Cosel TUHS3F, TUHS5F, TUHS10F, TUHS15F, TUHS25F Instruction Manual

Basic Characteristics Data

Switching

Model Circuit method

TUHS3F

TUHS5F

TUHS10F

TUHS15F

TUHS25F

*1 Refer to Specification.

Ref

*2

The v

*3

Flyback converter 80-250 *3

er to instruction manual.

alue changes depending on input and load.

frequency

[kHz]

Input

current

[A]

*

Inrush

current

protection

circuit

PCB/Pattern

Material

Single

sided

Double

sided

1 Resistor glass fabric base,epoxy resin Yes Yes

1 Thermistor glass fabric base,epoxy resin Yes Yes

Series/Parallel

operation availability

Series

operation

Parallel

*

2

TUHS-12

AC-DC Power Supplies PCB Mount Type

Instruction Manual

1 Pin Connection

2 Connection for Standard Use

3 Wiring Input/Output Pin

3.1 Wiring input pin

3.2 Wiring output pin

4 Function

4.1 Input voltage range

4.2 Overcurrent protection

4.3 Overvoltage protection

4.4 Isolation

4.5 Reducing standby power

5 Series and Parallel Operation

TUHS-14

TUHS-15

TUHS-16

TUHS-17

5.1 Series operation

5.2 Parallel operation

5.3 Various connection methods

5.4 Long hold-up time connection

6 Implementation-Mounting Method

6.1 Mounting method

6.2 Stress onto the pins

6.3 Cleaning

6.4 Soldering

7 Derating

7.1 TUHS3 Derating Curve

7.2 TUHS5 Derating Curve

7.3 TUHS10 Derating Curve

7.4 TUHS15 Derating Curve

7.5 TUHS25 Derating Curve

TUHS-17

TUHS-18

TUHS-19

TUHS-20

TUHS-13

AC-DC Power Supplies PCB Mount Type

Instruction Manual

1 Pin Connection

¿

TUHS3/TUHS5

AC2

AC1

+BC -BC

¿

TUHS10/TUHS15

AC2 2

AC1 1

+ BC 34

¿

TUHS25

AC2 2

AC1 1

Bottom View

-

BC

Bottom View

-Vout

+Vout

6

-

Vout

5 + Vout

6

-

5 + Vout

Vout

2

Connection for Standard Use

To use TUHS series, connection shown in Fig.2.1 (a) or (b) and

¡

external components are required.

¿

AC input or DC input

F1 R1

C1(TUHS25)

Fig.2.1(a) Connection for standard use (AC input or DC input)

No.

Symbol

1 F1 Input fuse

2 C1 Input Capacitor

3 Cbc Smoothing Capacitor

4 R1

5 SK1 Surge Protective Device

¿

DC input

Inrush current protection resistor 3.1 “Wiring input pin (4)”

AC1

SK1

AC2

+BC

-

BC

+

Cbc

Table 2.1 External components

Components Reference

+Vout

-

Vout

3.1 “Wiring input pin (1)”

3.1 “Wiring input pin (2)”

3.1 “Wiring input pin (3)”

3.1 “Wiring input pin (5)”

Load

-

+ BC 34

Fig.1.1 Pin connection (bottom view)

Table 1.1 Pin connection and function

No.

1 2 3 4 5 6

Connection

AC1 AC2 +BC +BC output

-BC -BC output

+VOUT +DC output

-VOUT -DC output

BC

AC input

Function

AC1

AC2

+BC

-

F1 D1

R1

Cbc

Fig.2.1(b) Connection for standard use (DC input)

BC

+

+Vout

-

Vout

Load

TUHS-14

AC-DC Power Supplies PCB Mount Type

Instruction Manual

3

Wiring Input/Output Pin

3.1 Wiring input pin

(1) F1:External fuse

Fuse is not built-in on input side. In order to protect the unit, install

¡

the slow-blow type fuse on input side (as shown in Table 3.1).

In the case of using DC input, please use a DC fuse.

Table 3.1(a) Recommended fuse (AC input)

Model TUHS3 TUHS5 TUHS10 TUHS15 TUHS25

Rated current 2A 2A 2A 2A 3.15A

Table 3.1(b) Recommended fuse (DC input)

Model TUHS3 TUHS5 TUHS10 TUHS15 TUHS25

Rated current 2A 2A 2A 2A 2A

(2) C1:Input Capacitor(TUHS25)

To comply with conducted noise CISPR22-B, EN55022-B, connect

capacitor C1 which is 0.1μF or more at AC input terminal.

