Power Factor Correction Module

PFCU390HPx07
Power Factor Correction
Half-brick
Power Factor Correction Module
85-264Vrms* 45 - 65Hz / 360 - 800Hz
Input Voltage
Input Frequency
390Vdc
Up to 700W
SRS-G MODULE
0HPC07
N
PFCU39 CTOR CORRECTIO
W
FA
POWER Vrms 390Vdc 700
100-240 60 - 800Hz CODE 1WX10
Hz, 3 7
CAGE
45 - 6545
8680
S/N S1
Control Features
Operational Features
•
•
•
•
•
•
•
•
•
Universal input voltage range: 85-264Vrms
Universal input frequency range: 45 - 65Hz / 360 - 800Hz
Up to 700W output power
≥0.99 Power Factor
High efficiency: >96% (230Vrms)
>94% (115Vrms)
Internal inrush current limit
Auxiliary 10V bias supply
Can be paralleled with current sharing
Compatible with SynQor DC-DC converters & AC line filters
•
•
•
•
Industry standard Half-brick
Size: 2.4” x 2.5” x 0.51” (60.6 x 63.1 x 13mm)
Total weight: 4.9 oz (139 g)
Flanged baseplate version available
(With SynQor AC Line Filter)
• EN55011 and EN55022, FCC
• EN61000-3-2
• EN61000-3-3
• EN61000-4-4/5/6/11
CONTENTS
Input/Output to baseplate isolation 2150Vdc
UL 60950-1:2007
CAN/CSA-C22.2 No. 60950-1:2007
EN60950-1/A12:2011
CE Marked
Page No.
* The label shows a narrower input voltage range to be consisitent
with labeling requirements of IEC60950-1, Section 1.7
Product # PFCU390HPx07
Phone 1-888-567-9596
Input current limit and auto-recovery short circuit protection
Auto-recovery input under/over-voltage protection
Auto-recovery output over-voltage protection
Auto-recovery thermal shutdown
Compliance Features
Safety Features
•
•
•
•
•
PFC Enable
Load Enable (also: Power Out Good signal)
AC Power Good Signal
Clock synchronization
Output current monitor / Active current sharing
Protection Features
Mechanical Features
•
•
•
•
Up to 96%
Output Voltage Output Power Power Factor Full Load Efficiency
The PFCQor Power Factor Correction module is an
essential building block of an AC-DC power supply.
Used in conjunction with a hold-up capacitor,
SynQor’s high efficiency DC-DC converters and
SynQor’s AC line filter, the PFCQor will draw a nearly
perfect sinusoidal current (PF>0.99) from a single
phase AC input. The PFCQor is capable of being
paralleled for higher power levels. The module is
supplied completely encased to provide protection
from the harsh environments seen in many industrial
and transportation environments.
•
•
•
•
•
≥0.99
Typical Application of the PFC Module . . . . . . . . . . . . . . . . . . . . . . . . . 2
Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standards & Qualification Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Encased Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Encased Mechanical with Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Doc.# 005-0006254 Rev. D05/13/2014
Page 1
PFCU390HPx07
Power Factor Correction
Half-brick
Technical Specification
Typical Application of the PFC Module
F2
F1
L1IN
SynQor
AC Line Filter
MOV1
L1
L1OUT
+Vout
CLK Sync
SynQor
PFC Module
TVS1
IMON
GND
L2/NIN
AC Good
L2/NOUT
+Vout
ON/
OFF
+Sense
SynQor
DC-DC
Converter
Trim
CHold-Up
Load ENA
PFC ENA
+VIN
AUX
L2/N
-Sense
-Vout
-Vout
-VIN
CY1
ENABLE
F3
●
●
●
+Vout
+VIN
F1:
MOV1, TVS1: 10A / 250V Fuse
Must prevent peak voltage from exceeding 575V during all
transients.
