trim Vref %=100(Vo,nom - Vdesired) / Vo_nom Vref=1.22V 50000 5000 10 12 14 16 18 20 % Increase in Output Voltage, D(%) Figure 6-1 Trim-up Resistance vs. Percentage Voltage Trim-up The trim-up resistor (Rt_up) values from +5% to +20%, can be found in Table 6-1.
  • Page 15 PMBus Interface RS (+) Vo(+) AC(L) Vo(+) Vout Load Vo(-) AC(N) Vo(-) PFH500F Rt_up Case Trim ON/OFF Aux Power SGND Inrush -VBUS + VBUS Control Figure 6-2 External Trim-up Circuit Connection With a resistor connected between the trim pin and Vout (-) pin, the output voltage can be adjusted down. To adjust the output voltage down a percentage of Vout (%) from Vo,nom, the trim resistor should be chosen according to the following equation (in k).
  • Page 16: Vout

    The trim-down resistor (Rt_down) values for the trim-down voltage range from -5% to -40% can be found in Table 6-2. The trim down connection diagram is shown in Figure 6-4. Table 6-2 External Trim-down Resistor Value for Various Output Voltage Adjustment % Trim-down Trim-down Measured...
  • Page 17 6-4. Output Over-Voltage Protection (OVP) PFH series module is equipped with OVP protection function. The OVP function activates when Vo > the pre-set OVP trip set-point. When the OVP triggers, the module output will be shut down either with latch or auto-recovery depending on the option code specified.
  • Page 18 6-7. Module Over-Temperature Protection (OTP) PFH series module is equipped with internal OTP protection function. There are four (4) OTP protection devices located at various key locations of the potted module. There are two (2) NTC thermistors, one located on the hot spot of the PFC converter side, and another on the hot spot of the DC-DC converter side.
  • Page 19: Vout

    Voltage Stable at Module Output Terminals PMBus Interface RS (+) Vo(+) AC(L) Vo(+) Vout Load Vo(-) AC(N) Vo(-) PFH500F Case Trim ON/OFF Aux Power SGND Inrush -VBUS + VBUS Control Fig.6-6 Remote Sensing is not used (Local Sensing) 6-9. ON-OFF Control (ENA Terminal) PFH series module has an ON-OFF control pin, which is used to enable (or turn on) or disable (or turn off) the module.
  • Page 20: Power Good

    PMBus Interface PMBus Interface RS (+) RS (+) Vo(+) Vo(+) AC(L) AC(L) Vo(+) Vo(+) Vout Vout Load Load Vo(-) AC(N) AC(N) Vo(-) Vo(-) Vo(-) PFH500F PFH500F Case Case Trim Trim ON/OFF ON/OFF Aux Power Aux Power SGND SGND Inrush Inrush + VBUS + VBUS -VBUS...
  • Page 21 In a two-module load share system, if Unit #2 provides the load current, Io2, is higher than what Unit #1 provides, i.e. Io2 > Io1, then the output voltage of Unit #2, Vo2, will be lower than the output voltage of Unit #1, i.e. Vo2 < Vo1.
  • Page 22 Fig.6-8b Two PFH Modules Running at 18A Load, and then One PFH Unit Shutdown 6-13. PMBus Communication The full featured PFH series module has equipped five (5) PMBus pins (Pin 13 to Pin 17), which allows the host computer to communicate with the PFH module controller to read out and/or command (or set) the module operating parameters.
  • Page 23 Fig.6-9 Output Noise or Ripple (including Spike Noise) Measurement Method 6-15. Series Operation To double the output voltage of PFH series module output, it is possible to connect two or more PFH500 series modules in series. For two modules connected in series configuration, the connection diagrams are shown in Figure 6-10a and Figure 6-10b.
  • Page 24 6-16. Isolation Resistance The isolation resistance between Output and PFH module case should be more than 100M with 500VDC applied. For safety concern, the isolation resistance test must be done first before Hipot test and/or powering on the module with ac power.
  • Page 25 PMBus Interface PMBus Interface RS (+) RS (+) Vo(+) Vo(+) Vo(+) Vo(+) Vo(-) Vo(-) Vo(-) Vo(-) Trim AC(L) AC(L) Trim PFH500F PFH500F ON/OFF ON/OFF AC(N) AC(N) Hipot Tester Aux Power Aux Power SGND SGND Case Case Inrush Inrush Hipot Tester -VBUS + VBUS Control...
  • Page 26 7. Thermal Considerations and Mounting Method 7-1. Thermal Considerations The PFH series module is designed for both convection and conduction cooling applications. This product can be mounted in any orientation, but for forced convection applications, be sure to provide adequate airflow around power supply to avoid heat accumulation.
  • Page 27 7-2. Output Current/Case Temperature Thermal Derating PFH500F-28 module is derated according to Figure 7-2. Derating varies based on AC input voltage and desired case temperature/output current. Case Temperature (C) 110VAC<Vin<170VAC 170VAC<Vin<265VAC Fig.7-2 PFH500F-28-xxx Derating Curves For the sake of the components long term reliability, it is recommended to use PFH series power module strictly according to these derating curves or derating guidelines.
  • Page 28 (1) Recommended washing solution ・IPA(Isopropyl Alcohol) (2) Washing method In order to avoid penetration inside the power module, washing should be done with brush. Then, dry up thoroughly after washing. 8. Damaged Power Module Verify following items before concluding power module damage. (1) No output voltage - Is specified input voltage applied? - During output voltage adjustment, is the fixed resistor used correct?
  • Page 29 9. Warranty Period Warranty period is 3 years or whatever is specified on the purchasing agreement. For damages occurring at normal operation (as recommended by this Instruction Manual including the derating curves) during this warranty period, repair is free of charge. Following cases are not covered by warranty (1) Improper use like dropping products, applying shock, and/or dropping/spilling fluid to the module (2) Operating the PFH series module outside the specification or not following this Instruction Manual...