(3) Cbc:Smoothing capacitor

In order to smooth voltage, connect Cbc between +BC and -BC.

¡

Recommended capacitance of Cbc is shown in Table3.2.Hold-up

time and load factor is shown in gure 3.1-gure 3.10.

Keep the capacitance within the allowable external capacitance.

¡

Select a capacitor of which the ripple voltage does not exceed

¡

25Vp-p.

When the power supply is operated under -20degC, it may cause

¡

the smoothing voltage unstable due to the characteristic of equiva-

lent series resistor. Please choose the capacitor which has more

than recommended capacitance.

Table 3.2 Input Capacitor C1

No. Model

1 TUHS3

2 TUHS5 22μF 10μF to 68μF

3 TUHS10 47μF 22μF to 150μF

4 TUHS15 68μF 33μF to 220μF

5 TUHS25 120μF 47μF to 390μF

300

F

250

200

F

150

F

100

Hold-up time[ms]

50

4. F

0

020406080100

Rated Input

Voltge

DC400V or more

(AC200Vin)

DC200V or more

(AC100Vin)

load factor[%]load factor[%]

Fig.3.1 TUHS3 hold-up time(AC100V) Fig.3.2 TUHS3 hold-up time(AC200V)

Allowable capacitance

Cbc

range

18μF 4.7μF to 68μF

1600

F

1400

1200

1000

F

800

600

Hold-up time[ms]

F

400

200

4. F

0

020406080100

300

250

200

150

100

Hold-up time[ms]

50

0

020406080100

load factor[%]load factor[%]

1600

1400

1200

1000

800

600

Hold-up time[ms]

400

200

0

020406080100

Fig.3.3 TUHS5 hold-up time(AC100V) Fig.3.4 TUHS5 hold-up time(AC200V)

300

250

200

150

100

Hold-up time[ms]

50

0

020406080100

load factor[%]load factor[%]

1600

1400

1200

1000

800

600

Hold-up time[ms]

400

200

0

020406080100

Fig.3.5 TUHS10 hold-up time(AC100V) Fig.3.6 TUHS10 hold-up time(AC200V)

300

150

250

200

68

150

100

Hold-up time[ms]

50

0

020406080100

load factor[% l] oad factor[%]

1600

1400

1200

150

1000

800

68

600

Hold-up time[ms]

47

400

33

200

0

020406080100

Fig.3.7 TUHS15 hold-up time(AC100V) Fig.3.8 TUHS15 hold-up time(AC200V)

300

250

200

150

100

Hold-up time[ms]

50

0

020406080100

load factor[%]load factor[%]

1600

1400

1200

1000

800

600

Hold-up time[ms]

400

200

0

020406080100

Fig.3.9 TUHS25 hold-up time(AC100V) Fig.3.10 TUHS25 hold-up time(AC200V)

(4) R1: Inrush current limiting resistor

Connect resistor R1 between AC input and power supply to limit

¡

inrush current to 50A(TUHS3/5/10/15) and 60A(TUHS25).

Select a resistor which has enough permissible current capability.

The power thermistors are heat-generating components. Pay

¡

attention to the rated operating temperature when using the power

thermistors.

When the power turns ON/OFF repeatedly within a short term,

¡

please keep enough interval to cool down the power supply before

turning it on again.

In this case, recommend using thermistor with thermal resistor in

¡

parallel or inrush current limiting circuit by triac.

(5) SK1: Surge Protective Device

Connect a surge protective device to improve Surge immunity.

¡

TUHS-15

AC-DC Power Supplies PCB Mount Type

Instruction Manual

(6) D1: Reverse Input Voltage Protection(DC input)

Avoid the reverse polarity input voltage. It cause the power supply

¡

failure. It is possible to protect the unit from the reverse input volt-

age by installing an external diode.

+Vout

Load

-

BC

Vout

-

F1 D1

R1

AC1

AC2 +BC

+

Cbc

Fig.3.11 Reverse input voltage protection

3.2 Wiring output pin

(1) Co:Output capacitor

In the TUHS series, the output capacitor is basically unnecessary.

¡

Reduce the ripple voltage by connecting the output capacitor.

