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

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

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Hauptniederlassung
Lechwiesenstr. 9
86899 Landsberg am Lech

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

Internet: www.fortecag.de

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Büro Nord
Am Hasenkamp 36
22457 Hamburg

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

Internet: www.fortecag.de

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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

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(Tochter der FORTEC):
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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

3.2 Input voltage derating

■

Fig.3.4 shows the input voltage derating curve of TUNS700F.

Fig.3.4

TUNS700F

Fig.3.5

TUNS700F12

Output current

Fig.3.6

TUNS700F28/48

Output current

and Input voltage

derating

A-9

In case of both Input voltage derating and load derating are required, please multiply respective
mitigation rate (see Fig.3.5, Fig.3.6).

Input voltage

derating

and Input voltage

derating

L

o

a

d

f

a

c

t

o

r

[

%

]

Input Voltage [AC V]

85 100

85

100

Tc： Aluminum base plate temperature

Tc： Aluminum base plate temperature

Applications Manual

TUNS300/500/700

4.1 Output voltage adjustment

■

The output voltage is adjustable in the output voltage variable range (Table 4.1).

■

Overvoltage protection may be activated if output voltage is set up over the certain level.

■

■

About -Y1 options (48V output only)

1)

2)

3) Boost terminal (BC terminal) voltage will be changed to DC390Vtyp.

Table 4.1

4.2 Output voltage adjustment by potentiometer

■

The output voltage is adjustable by external potentiometer as shown in Fig.4.1.

■

■

Fig.4.1

Table 4.2

A-10

0.15

VR[kΩ]

5 5 5 5

±20%

R1[kΩ]

3.3 12 27 27

R2[kΩ]

0.15 0.15 0.15

1

VR[kΩ]

5 5 5 5

±10%

R1[kΩ]

6.8 27 47 47

R2[kΩ]

1 1 1

2.2 2.2 2.2

VR[kΩ]

5 5 5 5

Standard Option：-Y1

±5%

R1[kΩ]

12 39 68 68

R2[kΩ]

2.2

When the output voltage is increased, the maximum output current must be reduced not to
exceed the rated power. When the output voltage is reduced, the maximum output current must
be kept within its rated current.

The potentiometer(VR) and resistor (R1, R2) might not meet requirements of fluctuation
characteristics of ambient temperature; therefore, cermet type potentiometer
(≦±300ppm/℃) and metallic film resistor (≦±100ppm/℃) are recommended.

Connection devices

outside the

power supply

Output voltage

12V 28V 48V

Output voltage

adjustment

Recommended

component values

Standard Standard

（

115～135%

）

（

125%～140%

）

Boost terminal

voltage

DC380Vtyp DC380Vtyp DC380Vtyp

DC390Vtyp

（

80%～120%

） （

80%～110%

）

（

80%～120%

）

Overvoltage protection

operation value

15.0～16.8V 35.0～39.2V 55.2～64.8V

60.0～67.2V

（

125～140%

） （

125～140%

）

Standard Standard Standard Option：-Y1

Output voltage

variable range

9.6～14.4V

22.4～33.6V 38.4～52.8V

38.4～57.6V

（

80%～120%

）

Variable range upper limit in the standard of 48V output is 52.8V (rated voltage + 10%). Please
use the option -Y1 if up to +20% output voltage adjustment is necessary.

On the safety standards, the output of the options -Y1 are treated with the ELV. The
manufacturer must provide protection against inadvertent contact to the operator.

Overvoltage protection operation value will be changed to the value shown in
Table 3.1.

Output voltage

12V 28V 48V

Output voltage

variable range

-VOUT

+VOUT

VR
5kΩ

+S

TRM

-S

R1

R2

TUNS

LOAD

2.1 Pin configuration

4. Output voltage adjustment

Applications Manual

TUNS300/500/700

■

Fig.4

.2

＜

Output voltage decreasing

＞

Fig.4

.3

＜

Output voltage increasing

＞

When variable only in one side direction of the output voltage from the rated voltage, please do
the connection shown in Fig.4.2 or Fig.4.3.
The resistance can be calculated by the following equation. In addition, because there is that it
is not a calculated value as in the variations of the internal components, it is recommended that
you adjust the potentiometer.