F2, F3 :
Use fuse recommended in converter specification
CHold-Up:
100 - 1,000 µF (Dependent on Power Level and Line Frequency)
CY1-Y4:
See “EMI Considerations” in application notes
ON/
OFF
+Sense
SynQor
DC-DC
Converter
Trim
-Sense
-VIN
Suggested Parts:
250VAC, 10A; Littelfuse 0216010.MXEP
F1:
-Vout
CY3
MOV1: 300VAC, 60J; EPCOS S10K300E2
TVS1: 400V, 3J; Use two VISHAY 1.5KE200CA devices connected in series
CHold-Up:
450V, 390uF; United Chemi-Con ELXS451VSN391MR50S
CY2
CY1, CY3: 3.3nF, 500VAC; Vishay VY1332M59Y5UQ6TV0
CY2, CY4: 10nF, 300VAC; Vishay VY2103M63Y5US63V7
CY4
Isolated AC Good
Figure A: Typical Application of the PFCQor module to create a multiple-ouput AC-DC Power Supply
Product # PFCU390HPx07
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Doc.# 005-0006254 Rev. D05/13/2014
Page 2
PFCU390HPx07
Input:100-240Vrms
Output:390Vdc
Power:Up to 700W
Technical Specification
PFCU390HPx07 Electrical Characteristics
Operating conditions of 115Vrms, 60Hz input, 700W output, 390uF bulk capacitance, and baseplate temperature = 25°C unless otherwise noted; full
operating baseplate temperature range is -40 °C to +100 °C with appropriate power derating. Specifications subject to change without notice.
Parameter
Min.
Typ.
Max.
Units
Notes
ABSOLUTE MAXIMUM RATINGS
Input Voltage (L1 to L2/N)
Operating
Continuous
-40
-45
-0.3
0
-2
-2
264
375
290
410
400
575
2150
100
125
16
10
575
5.5
Vrms
Vpk
Vrms
Vpk
Vrms
Vpk
Vdc
°C
°C
V
mADC
V
V
85
264
Vrms
85
290
Vrms
Transient (≤2s )
Non-Operating
Isolation Voltage (Input / Output to Baseplate)
Operating Temperature
Storage Temperature
Voltage at AC GOOD and LOAD ENA pins
Current drawn from AUX pin
Voltage at PFC enable pin
Voltage at CLK SYNC In
INPUT CHARACTERISTICS (L1 to L2/N)
Operating Input Voltage Range
AC Input Continuous
AC Input 100ms Transient
Input Under-Voltage Lockout
Operating Input Frequency
50/60Hz
400Hz
Power Factor of AC Input Current
30
45
360
65
800
Relative to Vout- pin
Relative to Vout- pin
Relative to Vout- pin
Available output power reduced
when <85 Vrms
>1s Duration
Hz
Hz
0.99
0.97
Total Harmonic Distortion of AC Input Current
Inrush of AC Input Current
Enabled AC Input Current (no load)
Disabled AC Input Current
Maximum Input Power
Maximum Input Current
OUTPUT CHARACTERISTICS
Output Voltage Set Point
Output Voltage Regulation
Over Line
Over Load
Over Temperature
Total Output Voltage Range:
Input Voltage within Continuous Range
Input Voltage within Transient Range
Input Voltage Brownout/Dropout
Output Voltage Ripple and Noise
Peak-to-Peak
RMS
Operating Output Current Range
Output Over-Voltage Shutdown Threshold
Output (Hold-up) Capacitance
Vrms
Baseplate temperature
50/60Hz
400Hz, min 400W output
8
10
25
100
20
750
8
%
A
A
mArms
mArms
W
Arms
395
Vdc
Vin <240 Vrms, see figure 10
±0.3
±2
±1.5
%
%
%
Vin <240 Vrms, see figure 10
380
365
200
395
430
395
Vdc
V
V
Vin <240 Vrms, see figure 10
0
420
100
10
4
1.8
460
1,000
V
V
A
V
µF
385
390
230V, 400Hz
Vin >85Vrms
85 VAC in
See application section
60Hz, see Note 1
Dependent on Hold-up capacitor
See Note 2
Note 1: 300 µF electrolytic hold-up capacitor having a typical ESR of 0.5Ω. More capacitance/Lower ESR will reduce the line frequency ripple.
