TDK-Lambda PFH500F-28 series Instruction Manual

PFH500F-28-xxx Series

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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. 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.

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.

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CAUTION

 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.

1 Rev. 2.0 June 11, 2018

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:

X

Module
Feature

F: Full
Features

S: Simple
Features

-UVW (Option Codes)

-000 Thru-hole Latch Non-Latch Non-Latch 0.240” No Droop Load Share

-0D0 Thru-hole Latch Non-Latch Non-Latch 0.240” With Droop Load Share

-100 Threaded Latch Non-Latch Non-Latch 0.240” No Droop Load Share

-1D0 Threaded Latch Non-Latch Non-Latch 0.240” With Droop Load Share

YZ

Output

(V)

28: 28V
12: 12V
48: 48V

U

Case

Mounting

0: Thru-hole

1: Threaded

OVP

(Latch)

Standard:

Latch

OCP

(Non-Latch)

Standard:

Non-Latch

OTP

(Non-Latch)

Standard:

Non-Latch

Pin Length

(0.240”)

Standard:

0.240”

Parallel Operation

(Droop Load Share)

0: No Droop Load Share

D: Droop Load Share

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2. Module Pinout:

PIN FUNCTION PIN FUNCTION

1
2
3
4
5
6
7
8
9

10

AC Input (Line)

AC Input (Neutral)

Vout (-)
Vout (-)

ON/OFF

Trim

Remote Sense (+)

Vout (+)
Vout (+)

Power Good

11
12
13
14
15
16
17
18
19
20

Secondary Signal GND

Aux Power Supply

PMBus Clock

PMBus Data

PMBus Alert
PMBus Address 2
PMBus Address 1

Inrush Control

- Boost Voltage Bus (-VBUS)

+ Boost Voltage Bus (+VBUS)

- Module case can be connected to Frame Ground through M3 mounting threaded hole(s).

- Consider terminal contact resistance when connecting AC(L), AC(N), +VBUS, –VBUS, Vout(+), Vout(-).

- Note that +VBUS and –VBUS terminals are primary voltage with high voltage rating (385VDC).

- Do not connect any load(s) across +VBUS and -VBUS terminals. Otherwise, it may damage the module.

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3. Circuit Block Diagram

Fuse

Vbus
OVP1
UVP2

Vbus

Bulk Caps

DC-DC
Bridge
Converter

Supplies

DC-DC Circuit

Ipeak
Sense

Digital
Isolators

Bias

Synchro.
Rectifiers

DC-DC
Digital
Controller

(OVP/UVP)

URT

OTP2

Vo

Output Filter

Vo_sns

ON/OFF

Trim

Rs

PG

PMBus

Vaux

Io SNS

PFC Circuit

Vac

Inrush
Circuit

EMI Filter

Surge Prot.

Vin Detect
UVP/OVP

Iin Detect
OCP1

OTP1

Bridgeless
PFC Conv.

Relay

PFC
Digital
Controller

URT

NOTE: The blocks with red font are the external components required for the operation of PFH module.

Switching Frequency:

a) PFC Converter (fixed) : 145kHz

b) DC/DC Converter (fixed):

28Vo : 145kHz (primary), 290kHz (secondary ripple)

DC/DC Converter Circuit (fixed)

12Vo & 48Vo : TBD

c) Bias Converter (fixed): 135kHz

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4. Sequence Timing Diagram

Note: PFH series product has a remote ON/OFF pin that is referenced to output return.

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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.

PFH500 series employs conduction cooling method. Use a heat sink and fan(s) to remove the heat generated
by heavy load operation.

For selection of heat sink(s) and the heat sink heat transfer method, refer to the Power Module Application
Note.

Vac(L)

Input

Vac(N)

PMBus_Clock

PMBus_Alert

RS (+)

Vo(+)
Vo(+)

Vo(-)
Vo(-)

Trim

PG

ON/OFF

Aux Power

SGND

+ VBUS

C9

C11

L=50 mm

C13

C14

C12

C15

C16

Vo(+)

Output

Vo(-)

PMBus_Data

PMBus_Add2

PMBus_Add1

PMBus Interface

R1

RLa

AC(L)

R2

C5

AC(N)

F1

C1

L1

C4

C2

L2

C3

PFH500F

Case

C7

Earth GND

Input EMI Filter

for CISPR-22 Class A/B

C6

Inrush

Control

RLb

-VBUS

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C10

Fig.5-1 Basic connection

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.