Output voltage

decreasing

Output voltage

increasing

A-11

TRM

RU

+VOUT

-VOUT

RT

2.7kΩ

Shunt
regulator

Vref

+S

-S

TRM

RD

+VOUT

-VOUT

RT

2.7kΩ

Shunt
regulator

Vref

+S

-S

Ｖ

OD

：

Output voltage needed to set up[V]

Ｖ

OR

：

Rated output voltage[V]

ＲＴ

：

Resistor of TRM[kΩ]
12V : 6.8 [kΩ]
28V : 8.2 [kΩ]

48V : 8.2 [kΩ]

：

Reference voltage [V]

Ｖ

ref = 2.495 [V]

Ｖ

ref

Ｖ

OU

：

Output voltage needed to set up[V]

Ｖ

OR

：

Rated output voltage[V]

ＲＴ

：

Resistor of TRM[kΩ]
12V : 6.8 [kΩ]
28V : 8.2 [kΩ]

48V : 8.2 [kΩ]

：

Reference voltage [V]

Ｖ

ref = 2.495 [V]

Ｖ

ref



=

2.7

−

−

[

Ω]



=





ܱܴ

−





=





ܱܦ

−





=

2.7







− 1



−

[

Ω]



=





ܱܴ

−





=





ܱܷ

−



Applications Manual

TUNS300/500/700

4.3 Output voltage adjustment by external voltage

■

■

Overvoltage protection will be activated if output voltage is adjusted over the certain level.

■

During startup , VTRM should be applied before input voltage.

■

Fig.4

.4

(1) Output voltage 　12V

Vo = -1.526×V

TRM

+ 15.91

(2) Output voltage 　28V

Vo = -3.367×V

TRM

+ 36.44

(3) Output voltage 　48V

Vo = -6.010×V

TRM

+ 63.09

Please use low impedance for VTRM as current will flow through TRM terminal.

Output voltage

adjustment by

external voltage

＜

V

TRM

→　

Output voltage Calculating formula

＞

A-12

The output voltage can be adjustable by applying voltage between the TRM terminal and -S
terminal.

-VOUT

+VOUT

+S

TRM

-S

V

TRM

TUNS

External
voltage source

8.0

9.0

10.0

11.0

12.0

13.0

14.0

15.0

16.0

0.0 1.0 2.0 3.0 4.0 5.0

O

u

t

p

u

t

v

o

l

t

a

g

e

V

o

[

V

]

VTRM [V]

Output voltage 12V

18.0

20.0

22.0

24.0

26.0

28.0

30.0

32.0

34.0

36.0

38.0

0.0 1.0 2.0 3.0 4.0 5.0

O

u

t

p

u

t

v

o

l

t

a

g

e

V

o

[

V

]

VTRM [V]

Output voltage 28V

+20% +20%

+20%

-20%

-20%

-20%

+10%

Applications Manual

TUNS300/500/700

5.1 Parallel operation

■

Option:-P is for parallel operation (TUNS700F only).

■

Terminal is different from the standard. See Figure 5.2.Position is the same as standard.

■

There is no remote sensing function and the output voltage variable function.

■

■

Total number of units should be 5 pieces or less.

■

■

The length and width of output should be as same as possible to optimize the current sharing.

■■■

Fig.5.1

Fig.5.2

TUNS700F□□-P

Pin Assignment

A-13

(Output current in parallel operation)

=(the rated current per unit) × (number of unit) × 0.9

Input capacitor C11, Boost voltage capacitor (Cbc, C20, C30), Inrush current protection resistor
RFR1, Output capacitor (Co) can not be shared. Please connect them to each power supply for
parallel operation. In addition, To avoid startup time difference, please use same value for Cbc
and RFR1 for each power supply.

Connect each input pin with as low impedance possible. When the number of the units in
parallel operation increases, input current increases. Adequate wiring design for input circuitry
such as circuit pattern, wiring and current for equipment is required.

If temperatures of aluminum base plates are different during among the power supplies for
parallel operation, voltage will vary significantly. balancing between module will not good.
Please consider the designing of heat dissipation to equalize the aluminum base plate
temperature.

+ M / -M terminal is the output voltage monitor terminal. Please do not take the current from +
M / -M terminal. Also, please do not connect the + M / -M each other parallel to the power
supply.

TUNS700F□□-P

Load

characteristic

The output current can be balanced by static load regulation the power supply. Output voltage -
output current characteristic is shown in Fig.5.1.

As variance of output current drawn from each power supply is 10% maximum, the total output
current must not exceed the value determined by the following equation.