+Vout

Co

Load

-

Vout

The specied ripple and ripple noise are measured by the method

¡

introduced in Fig.3.13.

Co

Measuring board

F

Load

F1 R1

SK1

C1(TUHS25)

AC1

AC2 +BC

Cbc

-

BC

+

Oscilloscope

BW:100MHz

+Vout

-

Vout

50mm

Coaxial Cable

R

C

Fig.3.13 Method of Measuring Output Ripple and Ripple noise

When connect the output to FG of an equipment, a noise may be-

¡

come big. The noise can be reduced by connecting external lter

and grounding capacitor on the input side.

F1L1R1

C1

AC1

SK1

AC2 +BC

C11 C12

Cbc

+Vout

-

Vout

-

BC

+

C13

Load

Fig.3.12 Connecting Example of an External

Capacitor to the Output Side

Install an external capacitor Co between +VOUT and -VOUT pins

¡

for stable operation of the power supply.

Recommended capacitance of Co is shown in Table 3.3.

If output current decreases rapidly, output voltage rises transiently

¡

and the overvoltage protection circuit may operate.

In this case, please install a capacitor Co.

Table 3.3 Recomemended capacitance Co

output

No.

voltage 1 5V 2 12V 0 - 47μF 0 - 47μF 3 15V 0 - 47μF 0 - 47μF 0 - 120μF 0 - 120μF 4 24V 0 - 22μF 0 - 22μF 0 - 68μF 0 - 68μF

TUHS3 TUHS5 TUHS10 TUHS15 TUHS25

0 - 100μF 0 - 100μF 0 - 330μF

-

0 - 1000μF

0 - 150μF 0 - 150μF 0 - 470μF

0 - 390μF 0 - 220μF

Fig.3.14 Recomemended circuit of connect output to FG

4 Function

4.1 Input voltage range

The range is from AC85V to AC264V or DC120V to DC370V

¡

(please see SPECIFICATIONS for details).

In case of less than AC85V or DC120V, it is possible to operate

¡

continuously by input voltage derating as shown Fig.4.1.

In cases that conform with safety standard, input voltage range is

¡

AC100-AC240V (50/60Hz) and DC120-DC370V.

100

50

Load[%]

AC50V DC70V

AC85V DC120V

(a)TUHS3 (b)

Fig.4.1 Input voltage derating

100

Load[%]

40

Vi Vnin

AC50V DC70V

TUHS5,TUHS10,TUHS15,TUHS25

AC85V DC120V

TUHS-16

AC-DC Power Supplies PCB Mount Type

4.2 Overcurrent protection

Overcurrent protection is built-in and comes into effect at over

¡

105% of the rated current.

Overcurrent protection prevents the unit from short circuit and

overcurrent condition. The unit automatically recovers when the

fault condition is cleared.

When the output voltage drops at overcurrent, the average output

¡

current is reduced by intermittent operation of power supply.

4.3 Overvoltage protection

The overvoltage protection circuit is built-in and comes into effect

¡

at 110% to 160% of the rated output voltage. When the load fac-

tor is less than 30%, output voltage may be increased more than

maximum voltage depending on the failure mode.

Please note that devices inside the power supply might fail when

¡

voltage more than rated output voltage is applied to output pin of

the power supply. This could happen when the customer tests the

overvoltage performance of the unit.

4.4 Isolation

For a receiving inspection, such as Hi-Pot test, increase (de-

¡

crease) the voltage gradually for a start (shut down). Avoid using

Hi-Pot tester with timer because it may generate voltage a few

times higher than the applied voltage, at ON/OFF of a timer.

Instruction Manual

5 Series and Parallel

Operation

5.1 Series operation

Series operation is available by connecting the outputs of two or

¡

more power supplies as shown below. Output current in series

connection should be lower than the lowest rated current in each

unit.

(a)

Power Supply

(b)

Power Supply

Fig.5.1 Examples of series operation

Load

4.5 Reducing standby power

¡A circuit reducing standby power is built in TUHS. (standby power of AC100V input : 0.5W max)

The load factor: Io=0-30%, the internal switch element is intermit-

tent operated, and the switching loss is decreased. The speci-

fication of the Ripple/Ripple Noise changes by this intermittent

operation. The value of the ripple/ripple Noise when intermittent

operates changes in the input voltage and the output current.

Please contact us for details.

5.2 Parallel operation

Parallel operation is not possible.