Also, the line inrush surge current will flow through the PFH module during initial line power application (or
line power switch in). Be sure to check I2t rating of external power switch (or circuit breaker), and external line
fuse to make sure that the fuse will not blow, and/or the circuit breaker will not trip.

Recommended External Fuse：10A, 250V (Fast Acting)

Note) Select fuse based on rated voltage, rated current and surge current capability.

(1) Voltage Ratings

100VAC line : AC125V
200VAC line : AC250V

(2) Current Ratings

Rated current is determined by the maximum input current based on operating conditions and can be

calculated by the following formula.

(max)Iin

Iin (max) : Maximum Input Current
Pout : Maximum Output Power
Vin (min) : Minimum Input Voltage

η : Efficiency

PF : Power Factor

For Efficiency and Power Factor values, refer to separate document “PFH500F Series Evaluation Data”.

C1 and C4: 1uF; C5: 2.2uF (Film Capacitor or Class X Safety Capacitor)

These capacitors are connected across the lines to protect against differential mode interference. Their failure
does not create conditions for electric shock, although it can generate a fire risk if failed. Since the X cap is
connected across the line and neutral, the current flowing through the cap can be high. When selecting X
capacitor, be sure to check the allowable maximum ripple current rating of this capacitor.

TDK Lambda Americas recommends the customers to verify the actual ripple current flowing through each X
capacitor by measuring the capacitor actual current.

Connect C5 as close to the input terminals of PFH500 series power module [i.e. AC(L) and AC(N)] as possible.



Pout



(Arms)

PFη(min)Vin

(Formula 5-1)

Recommended Voltage Rating of X - Capacitors: 250VAC

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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.

Note: An in-proper designed common mode choke may not help the noise reduction, in fact, it may actually

cause PFH500 series module malfunction due to filter resonance. Consult TDK Lambda for technical
assistance in selecting a right EMI filter.

C2, C3 : 3300pF (Ceramic Capacitor or Class Y Capacitor)

Y-capacitors are designed to enhanced electrical and mechanical reliability standards. Y-capacitors are used in
applications where failure of the capacitor could lead to the danger of electrical shock to the user, if the ground
connection is lost.

Y capacitance values are limited to reduce the current flowing through the capacitor when AC line voltage is
applied. Low capacitance helps to reduce the energy stored to a safe limit when DC voltage is applied. Y
capacitors must be tested to applicable safety standards to qualify them for use as Y-capacitors.

Y capacitors are used to protect against common mode noise generated from the PFH500 series module. Be
sure to consider leakage current requirement of your equipment or instrument when selecting this capacitor.

High withstand voltage are applied across this capacitor depending on the application. Select capacitor with high
withstand voltage rating such as Y2 capacitor (rated voltage: 150Vac to 300vac, peak tested voltage: 5kV).

R1: 470 kΩ, 2W

Connect bleeder resistor R1 across ac input terminals as shown in Figure 5-1.

C6, C7: 1000pF (Ceramic Capacitor or Class Y Capacitor)

Add these Y capacitors as EMI common-mode noise countermeasure. Be sure to consider leakage current of
your equipment when selecting these capacitors.

High withstand voltage are applied across this capacitor depending on the application. Select capacitor with high
withstand voltage rating such as Y2 capacitor

Connect C6 as close as possible to AC(L) terminal, C7 as close as possible to AC(N) terminal.

C9, C10: Electrolytic Capacitors

PFH500X: 470µF / 450V/ 105 ºC x 2 in parallel

Refer to “Selection Method of External Bulk Capacitor for Boost Converter” below.

Allowable maximum external capacitance at nominal capacitance value is shown below.

Recommended Voltage Rating: 450VDC (105 ºC rated capacitor)
Recommended Maximum Total Capacitance: 940 µF‐1410 µF

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