2.1 Pin configuration

5. Parallel operation (option:‐P)

⑦-VOUT

⑧-M

①AC1
②AC2

③R ④+BC

⑨+M

⑥+VOUT

⑤-BC

⑩NC
⑪IOG

4-FG

Bottom view

Applications Manual

TUNS300/500/700

6.1 Ripple voltage of boost voltage

■

At low temperature, ripple voltage of boost voltage increases due to Cbc freezes.

■

Select a capacitor of which ripple voltage of boost voltage does not exceed 30Vp-p
on an actual operating condition.
And check the maximum allowable ripple current of the capacitor.

■

Fig.6.1 and Fig.6.2 shows the relationship between ripple voltage of boost voltage and
temperature(Vin=AC85V).

Fig.6.1

TUNS500F

Relationship

between

ripple voltage of

boost voltage

and temperature

(Vin=AC85V)

A-14

2.1 Pin configuration

6. Operation Under Low Temperature Conditions

Applications Manual

TUNS300/500/700

Fig.6.2

TUNS700F

Relationship

between

ripple voltage of

boost voltage

and temperature

(Vin=AC85V)

A-15

Applications Manual

TUNS300/500/700

7.1 Holdup time

■

Holdup time is determined by the capacitance of Cbc.

Fig.7.1

TUNS300F

Relationship

between

holdup time

and Cbc

Fig.7.2

TUNS500F

Relationship

between

holdup time

and Cbc

Fig.7.3

TUNS700F

Relationship

between

holdup time

and Cbc

Fig.7.1, Fig.7.2 and Fig.7.3 show the relationship between holdup time and output current
within the allowable capacitance of Cbc.

A-16

10

100

1000

0 20 40 60 80 100 120

Output current [%]

H

o

l

d

u

p

t

i

m

e

[

m

s

]

Cbc=390uF
Cbc=470uF
Cbc=1,560uF
Cbc=2,200uF

10

100

1000

0 20 40 60 80 100 120

Output current [%]

H

o

l

d

u

p

t

i

m

e

[

m

s

]

Cbc=390uF
Cbc=780uF
Cbc=1,560uF
Cbc=2,200uF

2.1 Pin configuration

7. Holdup Time

Applications Manual

TUNS300/500/700

8.1 Mounting method

■

Fig.8.1

Mounting method

When implementing the power supply to the printed circuit board, please fix the power
supply to the printed circuit board by screw before the soldering.

If it is screwed to the substrate after soldering, there is a possibility of failure by adding
mechanical stress to the soldering point and the internal connections of power supply.

A-17

Heat sink

Heat sink
retention screws

Silicone grease
/ Heat dissipation sheet

Power supply

Power supply

retention screws

Power supply

soldering

printed circuit board

2.1 Pin configuration

8. Mounting method

①

②

Applications Manual

TUNS300/500/700

9.1 Thermal Design

■

Home> Technical Data> Application Manual
♦Power Module Type

9.Thermal Considerations

http://www.cosel.co.jp/en/data/pdf/thermal_considerations.pdf

9.2 Examples of Convection cooling

■

Here is an example of convection cooling with heatsink.

■

Fig.9.1

Convection cooling

Heatsink example

Fig.9.2

Environment

A-18

Please refer to the applications manual "9.Thermal Considerations" on our website.

Please consider this example as a design guideline because it changes by the heat dissipation
environment. Please measure the temperature of the actual equipment eventually.

2.1 Pin configuration

9. Thermal Design

237.5×150×45mm

（

EX239-150-DE MIZUTANI ELECTRIC IND.CO.,LTD

）

Thermal resistance ：0.39℃/W

Applications Manual

TUNS300/500/700

Heatsink

Power supply

Grease

※

（

Between Power supply and Heatsink

）

Printed board

（

FR-4 t=1.6mm

）

※

Silicone grease

Momentive YG6260

External components

100

50

×

Ambient temperature measurement point

Free air

Power supply

Printed board

Heatsink

[mm]

Fig.9.3

TUNS300F

result

Fig.9.4

TUNS500F

result

Fig.9.5

TUNS700F

result

※

Maximum ambient temperature is limited at 70 ℃ MAX to be considered the life of the electrolytic capacitor.

A-19

Applications Manual

TUNS300/500/700

9.3 Examples of Forced air cooling

■

Here is an example of forced air cooling with heatsink.

■

■

Fig.9.6

Forced air cooling

Heat sink example

Fig.9.7

Environment

Please consider this example as a design guideline because it changes by the heat dissipation
environment. Please measure the temperature of the actual equipment eventually.