Note 2: The PFCQor is able to operate with a minimum of 100uF of hold-up capacitance, but Synqor recommends at least 330uF if the power system will be
required to conform to lightning surge standards. This is because the PFCQor relies on the hold-up capacitor to absorb the energy from a lightning surge.
Product # PFCU390HPx07
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Doc.# 005-0006254 Rev. D05/13/2014
Page 3
Technical Specification
PFCU390HPx07
Input:100-240Vrms
Output:390Vdc
Power:Up to 700W
PFCU390HPx07 Electrical Characteristics (continued)
Operating conditions of 115Vrms, 60Hz input, 700W output, 390uF bulk capacitance, and baseplate temperature = 25°C unless otherwise noted; full
operating baseplate temperature range is -40 °C to +100 °C with appropriate power derating. Specifications subject to change without notice.
Parameter
Min.
Typ.
Max.
Units
Notes
DYNAMIC CHARACTERISTICS
Turn-On Transient
Start-up Inhibit Time
10
Turn-On Time
2
Output Voltage Overshoot
ISOLATION CHARACTERISTICS (Input/output to baseplate)
Isolation Voltage
Isolation Resistance
100
Isolation Capacitance
100
TEMPERATURE LIMITS FOR POWER DERATING CURVES
Semiconductor Junction Temperature
Board Temperature
Transformer Temperature
Maximum Baseplate Temperature, Tb
FEATURE CHARACTERISTICS
Output Precharge
Output Current
100
Output Short-Circuit Withstand
Free Running Switching Frequency
200
Clock Synchronization Input (CLK SYNC)
Frequency Range
150
Logic Level High
2
Logic Level Low
Duty Cycle
20
PFC Enable (PFC ENA)
Off-State Voltage
2
On-State Voltage
Internal Pull-Up Voltage
5
Internal Pull-Up Resistance
10
AC Good (AC GOOD)
AC Input Voltage for AC Good
119
AC Good State
0
AC Not Good State
Maximum Sink Current
Load Enable
(also: Output Power Good) (LOAD ENA)
Enable (Good) State
0
Disable (Not Good) State
Maximum Sink Current
Output Voltage for Load Enable (Good) State
Rising / Startup
360
Falling / Shutdown
200
Over-Temperature Trip Point
130
Auxiliary Bias Supply
Voltage Range (≤3 mA Load)
7
Maximum Source Current
Equivalent Series Resistance
1
RELIABILITY CHARACTERISTICS
Calculated MTBF (Telcordia) TR-NWT-000332
2.5
Calculated MTBF (MIL-217) MIL-HDBK-217F
2
Field Demonstrated MTBF
Product # PFCU390HPx07
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ms
s
%
0
2150
V
MΩ
pF
125
125
125
100
°C
°C
°C
°C
indefinite
mA
s
kHz
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250
0.8
80
Each of 4 interleaved phases
kHz
V
V
V
0.8
Vpk
kΩ
375
0.4
15
300
Vpk
V
V
mA
0.4
15
300
V
V
mA
V
V
°C
11
10
Open Collector
Open Collector
At internal PCB
V
mA DC
kΩ
106 Hrs.
106 Hrs.
106 Hrs.
Tb = 70°C
Tb = 70°C
See our website for details
Doc.# 005-0006254 Rev. D05/13/2014
Page 4
Technical Specification
100
60
95
50
Power Dissipation (W)
Efficiency (%)
90
85
80
75
115 Vin
40
30
20
115 Vin
10
230 Vin
70
90 Vin
65
0
100
200
300
400
500
600
PFCU390HPx07
Input:100-240Vrms
Output:390Vdc
Power:Up to 700W
230 Vin
90 Vin
0
0
700
100
200
300
400
500
600
700
Output Power (W)
Output Power (W)
Figure 1: Efficiency at nominal output voltage vs. load power for
90Vrms, 115Vrms and 230Vrms (60Hz) input voltage at Tb = 25°C.