¡

Redundancy operation is available by wiring as shown below.

¡

I

1 I3

Power Supply

2

I

Power Supply

Fig.5.2 Example of Redundancy Operation

Even a slight difference in output voltage can affect the balance

¡

1

between the values of I

Please make sure that the value of I

current of a power supply.

and I2.

3

does not exceed the rated

3

the rated current value

I

Load

TUHS-17

AC-DC Power Supplies PCB Mount Type

5.3 Various connection methods

Using one smoothing capacitor, up to two TUHS can be operated.

¡

Shown an example in Fig.5.3.

Total output wattage must be less than the maximum wattage of

¡

TUHS which AC is supplied.

When connect different wattage of TUHS, please input AC into the

¡

power supply which the wattage is higher.

When smoothing capacitor is commonly used, noise may become

¡

big because of the length of the power line. The noise can be

attenuate by connecting Line Filter between TUHS and R1.

Avoid connecting AC input and DC input at the same time because

¡

it may damage the TUHS or an equipment(Fig.5.4).

+BC

+Vout

Vout

-

BC

-

+Vout

-

Vout

-

BC

+

Load

R1

F1

SK1

C1(TUHS25)

Cbc

+BC

AC1

AC2

AC1

AC2

+BC

+Vout

Vout

-

BC

-

+Vout

Vout

-

-BC

+

Load

F1 D1

AC1

AC2

+BC

Cbc

AC1

AC2

(a) AC input , Cbc common (b) DC input , Cbc common

Fig.5.3 TUHS connect method

Instruction Manual

6 Implementation

.

-

Mounting Method

6.1 Mounting method

The unit can be mounted in any direction. When two or more pow-

¡

er supplies are used side by side, position them with proper inter-

vals to allow enough air ventilation. The temperature around each

power supply should not exceed the temperature range shown in

derating curve.

Avoid placing the AC input line pattern layout underneath the unit.

¡

It will increase the line conducted noise. Make sure to leave an

ample distance between the line pattern layout and the unit. Also

avoid placing the DC output line pattern underneath the unit be-

cause it may increase the output noise. Lay out the pattern away

from the unit.

Avoid placing the signal line pattern layout underneath the unit

¡

because the power supply might become unstable. Lay out the

pattern away from the unit.

6.2 Stress to the pins

F1 R1

SK1

AC1

AC2

Cbc

+BC

-

+

BC

+Vout

-

Vout

Load

Fig.5.4 TUHS Connection prohibition

5.4 Long hold-up time connection

It is possible that setting the hold-up time of the power supply for a

¡

long time by connecting like Fig.5.5. Please set the charge current

of the CL to become less than 1A. Please use the diode which

reverse voltage is 600V or more.Please contact us for detail.

F1 R1

C1(TUHS25)

+

CL

AC1

SK1

AC2

RL

DL

Cbc

+BC

-

+

BC

+Vout

-

Vout

Load

Applying excessive stress to the input or output pins of the power

¡

module may damage internal connections. Avoid applying stress

in excess of that shown in Fig. 6.1.

Input/output pin are soldered to the PCB internally. Do not pull or

¡

bend a lead powerfully.

If it is expected that stress is applied to the input/output pin due

¡

to vibration or impact, reduce the stress to the pin by taking such

measures as xing the unit to the PCB by silicone rubber, etc.

Less than

19.6N(2kgf)

Less than

19.6N(2kgf)

Less than

19.6N(2kgf)

Fig. 6.1 Stress to the pins

6.3 Cleaning

If you need to clean the unit, please clean it under the following

¡

conditions. Cleaning Method: Varnishing, Ultrasonic or Vapor

Cleaning Cleaning agent: IPA (Solvent type)

Cleaning Time: Within total 2 minutes for varnishing, ultrasonic

and vapor cleaning

Please dry the unit sufciently after cleaning.

¡

If you do ultrasonic cleaning, please keep the ultrasonic output at

¡

or below.

15W/

TUHS-18

Fig.5.5 Long hold-up time connection

6.4 Soldering

Flow soldering: 260C for up to 15 seconds.

¡

Soldering iron (26W): 450C for up to 5 seconds.

¡

100

Ambient temperature[C]

Load factor[%]

100

Ambient temperature[C]

Load factor[%]

100

Ambient temperature[C]

Load factor[%]

100

Ambient temperature[C]

AC-DC Power Supplies PCB Mount Type

7 Derating

It is necessary to note thermal fatigue life by power cycle.