If it is difficult to measure the center of the baseplate, please measure the leeward side of the
baseplate edge.

A-20

Full brick size heatsink (Mounting surface with heat dissipation sheet)

117×61×23mm

（

ATS-1111-C1-R0 Advanced Thermal Solutions, Inc.

）

Applications Manual

TUNS300/500/700

125

125

×

Ambient
temperature
measurement point

20

66.6

AIR

Anemometer

800

FAN

20

470

×

Heatsink

Power
supply

External
components

Wind tunnel

[mm]

AIR

AIR

VELOCITY

[m/s]

THERMAL

RESISTANCE

[℃/W]

1.0 1.82

1.5 0.98

2.0 0.65

2.5 0.50

3.0 0.41

3.5 0.35

4.0 0.32

Fig.9.8

TUNS300F12

result

Fig.9.9

TUNS300F28

result

Fig.9.10

TUNS300F48

result

※

Maximum ambient temperature is limited at 70 ℃ MAX to be considered the life of the electrolytic capacitor.

A-21

Applications Manual

TUNS300/500/700

Fig.9.11

TUNS500F12

result

Fig.9.12

TUNS500F28

result

Fig.9.13

TUNS500F48

result

※

Maximum ambient temperature is limited at 70 ℃ MAX to be considered the life of the electrolytic capacitor.

A-22

Applications Manual

TUNS300/500/700

Fig.9.14

TUNS700F12

result

Fig.9.15

TUNS700F28

result

Fig.9.16

TUNS700F48

result

※

Maximum ambient temperature is limited at 70 ℃ MAX to be considered the life of the electrolytic capacitor.

A-23

Applications Manual

TUNS300/500/700

10.1 Consideration for board layout

■

Primary (input side)

：

AC, BC, R pin

Secondary (output side)

：

VOUT, S, TRM, IOG pin

FG (base plate)

：

Nut (4 places), Aluminum base plate, Heat sink

■

Primary - Secondary

：　

5mm or more

Primary -FG

：　

5mm or more

Secondary - FG

：　

1.6mm or more

Primary interphase

：　

3mm or more

Wiring of AC pin - BC pin

：　

3mm or more

■

Fig.10.1

Insulation

distance

Clearance and creepage requirements vary based on different safety standards and conditions of
usage. Please place the components and wiring pattern according to those safety standards.

A-24

The potential voltage of each terminal is given below. External components that are connected to
these terminals should be at same potential voltage.

In order to meet the breakdown voltage specification of products, insulation distance between
components and between patterns is recommended to ensure the following.

Applications Manual

TUNS300/500/700

Bottom view

2.1 Pin configuration

10. Board layout

■

■

Fig.10.2

Same Surface

Mount

■

Fig.10.3

Recommended

external circuit

①

Input fuse ： F11

⑥

Y Capacitors　： CY1

②

Noise filters

⑦

Output capacitors
Line filter　： L11、L12 Electrolytic capacitor　： Co
Interphase capacitor　： CX1、CX2 Ceramic capacitor　： C40
Y capacitor　： CY2、CY3

⑧

FG terminals

③

Input capacitor ： C11

⑨

Surge Suppression

④

Inrush current limiting resistor ： TFR1 Varistor　： SK11、SK21、SK22

⑤

Capacitor for boost voltage Surge absorber　： SA11

Electrolytic capacitor　： Cbc

⑩

Discharging resistor ： R1
Film Capacitors　： C20、C30

When installing the electrolytic capacitor and the power supply on the same surface of the printed
circuit board, please pay attention to the distance between the base plate and electrolytic
capacitor. Exterior of the electrolytic capacitor is assumed to be the same potential as the negative
electrode.

High-frequency noise radiates directly from the unit to the atmosphere. Therefore, design the
shield pattern on the printed circuit board and connect to FG. The shield pattern prevents noise
radiation.

There are notes for printed circuit board design at recommended circuit in this applications
manual. Please see below.

A-24

Applications Manual

TUNS300/500/700

Aluminum base plate, Heatsink：FG

Electrolytic
capacitor

Peripheral
components

Heatsink

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

A-26

Applications Manual

TUNS300/500/700

When the fuse is blown out, input voltage would be applied between the terminals of

the fuse F11.

Please keep the distance of the pattern between the terminals of the fuse more than

2.5mm if you must be complied safety approvals.