Figure 2: Power dissipation at nominal output voltage vs. load power
for 90Vrms, 115Vrms and 230Vrms (60Hz) input voltage at Tb = 25°C.
Figure 3: Typical Input Voltage and Current waveforms at fullrated
power (115Vrms, 60Hz) Yellow: Vin (100V/div), Green: Iin (5A/div),
Timebase: (5ms/div).
Figure 4: Typical Input Voltage and Current waveforms at full rated
power (115Vrms, 400Hz). Yellow: Vin (100V/div), Green: Iin (5A/div),
Timebase: (1ms/div).
3
2.5
Amplitude (% of fundamental current)
Amplitude (% of fundamental current)
3
PFCQor
EN 61000-3-2*
MIL-1399
2
MIL-461 CE101
1.5
1
0.5
0
PFCQor
2.5
EN 61000-3-2*
MIL-1399
2
MIL-461 CE101
1.5
1
0.5
0
1
3
5
7
9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49
1
Overtone #
3
5
7
9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49
Overtone #
Figure 5: Frequency spectrum of input current at full rated power
(115Vrms, 60Hz).
Figure 6: Frequency spectrum of input current at full rated power
(230Vrms, 60Hz).
*Only odd harmonic limits are shown for EN 61000-3-2. The PFCQor does meet all EN 61000-3-2 even harmonic limits.
Product # PFCU390HPx07
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Doc.# 005-0006254 Rev. D05/13/2014
Page 5
Technical Specification
Figure 7: Output voltage with 500μF Hold-up capacitor at full rated
power (115VAC, 60Hz) Red: Vout (5V/div), Timebase: (5ms/div)
Figure 8: Output voltage startup waveform (115VAC, 60Hz) Red:
(100V/div), Timebase: (500ms/div)
435
800
430
700
425
600
420
Output Voltage (V)
Power Output (W)
PFCU390HPx07
Input:100-240Vrms
Output:390Vdc
Power:Up to 700W
500
400
85 Vac
100 Vac
300
115 Vac
200
Max
415
Typical
410
Min
405
400
395
390
>180 Vac
385
100
380
0
0
20
40
60
80
100
375
120
85
Base Plate Temperature (ºC)
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135
160
185
210
235
260
285
Input Voltage (Vrms)
Figure 9: Output power vs. baseplate temperature derating curve
Product # PFCU390HPx07
110
Figure 10: DC output voltage range vs. input voltage
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Doc.# 005-0006254 Rev. D05/13/2014
Page 6
PFCU390HPx07
Power Factor Correction
Half-brick
Standards & Qualification Testing
Standards Compliance, Qualification Testing & EMC Characteristics
Parameter
Notes & Conditions
STANDARDS COMPLIANCE
UL 60950-1:2007
CAN/CSA-C22.2 No. 60950-1:2007
EN60950-1/A12:2011
CE Marked
Basic Insulation
to
Baseplate
Note: An external input fuse must always be used to meet these safety requirements. Contact SynQor for official safety certificates on new releases or
download from the SynQor website.
Parameter
# Units
Notes & Conditions
QUALIFICATION TESTING
Life Test
32
95% rated Vin and load, units at derating point, 1000 hours
Vibration
Mechanical Shock
5
5
10-55 Hz sweep, 0.060” total excursion, 1 min./sweep, 120 sweeps for 3 axis
100g minimum, 2 drops in x, y, and z axis
Temperature Cycling
Power/Thermal Cycling
Design Marginality
10
5
-40 °C to 100 °C, unit temp. ramp 15 °C/min., 500 cycles
Toperating = min to max, Vin = min to max, full load, 100 cycles
5
Tmin-10 °C to Tmax+10 °C, 5 °C steps, Vin = min to max, 0-105% load
Humidity
Solderability
Altitude
5
15 pins
2
85 °C, 95% RH, 1000 hours, continuous Vin applied except 5 min/day
MIL-STD-883, method 2003
70,000 (21km), see Note
Note: An external input fuse must always be used to meet these safety requirements. Contact SynQor for official safety certificates on new releases or
download from the SynQor website.
