Cosel TUNS300, TUNS500, TUNS700 Applications Manual

The information contained in this document has been carefully researched and is, to the best
of our knowledge, accurate. However, we assume no liability for any product failures or
damages, immediate or consequential, resulting from the use of the information provided
herein. Our products are not intended for use in systems in which failures of product could
result in personal injury. All trademarks mentioned herein are property of their respective
owners. All specifications are subject to change without notice.

Application Manual

TUNS 300/500/700

Cosel

Our company network supports you worldwide with offices in Germany, Austria,

Switzerland, Great Britain and the USA. For more information please contact:

FORTEC Elektronik AG
Hauptniederlassung
Lechwiesenstr. 9
86899 Landsberg am Lech

Telefon: [phone]
Telefax: [phone]
E-Mail: [e-mail]

Internet: www.fortecag.de

FORTEC Elektronik AG
Büro Nord
Am Hasenkamp 36
22457 Hamburg

Telefon: [phone]
Telefax: [phone]
E-Mail: [e-mail]

Internet: www.fortecag.de

FORTEC Elektronik AG
Büro West
Hohenstaufenring 55
50674 Köln

Telefon: [phone]
Telefax: [phone]
E-Mail: [e-mail]
Internet: www.fortecag.de

FORTEC Elektronik AG

Büro Wien
Nuschinggasse 12
A-1230 Wien

Telefon: [phone]
Telefax: [phone]
E-Mail: [e-mail]
Internet: www.fortec.at

ALTRAC AG
(Tochter der FORTEC):
Bahnhofstraße 3
CH-5436 Würenlos

Telefon: [phone]
Telefax: [phone]
E-Mail: [e-mail]
Internet: www.altrac.ch

Rev. 1.4E

08-Jan-2016

Applications Manual

for TUNS300/500/700

Applications Manual for TUNS300/500/700

1. Pin Assignment

Pin Assignment

2. Connection for Standard Use

Connection for standard use
Input fuse :

F11

Input capacitor :

C11

Y capacitors and noise filters :

CY,CX,L1

Output capacitors :

Co,C40

Smoothing capacitor for boost voltage :

Cbc

Capacitor for boost voltage :

C20,C30

Inrush current limiting resistor :

TFR1

Discharging resistor :

R1

3. Derating

Output current derating
Input voltage derating

4.Output voltage adjustment

Output voltage adjustment
Output voltage adjustment by potentiometer
Output voltage adjustment by external voltage

5. Parallel operation (option :-P)

Parallel operation

6. Operation under low temperature conditions

Ripple voltage of boost voltage

7. Holdup time

Holdup time

8. Mounting method

Mounting method

9.Thermal Design

Thermal Design
Examples of Convection cooling
Examples of Forced air cooling

10. Board layout

Consideration for board layout
Reference PCB layout

11. Example of

which reduces EMI

Means of the EMI reduction
Switching frequency noise reduction (200kHz)
High frequency band noise reduction (more than 10 MHz)
EMI measure example

Note：Information contained in this document is subject to change without notice for improvement.

The materials are intended as a reference design, component values and circuit examples
described in this document varies depending on operating conditions and component variations.
Please select the components and design under consideration of usage condition etc.

11.2

A-29

11.3

A-29

11.4

A-29

10.2

A-28
A-29

11.1

A-29

8.1

A-17
A-18

9.1

A-18

A-16

7.1

A-16
A-17

A-13

5.1

A-13
A-14

6.1

A-14

4.1

A-10

4.2

A-10

4.3

A-12

A-8

3.1

A-8

3.2

A-9
A-10

2.7

A-5

2.8

A-6

2.9

A-7

2.4

A-4

2.5

A-4

2.6

A-5

A-2

2.1

A-2

2.2

A-3

2.3

A-3

Contents

Page
A-1

1.1

A-1

A-18
A-20

9.2

9.3

A-24

10.1

A-24

1.1 Pin Assignment

Fig.1.1

Pin Assignment

Table 1.1

Pin configuration

and function

A-1

⑪

IOG Inverter operation monitor

- FG Mounting hole(FG)

⑨

+S Remote sensing(+)

⑩

TRM Adjustment of output voltage

⑦

-VOUT -DC output

⑧

-S Remote sensing(-)

⑤

-BC -BC output

⑥

+VOUT +DC output

③

R External resistor for inrush current protection

④

+BC +BC output

No.