Noise filter is build by Line filters (L11, L12), X capacitor (CX1, CX2) and Y capacitor

(CY2,CY3). And the Noise filter is used to reduce conduction noise from power supply.

Off-the-shelf Noise filter is also available.
If the Line filter is placed near the components which is switching at high frequency,

the conduction noise may be increased because the noise goes into the Line filter.

Therefore, the Line filter should be shielded or keep the distance from the source

of noise.

The effect of noise reduction by Y capacitor depends on the place of the FG connection.
Recommend connecting Y capacitor to the FG terminal of the power supply as close as
possible. Please evaluate before use.

Huge ripple current flows into the capacitor C11.

Place the capacitor C11 near the power supply as close as possible.

①

Input fuse ：F11

②

Noise filter

③

Input capacitor ：C11

×

Not good

○

Good

Power supply

C11

Power supply

C11

CX

CX

LF

LF

Input Output Input Output

The high voltage(Approx. 380VDC) is appeared between +BC,R and -BC terminals.

The distance between +BC, R and -BC terminals must be 3mm or more.

Huge ripple current flows into the capacitor C20. Place C20 near the power supply
as close as possible.

CY1 should be connected to the FG terminal of the power supply as close as possible.

⑤

Capacitor for boost voltage ：Cbc,C20 R pin connected capacitor：C30

⑥

Y Capacitors：CY1

④

Inrush current limiting resistor ：TFR1

Inrush current will flow through the Cbc TRF1 from the R pin. Please have a pattern

width that is not damaged by the inrush current.

A-27

Applications Manual

TUNS300/500/700

Connecting the output capacitor (Co,C40) to the power module as close as possible for

stable operation and radiation noise reduction.

The output line impedence could cause unstable output voltage, which can be reduced

by adding the output capacitor close to the load.

When the output ripple and ripple noise must be reduced, ceramic capacitor C40 which

has good characteristics at high frequency should be used.

If through-hole type ceramic capacitor is used, the effect of the noise reduction would be

reduced by the impedance of the lead frame of the components.

Please evaluate before using.

Connect the FG terminal of the power supply to the PWB by screw. If the FG terminals

of the power supply is not connected properly, malfunction or failure could happen.

Expose the solder mask around the hole of the FG connection on the PWB to connect

FG terminals by screws.

⑦

Output capacitors ：Co, C40

⑧

FG terminals of the power supply

⑨

Surge Suppression

Device

：

SK11,SK21,SK22, and SA11

In isolation test, test voltage is applied to the SA11. When the test voltage beyond the
specification of the SA11 is applied, please remove the SA11 during the test, or lower
the test voltage.
Note. When conducting isolation test between the primary and the secondary,
high voltage is applied to SA11,SK11,SK21, and SK22, by the partial pressure of the
Y capacitor.

Please keep distance between electrodes, when using multiple resistors as R1 due to
the power loss dispersion.

In the case of obtaining safety standards, please keep insulation distance
required by the standards.

⑩

Discharging resistor：R1

Resistance

PWB Pattern

10.2 Reference PCB layout

Fig.10.4

Example of

the pattern

layout

(Top view)

A-28

Applications Manual

TUNS300/500/700

Fig.10.4(a) Example of the pattern and components layout (Top layer)

Fig.10.4(b) Example of the pattern and components layout (Bottom layer)

Secondary FGPrimary (BC Line)Primary (Input Line)

11.1 Means of the EMI reduction

■

Fig.2.1 show the recommended circuit example for EN55022 ClassA.
To meet class B or further noise reduction, external components and metal shield should be
changed accordingly. Please refer to the circuit showed on section 11.4.

11.2 Switching frequency noise reduction (200kHz)

■

6dB noise reduction can be achieved either by doubling the values of CY2, CY3 or increase
the values ofL11 and L12.

■

When Cy2, Cy3 is increased to 4,700pF, 0.022uF capacitor should be added as Cy4, Cy5
to keep 3kV isolation between primary and secondary.

As another example, if the value of Cy2, Cy3 are 3300pF, each CY4, CY5

value should be 0.01uF

■

Please note that leakage current would become large if Cy2, Cy3 is increased.

11.3 High frequency band noise reduction (more than 10 MHz)

■

EMI noise over 10 MHz varies depending on position of the external components and
PC board layout.

■

High frequency noise can be reduced by increasing the value of C20 or Y capacitors at

output side (CY4 and CY5).

■

Place the capacitors C20, CY4 and CY5 as close as possible to the power modules.