EMC CHARACTERISTICS (With SynQor AC Line Filter)
Conducted emissions
EN55011 and EN55022, FCC PART 15
Line frequency harmonics
Voltage fluctuations
EN61000-3-2
EN61000-3-3
ESD air
Radiated immunity
Fast transients
EN61000-4-2
EN61000-4-3
Line surge immunity
Conducted immunity
Power freq. mag. field
Voltage dip immunity
EN61000-4-5
EN61000-4-6
EN61000-4-8
EN61000-4-11
Product # PFCU390HPx07
EN61000-4-4
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Doc.# 005-0006254 Rev. D05/13/2014
Page 7
PFCU390HPx07
Power Factor Correction
Half-brick
Application Section
Basic Operation and Features
The PFCQor power factor correction module is an essential
building block of an overall high power AC-DC power
supply. As shown in Fig. A, a typical power supply would be
comprised of a SynQor AC Line Filter, a SynQor PFCQor
module, an energy storage hold-up capacitor and one or more
SynQor DC-DC converters, depending on how many output
voltages are required. Fuses are needed in various places to
meet safety requirements.
The primary purpose of the PFCQor is to shape the input
current that is drawn from a single-phase sinusoidal AC source
into a nearly perfect sinusoidal waveform so that the AC-DC
power supply will present a very high power factor load (PF >
0.99) to this source. In doing this wave-shaping, the PFCQor
ensures that the harmonic components of the AC current
waveform are well below the levels called for in EN61000-3-2.
The total harmonic distortion of the AC current waveform is
typically less than 10%. Figures B-1 and B-2 show what the
typical input current of an AC-DC power supply looks like
with and without power factor correction.
The PFCQor accomplishes its wave-shaping task by first
rectifying the filtered AC source voltage, and then processing
the input power through a non-isolated, high-efficiency,
high-frequency “boost converter” that both gives the input
AC current its sinusoidal shape and provides a regulated DC
voltage across the hold-up capacitor.
The hold-up capacitor handles the cyclic imbalance between
the flow of energy drawn from the AC source and the flow
of energy delivered to the DC-DC converters. This energy
imbalance has a cyclic frequency twice that of the AC source
voltage (e.g. 120Hz for a 60Hz input). This relatively low
frequency makes the hold-up capacitor relatively large. Another
purpose of the hold-up capacitor is to be a source of energy so
that the DC-DC converters can continue to deliver load power
during a temporary brownout or dropout of the AC source. A
typical power supply will have sufficient hold-up capacitor to
give a “hold-up time” in the 20ms range, but longer times can
be achieved with yet more hold-up capacitance.
Besides shaping the AC current waveform, the PFCQor
performs several other important functions. At start-up it
controls the level of inrush current drawn from the AC source
to charge the hold-up capacitor. It limits the DC current that
can be drawn from its output and it will shut-down if a short
circuit appears across the output. It will also shut-down if the
AC input voltage is out of its range (either too high or too low)
for too long, or if the temperature of the module is too high.
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In addition, the PFCQor has several input and output control
signals that include PFC ENABLE, LOAD ENABLE (which
doubles as a POWER OUT GOOD signal), AC GOOD,
CLOCK SYNCHRONIZATION, and OUTPUT
CURRENT MONITOR. All of these signals are described
in more detail below. There is also an auxiliary bias supply that
can be used to power a low power control circuit at the output
of the PFCQor.
StartUp Sequence
When the AC source voltage is first applied, regardless of
whether the PFCQor is enabled or disabled through its
PFC ENABLE pin, the PFCQor will pre-charge the output
hold-up capacitor with a current limited to approximately
100mA. This pre-charging continues until the output voltage
is within approximately 10V of the peak voltage of the AC
source. If, at this time, the PFC ENABLE input is logically
high, and the PFCQor is therefore disabled, the PFCQor will
remain in this pre-charged state indefinitely.