Pin

Connection

Function

①

AC1

AC input

②

AC2

2.1 Pin configuration

1. Pin Assignment

Applications Manual

TUNS300/500/700

2.1 Connection for standard use

■

■

Fig.2.1

Connection for

standard use

Table 2.1

Components

name

・

Parts name are shown in Table 2.1 as reference.

・

External parts should be changed according to the ambient temperature, and
input and output conditions.
For details, refer to the selection method of individual parts.

To use the TUNS300/500/700 series, external components should be connected as shown
in Fig.2.1.

The TUNS300/500/700 series should be conduction-cooled. Use a heatsink or fan to
dissipate heat.

A-2

Heatsink

2.1 Pin configuration

2. Connecrion for Standard Use

Rating Part name Rating Part name Rating Part name

1 F11

AC250V/10A

0325010

(Littelfuse)

AC250V/15A

0325015

(Littelfuse)

AC250V/15A

0325015

(Littelfuse)

2 C11

AC275V/2.2uF

ECQUAAF225
(Panasonic)

AC275V/2.2uF

ECQUAAF225
(Panasonic)

AC275V/1.5uF

× 2parallel

ECQUAAF155　 × 2 (parallel)
(Panasonic)

3 CY1

AC250V/2200pF

DE1E3KX222M
(Murata Manufacturing)

AC250V/2200pF

DE1E3KX222M
(Murata Manufacturing)

AC250V/2200pF

DE1E3KX222M
(Murata Manufacturing)

4 L11

6mH/12A

ADM-25-12-060T
(Ueno)

6mH/12A

ADM-25-12-060T
(Ueno)

6mH/12A

ADM-25-12-060T
(Ueno)

5 L12

6mH/12A

ADM-25-12-060T

(Ueno)

6mH/12A

ADM-25-12-060T

(Ueno)

6mH/12A

ADM-25-12-060T

(Ueno)

6 CX1

AC275V/1.5uF

ECQUAAF155
(Panasonic)

AC275V/1.5uF

ECQUAAF155
(Panasonic)

AC275V/1.5uF

ECQUAAF155
(Panasonic)

7 CX2

AC275V/1.5uF

ECQUAAF155
(Panasonic)

AC275V/1.5uF

ECQUAAF155
(Panasonic)

AC275V/1.5uF

ECQUAAF155
(Panasonic)

8 CY2

AC250V/2200pF

DE1E3KX222M

(Murata Manufacturing)

AC250V/2200pF

DE1E3KX222M

(Murata Manufacturing)

AC250V/2200pF

DE1E3KX222M

(Murata Manufacturing)

9 CY3

AC250V/2200pF

DE1E3KX222M
(Murata Manufacturing)

AC250V/2200pF

DE1E3KX222M
(Murata Manufacturing)

AC250V/2200pF

DE1E3KX222M
(Murata Manufacturing)

F12

DC25V/2200uF

ELXZ250ELL222
(Nippon Chemi-Con)

DC25V/2200uF

ELXZ250ELL222
(Nippon Chemi-Con)

DC25V/2200uF

ELXZ250ELL222
(Nippon Chemi-Con)

F28

DC50V/1000uF

ELXZ500ELL102
(Nippon Chemi-Con)

DC50V/1000uF

ELXZ500ELL102
(Nippon Chemi-Con)

DC50V/1000uF

ELXZ500ELL102
(Nippon Chemi-Con)

F48

DC63V/470uF

ELXZ630ELL471

(Nippon Chemi-Con)

DC63V/470uF

ELXZ630ELL471

(Nippon Chemi-Con)

DC63V/470uF

ELXZ630ELL471

(Nippon Chemi-Con)

F12

DC25V/10uF

GRM31CR71E106
(Murata Manufacturing)

DC25V/10uF

GRM31CR71E106
(Murata Manufacturing)

DC25V/10uF

GRM31CR71E106
(Murata Manufacturing)

F28

DC50V/4.7uF

GRM31CR71H475
(Murata Manufacturing)

DC50V/4.7uF

GRM31CR71H475
(Murata Manufacturing)

DC50V/4.7uF

GRM31CR71H475
(Murata Manufacturing)

F48

DC100V/2.2uF

GRM31CR72A225

(Murata Manufacturing)

DC100V/2.2uF

GRM31CR72A225

(Murata Manufacturing)

DC100V/2.2uF

GRM31CR72A225

(Murata Manufacturing)

12 Cbc

DC450V/470uF

ELXS451VSN471
(Nippon Chemi-Con)

DC450V/390uF
×2parallel

ELXS451VSN391 × 2 (parallel)
(Nippon Chemi-Con)