¡

Please reduce the temperature uctuation range as much as pos-

sible when the up and down of temperature are frequently gener-

ated.

Please have sufcient ventilation to keep the temperature of point

¡

A in Fig.7.1 at Table7.1 or below. Please also make sure that the

ambient temperature does not exceed 85C.

Point A (Center of the Case)

Instruction Manual

7.2 Derating curve(TUHS5)

Derating curve is shown below. Note: In the hatched area, the

¡

specication of Ripple, Ripple Noise is different from other area.

80

75

60

40

Convection(0.2m/s) 1TUHS5F05,TUHS5F12,TUHS5F15

20

2TUHS5F24

0

0 20

40-40 -20 60 80

Fig.7.3 Ambient temperature Derating curve(convection cooling)

80

60

8575

Fig.7.1 Temperature Measuring Point on the case (Top View)

Table 7.1 Point A Temperature

Model

Output Voltage

TUHS3 TUHS5 TUHS10 TUHS15 TUHS25

ALL ALL ALL

12V, 24V

15V ALL

Point A 105C105C105C100C95C100

7.1 Derating curve(TUHS3)

Derating curve is shown below. Note: In the hatched area, the

¡

specication of Ripple, Ripple Noise is different from other area.

100

80

60

40

Load factor[%]

20

Convection (0.2m/s),Forced air (2.0m/s)

0

020100

Ambient temperature[C]

40-40-20 60 80

85

40

Forced air(2.0m/s)

20

0

0 20

40-40 -20 60 80

85

Fig.7.4 Ambient temperature Derating curve(Forced air)

C

7.3 Derating curve(TUHS10)

Derating curve is shown below. Note: In the hatched area, the

¡

specication of Ripple, Ripple Noise is different from other area.

80

60

40

Convection(0.2m/s) 1TUHS10F05,TUHS10F15

20

2TUHS10F12,TUHS10F24

0

0 20

55

40-40 -20 60 80

Fig.7.5 Ambient temperature Derating curve(convection cooling)

85

Fig.7.2 Ambient temperature Derating curve(TUHS3)

80

60

40

Forced air(2.0m/s) 1TUHS10F05,TUHS10F15

20

2TUHS10F12,TUHS10F24

0

0 20

40-40 -20 60 80

75 85

Fig.7.6 Ambient temperature Derating curve(Forced air)

TUHS-19

Load factor[%]

100

0

Ambient temperature[C]

Load factor[%]

100

0

Ambient temperature[C]

Load factor[%]

100

0

Ambient temperature[C]

Load factor[%]

100

0

Ambient temperature[C]

AC-DC Power Supplies PCB Mount Type

Instruction Manual

7.4 Derating curve(TUHS15)

Derating curve is shown below. Note: In the hatched area, the

¡

specication of Ripple, Ripple Noise is different from other area.

80

60

Convection(0.2m/s)

40

1TUHS15F12 2TUHS15F15

20

3TUHS15F24

0

0 2 100

45

40-40 -20 60 80

Fig.7.7 Ambient temperature Derating curve(convection cooling)

80

60

40

Forced air(2.0m/s) 1TUHS15F12,TUHS15F15

20

2TUHS15F24

0

0 2 100

40-40 -20 60 80

1

2

3

85

75 85

Application manuals available at our website.

Recommended external components are also introduced for your

reference.

Fig.7.8 Ambient temperature Derating curve(Forced air)

7.5 Derating curve(TUHS25)

Derating curve is shown below. Note: In the hatched area, the

¡

specication of Ripple, Ripple Noise is different from other area.

80

60

Convection(0.2m/s)

40

1TUHS25F05 2TUHS25F12,TUHS25F24

20

3TUHS25F15

0

0 2 100

Fig.7.9 Ambient temperature Derating curve(convection cooling)

80

75

60

40

Forced air(2.0m/s) 1TUHS25F05,TUHS25F15

20

2TUHS25F12,TUHS25F24

0

0 2 10 0

Fig.7.10 Ambient temperature Derating curve(Forced air)

TUHS-20

3

40-40 -20 60 80

2

1

85

75 85

Cosel TUHS3F, TUHS5F, TUHS10F, TUHS15F, TUHS25F Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Basic Characteristics Data

Instruction Manual