NOTE: During both this pre-charging time and for whatever
time afterwards that the PFCQor remains disabled it is
essential that all the load converters connected to the output
of the PFCQor be disabled so that the total load current
seen by the PFCQor is only a small fraction of the 100mA
charging current. To help facilitate this requirement, the
PFCQor’s LOAD ENABLE output can be used to disable
the load converters.
When the PFC ENABLE input pin is pulled low, and
after the pre-charging is completed if it is not already, the
boost converter within the PFCQor will start operating and
the PFCQor’s output voltage will be increased to its nominal
regulated value.
After this regulated voltage level is achieved, the PFCQor
will provide a logical low signal on its LOAD ENABLE output
pin. This signal should be used to enable the load converters so
that they can begin to draw power from the PFCQor.
If the PFC ENABLE input is de-asserted (pulled high or
allowed to float), the boost converter in the PFCQor will shut
down and the LOAD ENABLE output pin will return to a
logic high. This will then disable the load converters.
NOTE: The voltage across the hold-up capacitor will remain
in a charged state after the PFCQor is disabled as long as the
AC source voltage is present.
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Doc.# 005-0006254 Rev. D05/13/2014
Page 8
PFCU390HPx07
Power Factor Correction
Half-brick
Application Section
Brownout/Dropout Sequence
If the AC source voltage falls below the PFCQor’s specified
continuous minimum input voltage, the AC GOOD output
will de-assert (it will become a logic high), although the
PFCQor will continue to operate as described below. This
AC GOOD output signal can be used as a warning signal to
permit a graceful shutdown of the load after some period of
time that depends on the size of the hold-up capacitor.
If the AC source voltage is present but it is below its
continuous minimum input voltage limit, the PFCQor will still
draw whatever power it can (within its current limits) from the
AC source. This power may not be enough for the total load
power, in which case the hold-up capacitor will provide the
balance of the power. The voltage across the hold-up capacitor
will therefore drop as it discharges.
If the AC source voltage drops below its specified transient
minimum input voltage limit, the PFCQor’s boost converter
will shut down and no longer deliver power to the output.
Under this condition, all of the load power will be drawn from
the hold-up capacitor.
If and when the voltage across the hold-up capacitor drops
below its specified minimum limit, the LOAD ENABLE
output will be de-asserted to a logic high. Besides disabling
the load converters, this condition will cause the PFCQor
to return to the beginning of the STARTUP SEQUENCE
described above.
NOTE: Regardless of what happens to the PFCQor’s output
voltage under a brownout or dropout condition, if the AC
source voltage drops below its rated under-voltage value for 1
second or more, the PFCQor will shut down.
If, however, the voltage across the hold-up capacitor does not
drop below its specified minimum limit before the AC source
voltage returns to within its continuous operating range (and it
hasn’t been absent for more than 1 second), the PFCQor will
automatically re-establish its power flow. The hold-up capacitor
will be recharged immediately to the peak of the AC source voltage
(if it has fallen below this value) and to its nominal regulated
voltage level within a few cycles of the AC source waveform.
NOTE: During the first phase where the hold-up capacitor
is recharged (if it this phase exists) there will be an inrush
current drawn from the AC source that depends on the
details of how quickly the AC source voltage returns to its
normal operating condition.
When the AC source voltage as been within the PFCQor’s
specified continuous operating range for at least one cycle of the
source waveform, the AC GOOD output will again be asserted low.
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Control Features
Auxiliary Bias Power Supply (Pin 6):
The circuit shown below is an effective model for the AUX bias
power supply:
PFC Module
800V
1k
AUX
+10V
VOUT-
• The purpose of the AUX power supply is to provide a
low level of power to control circuitry at the output of the
PFCQor, such as the circuits shown earlier in this section.
• The AUX power supply is present and regulated whenever
the PFCQor’s output voltage is greater than approximately
75V. The AUX bias power supply is unspecified when
PFCQor’s output voltage is less than about 75V (it may,
for instance, come and go as the output voltage rises on its
way to 75V ).
PFC ENABLE (Pin 3):
The PFCQor uses the following circuit for this input logic
signal:
+5V
PFC Module
10k
50k
PFC ENA
800V
VOUT-
100k
1000p
• If this input is floating or tied high the PFCQor’s boost
converter is disabled and the LOAD ENABLE output
signal is de-asserted high.