11.4 EMI measure example

■

Fig.11.1 show the circuit example for EN55022 ClassB.

Fig.11.1

Example of EMI

measure circuit

Table 11.1

List of

component change

for EMI ClassB

requirement

A-29

2.1 Pin configuration

11. Example of which reduces EMI

Applications Manual

TUNS300/500/700

Heatsink

AC1

AC2

+VOUT

-VOUT

-BCFG

F11

+BC

Co

+

Load

C40

AC

INPUT

L11

CY2

CX1

CX2

CY3

L12

Noise
Filter

C11

-S

+S

R

+

C30

TFR1

Cbc

C20

CY1

CY4

CY5

FG

Rating Part name Rating Part nam e

1 CY2

AC250V/2200pF

DE1E3KX222M
(Murata Manufacturing)

AC250V/4700pF

DE1E3KX472M
(Murata Manufacturing)

2 CY3

AC250V/2200pF

DE1E3KX222M
(Murata Manufacturing)

AC250V/4700pF

DE1E3KX472M
(Murata Manufacturing)

3 C20

DC450V/0.68uF
×2parallel

AFS450V684K × 2parallel
(OKAYA ELECTRIC INDUSTRIES)

DC450V/0.68uF
×3parallel

AFS450V684K × 3parallel
(OKAYA ELECTRIC INDUSTRIES)

4 CY4

- - 0.022uF

LE223
(OKAYA ELECTRIC INDUSTRIES)

5 CY5

- - 0.022uF

LE223
(OKAYA ELECTRIC INDUSTRIES)

No. Symbol

Capacitor
for boost voltage

Y capacitor

EN55022 ClassB.

Item

EN55022 ClassA

(Recommended external c ircuit in Fig. 2.1)

Noise
filter

Y capacitor

Fig.11.2

Line conduction

Fig.11.3

Radiated

emission

A-30

Applications Manual

TUNS300/500/700

<EN55022b>

Limit (QP)
Limit (AV)

<TUNS700F48>

Range (VA,PK)
Range (VB,PK)

Limit(QP)

<TUNS700F48>

Horizontal(PK)
Vertical(PK)

<EN55022b>

Limit (QP)

0.15 30.000.50 1.00 5.00 10.00

0

100

10

20

30

40

50

60

70

80

90

Frequency

L

e

v

e

l

[MHz]

[dB(μV)]

<EN55022b>

<TUNS700F48>

0.15 30.000.50 1.00 5.00 10.00

0

100

10

20

30

40

50

60

70

80

90

Frequency

L

e

v

e

l

[MHz]

[dB(μV)]

<EN55022b>

<TUNS700F48 ClassB>

30 100050 100 500

0

80

10

20

30

40

50

60

70

Frequency

L

e

v

e

l

[MHz]

[dB(μV/m)]

<EN22 B>

<TUNS700F48>

30 100050 100 500

0

80

10

20

30

40

50

60

70

Frequency

L

e

v

e

l

[MHz]

[dB(μV/m)]

<EN22 B>

<TUNS700F48　ClassB>

Fig.11.2(a) External circuit on fig.2.1 Fig.11.2(ｂ) External circuit on fig.11.1

Fig.11.3(a) External circuit on fig.2.1 Fig.11.3(ｂ) External circuit on fig.11.1

Model Name : TUNE700F48
Power Supply : AC Single-Phase 50Hz 230V
Output current : Lated Load

Model Name : TUNE700F48
Power Supply : AC Single-Phase 50Hz 230V
Output current : Lated Load

Revision history

15

11

A-31

13
14

12

9

10

7 8-Jan-2016 Fig4.3　Calculation formula Correction
8

1.4E A-11

5 10-Aug-2015 [ 11.Example of　which reduces EMI ]　Addition
6 3-Dec-2015

[9.2 Examples of Convection cooling],[9.3 Examples of Forced air cooling] Addition

A-23,A-24

A-18～A-23

1.2E

1.3E

3 29-May-2015 [ 5. Parallel operation (option :-P) ]　Addition
4 29-May-2015 [ 8. Mounting method ] , [ 9.Thermal Design ]　Addition

A-13
A-17

1.1E

1.1E

1 29-May-2015 [ 3.2 Input voltage derating ]　Addition
2 29-May-2015 [ 4. Output voltage adjustment ]　Addition

A-9
A-10～A-12

1.1E

1.1E

No. date contentpageRev.

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