DC450V/390uF
×2parallel

ELXS451VSN391 × 2 (parallel)
(Nippon Chemi-Con)

13 C20

DC450V/0.68uF
×2parallel

AFS450V684K × 2 (parallel)
(OKAYA ELECTRIC INDUSTRIES)

DC450V/0.68uF
×2parallel

AFS450V684K × 2 (parallel)
(OKAYA ELECTRIC INDUSTRIES)

DC450V/0.68uF
×2parallel

AFS450V684K × 2 (parallel)
(OKAYA ELECTRIC INDUSTRIES)

14 C30

DC450V/0.68uF

×2parallel

AFS450V684K × 2 (parallel)

(OKAYA ELECTRIC INDUSTRIES)

DC450V/0.68uF

×2parallel

AFS450V684K × 2 (parallel)

(OKAYA ELECTRIC INDUSTRIES)

DC450V/0.68uF

×2parallel

AFS450V684K × 2 (parallel)

(OKAYA ELECTRIC INDUSTRIES)

15 TFR1

10Ω

F5K-100J14

(TAMURA THERMAL DEVICE)

10Ω

F5K-100J14

(TAMURA THERMAL DEVICE)

10Ω

F5K-100J14

(TAMURA THERMAL DEVICE)

16 R1

68kΩ
×3series

2parallel

CRS32 683
(HOKURIKU ELECTRIC INDUSTRY)

68kΩ
×3series

2parallel

CRS32 683
(HOKURIKU ELECTRIC INDUSTRY)

68kΩ
×3series

2parallel

CRS32 683
(HOKURIKU ELECTRIC INDUSTRY)

17

SK11
SK21
SK22

620V

TND14V-621K
(Nippon Chemi-Con)

620V

TND14V-621K
(Nippon Chemi-Con)

620V

TND14V-621K
(Nippon Chemi-Con)

18 SA11

4kV

DSA-402MA

(Mitsubishi Materials)

4kV

DSA-402MA

(Mitsubishi Materials)

4kV

DSA-402MA

(Mitsubishi Materials)

No. Symbol Item

TUNS300F TUNS500F

Input fuse

Input capacitor

Y capacitor

Noise
filter

Line Filter

X capacitor

Y capacitor

10 Co

Output
capacitor

11 C40

Bypass
capacitor

Smoothing
capacitor
Capacitor
for boost voltage
Capacitor

for boost voltage

Surge absorber

TUNS700F

Inrush cur rent

protection resistor

Discharging
resistor

Varistor

AC1

AC2

+VOUT

-VOUT

-BCFG

F11

+BC

Co

+

Load

C40

AC

INPUT

L11

CY2

CX1

SK11

SK21

SA11

CX2

CY3

L12

SK22

Noise
Filter

C11

-S

+S

R

+

C30

TFR1

Cbc

C20

CY1

R1

FG

Applications Manual

TUNS300/500/700

2.2 Input fuse: F11

■

No protective fuse is preinstalled on the input side. To protect the unit, install a slow-blow
type fuse shown in Table 2.2 in the input circuit.

Table 2.2

Recommended

fuse

2.3 Input capacitor: C11

■

Connect a film capacitor of 2 uF or higher as input capacitor C11.

■

Use a capacitor with a rated voltage of AC250V which complies with the safety standards.

■

If C11 is not connected, the power supply or external components could be damaged.

■

When selecting a capacitor, check the maximum allowable ripple current.

■

Ripple current includes low frequency component (input frequency) and high frequency
component (100kHz).

■

Ripple current values flowing into C11 as listed in Table 2.1 are shown in Fig.2.2.

■

The ripple current changes with PCB patterns, external parts, ambient temperature, etc.
Check the actual ripple current value flowing through C11.

Fig.2.2

Ripple current

values

C11

Rated current 10A 15A 15A

A-3

Model TUNS300F TUNS500F TUNS700F

Applications Manual

TUNS300/500/700

2.4 Y Capacitors and noise filters: CY, CX, L1

■

The TUNS300/500/700 series has no internal noise filter.
Connect external noise filters and capacitors (CY) to reduce conduction noise and stabilize
the operation of the power supply.

■

Noise filters should be properly designed when the unit must conform to the EMI/EMS
standards or when surge voltage may be applied to the unit.

■

Install the primary Y capacitor (CY1) as close as possible to the input pins (within 50 mm
from the pins).
A capacitance of 470 pF or more is required.

■

When the total capacitance of CYs exceeds 8,800 pF, input-output withstanding voltage
may be dropped. In this case, either reduce the capacitance of Y capacitors or install a
grounding capacitor between output and FG.

■

Use capacitors with a rated voltage of AC250V which comply with the safety standards
as CY.

2.5 Output capacitors: Co, C40

■

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 2.3.

■

Use low impedance electrolytic capacitors with excellent temperature characteristics.

■

When Using at ambient temperatures below 0 ºC, the output ripple voltage increases due
to the characteristics of equivalent series resistor (ESR). In this case, connect three
capacitors, Co, of recommended capacitance in parallel connection.

■

Specifications, output ripple and ripple noise as evaluation data values are measured
according to Fig.2.3.

Table 2.3

Recommended

capacitance

Co

Fig.2.3

Measuring

environment

48V 470uF 470uF 470uF

A-4

12V 2,200uF 2,200uF 2,200uF
28V 1,000uF 1,000uF 1,000uF

Output Voltage TUNS300F TUNS500F TUNS700F

R=50Ω

C=0.01uF

Load

1.5m 50Ω

Coaxial Cable

C40:
12V 10µF
28V 4.7µF
48V 2.2µF

+VOUT

-VOUT

-S

+S

Co

+

C40

50mm

Oscilloscope

BW:100MHz

R

C

Applications Manual

TUNS300/500/700

2.6 Smoothing capacitor for boost voltage: Cbc

■

In order to smooth boost voltage, connect Cbc between +BC and -BC.
Recommended capacitance of Cbc is shown in Table 2.4.

■

Install a capacitor Cbc with a rated voltage of DC420 V or higher within the allowable
capacitance.

■

When operated below 0ºC, operation may become unstable as boost ripple voltage
increases due to ESR characteristics. Choose a capacitor which has higher capacitance
than recommended.
Select a capacitor so that the ripple voltage of the boost voltage is 30 Vp-p or below.

■

If the ripple voltage of the boost voltage increases, the ripple current rating of the
smoothing capacitor may be exceeded. Check the maximum allowable ripple current of
the capacitor.

■

The ripple current changes with PCB patterns, external parts, ambient temperature, etc.
Check the actual ripple current value flowing through Cbc.

Table 2.4

Recommended

capacitance

Cbc

※

Refer to item 6 and 7 for selection method of Cbc.

2.7

Capacitor for boost voltage :C20,C30

■

Install film capacitors with a rating of 1uF/DC450V or higher as C20 and C30.

■

If C20 and C30 are not connected, the power supply or external components could be
damaged.

■

The ripple current flows into these capacitors. Check the maximum allowable ripple
current of the capacitor while selecting.

■

The frequency of the ripple current is 100 kHz to 200 kHz.

■

Ripple current values flowing into C20 and C30 as listed in Table 2.1 are shown in
Fig.2.4 and Fig.2.5.

■

The ripple current changes with PCB patterns, external parts, ambient temperature, etc.
Check the actual ripple current values flowing through C20 and C30.

Fig.2.4

Ripple current

values

C20

※

Ripple current value is total of 2 paralleled capacitors.

TUNS700F

390uF × 2 parallel 470uF ~ 2,200uF

A-5

TUNS300F

470uF 390uF ~ 2,200uF

TUNS500F

390uF × 2 parallel 390uF ~ 2,200uF

Model Recommended capacitance Allowable capacitance range

0

500

1000

1500

2000

2500

3000

3500

0 20 40 60 80 100 120

R

i

p

p

l

e

c

u

r

r

e

n

t

[

m

A

r

m

s

]

Output current [%]

TUNS300F(100VAC)
TUNS300F(200VAC)
TUNS500F(100VAC)
TUNS500F(200VAC)
TUNS700F(100VAC)
TUNS700F(200VAC)

Applications Manual

TUNS300/500/700

Fig.2.5

Ripple current

values

C30

※

Ripple current value is total of 2 paralleled capacitors.

2.8 Inrush current limiting resistor: TFR1

■

The TUNS300/500/700 must connect TFR1.

■

If TFR1 is not connected, the power supply will not operate.

■

Connect TFR1 between R and +BC.
Recommended resistance of TFR1 is shown in Table 2.5.

■

The surge capacity is required for TFR1.

■

Wirewound resistor with thermal cut-offs type is required.

■

Therefore, we don’t recommend connecting a large resistance as TFR1.

■

The inrush current changes by PCB pattern, parts characteristic etc.
Check the actual inrush current value flowing through the AC line.

Table 2.5

Recommended

resistor

TFR1

■

The selection method of TFR1 is shown below.

・

Calculation of resistance
Resistance can be calculated using the following formula.

TFR1:Inrush current limiting resistor
RL

:

Line impedance
Vin:Input voltage (rms)
Ip

:

Primary Inrush current (peak)

・

Calculation of required surge capacity
Required surge capacity can be calculated using the following formula.
Please contact to the component manufacturer regarding the surge current withstanding capability.

I2t

:

Current squared times
TFR1:Inrush current limiting resistor
Cbc:Smoothing capacitor for boost voltage
Vin:Input voltage (rms)

A-6

TUNS300F

4.7Ω ~ 22

Ω

TUNS500F

4.7Ω ~ 22

Ω

TUNS700F

4.7Ω ~ 22

Ω

Model Recommended resistance

Inrush current limiting resistor can be used to limit the primary inrush current. However, the
secondary inrush current can’t be limited by increasing the resistor value of inrush current
limiting resistor. The secondary inrush current is approx. 25 ~ 30A.

][

1

2

2

2

sA

TFR

VinCbctI×

=

][

2

1 Ω−

×

=

L

R

Ip

Vin

TFR

0

500

1000

1500

2000

2500

3000

3500

0 20 40 60 80 100 120

R

i

p

p

l

e

c

u

r

r

e

n

t

[

m

A

r

m

s

]

Output current [%]

TUNS300F(100VAC)
TUNS300F(200VAC)
TUNS500F(100VAC)
TUNS500F(200VAC)
TUNS700F(100VAC)
TUNS700F(200VAC)

Applications Manual

TUNS300/500/700

2.9 Discharging resistor: R1

■

If you need to meet the safety standards, connect a discharging resistor R1 at input
interphase.

■

Please select a resistor so that the input interphase voltage decreases in 42.4V or less
at 1 second after turn off the input.

■

Fig.2.6 shows the relationship between a necessary resistance of R1 and total capacitance
of input interphase capacitors.
And the data of Fig.2.6 is the values that assumed the worst condition.

■

Please keep margin for rated voltage and power of R1.

Fig.2.6

TUNS500F

Relationship

between

a necessary

resistance of R1

and total

capacitance of

input interphase

capacitors

A-7

0

50

100

150

200

250

300

350

400

450

0 1 2 3 4 5 6 7 8 9 10

Total capacitance of input interphase capacitors [uF]

R

1

[

k

Ω

]

Applications Manual

TUNS300/500/700

3.1 Output current derating

■

The TUNS300/500/700 series should be conduction-cooled.

■

Fig.3.1, Fig.3.2 and Fig.3.3 show the derating curve in relation to the temperature of
the aluminum base plate.
Note that operation within the shaded area will cause a significant level of ripple and
ripple noise.

■

Please measure the temperature of the aluminum base plate at the center.
Please measure the temperature on the aluminum base plate edge side when you cannot
measure the temperature of the center part of the aluminum base plate.
In this case, please take 5deg temperature margin from the derating characteristics
shown in Fig.3.1, Fig.3.2 and Fig.3.3.

■

■

Attention should be paid to thermal fatigue life due to temperature fluctuations by
self-heating. Make the range of temperature fluctuations as narrow as possible if
temperature often fluctuates.

Fig.3.1

TUNS300F

Output current

derating

Fig.3.2

TUNS500F

Output current

derating

Fig.3.3

TUNS700F

Output current

derating

A-8

In the case of forced air cooling, please measure the temperature on the aluminum base plate
edge side of the leeward side. Especially in the case of small heat sink, the temperature
difference between the base plate center and the base plate edge side will increase. In this case,
the temperature margin of 5deg is not required.

Aluminum base plate temperature Tc [℃]

L

o

a

d

f

a

c

t

o

r

[

%

]

-40 -20 0 20 40 60 100

80

(75)

100

50

0

(75)

-40 -20 0 20 40 60 100

80

(75)

100

50

0

(70)

①TUNS700F12
②TUNS700F28,TUNS700F48

①

②

Aluminum base plate temperature Tc [℃]

L

o

a

d

f

a

c

t

o

r

[

%

]

Aluminum base plate temperature Tc [℃]

L

o

a

d

f

a

c

t

o

r

[

%

]

-40

-200204060

100

80

100

50

0

Tc

Measuring

point

Base plate

2.1 Pin configuration

3. Derating

①TUNS500F12
②TUNS500F28,TUNS500F48

①

②

Applications Manual

TUNS300/500/700