• If this input is pulled low the PFCQor’s boost is enabled
after the pre-charger has charged the voltage across the
hold-up capacitor to within approximately 10 volts of the
peak of the AC source voltage.
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Doc.# 005-0006254 Rev. D05/13/2014
Page 9
PFCU390HPx07
Power Factor Correction
Half-brick
Application Section
LOAD ENABLE
(also: POWER OUT GOOD signal) (Pin 7):
• For high-side or remotely switched loads, an optoisolator
can be employed as shown below.
The PFCQor uses the following circuit for this output
logic signal:
VOUT+
AUX
PFC Module
PFC Module
Remotely
Switched
Load
5k
LOAD ENABLE
LOAD ENABLE
1000p
VOUT-
VOUT-
• When the LOAD ENABLE pin is internally pulled LOW
the load converters are permitted to draw power from the
PFCQor’s output.
• When the LOAD ENABLE floats all load converters
should disabled.
AC GOOD (Pin 8):
The PFCQor uses the following circuit for this output
logic signal:
• The LOAD ENABLE can be tied directly to the ON/OFF
control pins of SynQor’s DC-DC converters as shown in
Figure A.
• For loads that are not SynQor DC-DC converters and
that do not otherwise have a way to be enabled/disabled,
an external power MOSFET can be used to connect and
disconnect these loads from the PFCQor’s output based on
the status of the LOAD ENABLE signal, as shown below.
VOUT+
PFC Module
Switched
Load
AUX
50k
50k
LOAD ENABLE
VOUT-
PFC Module
AC GOOD
1000p
VOUT-
• The AC GOOD signal is internally pulled low whenever
the AC source voltage is within the PFCQor’s continuous
operating range for at least one cycle of the source waveform,
regardless of whether the PFCQor is enabled or disabled.
• When the peak of the AC source voltage is outside this
continuous operating range (either too high or too low), the
AC GOOD pin will float.
• The AC GOOD signal is typically used with a pullup
resistor and an opto-coupler (as shown in Fig. A) to provide
an isolated signal to the load that the AC source voltage is
no longer within the specified continuous operating range. If
this condition persists, the load power can only be delivered
for the “hold-up time”, and it may therefore be desirable to
have the load gracefully shut down. The AC GOOD signal
provides a warning for this action to be taken. When the AC
source voltage returns to the specified continuous operating
range, the AC GOOD signal will re-assert after a 100 ms
delay.
• The AC GOOD pin is valid whenever the AUX bias supply
power is valid (see above).
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Doc.# 005-0006254 Rev. D05/13/2014
Page 10
PFCU390HPx07
Power Factor Correction
Half-brick
Application Section
Output Current Monitor (Pin B):
The PFCQor uses the following circuit for this output
analog signal:
PFC Module
-
1.5k
IMON
+
VOUT-
• The IMON signal monitors the DC average output current,
line-frequency components are removed from IMON.
• The IMON output voltage is 0V at no-load and increases
linearly to 2V at full-load.
• Any monitoring of this output should be accomplished with
a high input impedance sensor as this pin is also used for
current sharing, see below.
Clock Synchronization (Pin 2):
The PFCQor uses the following circuit for this input
logic signal.
PFC Module
+5V
5k
Protection Features
Input Over- & Under-Voltage:
If the AC source voltage exceeds the maximum voltage rating
the PFCQor will shut down. However, under this condition the
PFCQor’s pre-charge circuit will continue to deliver 100mA
of current to the output whenever the AC source voltage is
higher than the dc output voltage. Care must be taken to
insure this condition does not allow the output voltage to rise
high enough to damage the PFCQor or the load converters.
If a brownout or dropout of the AC source voltage occurs,
and if it lasts long enough for the PFCQor’s output voltage
to drop below its specified minimum limit, the PFCQor will
shut down. Furthermore, regardless of what happens to the
PFCQor’s output voltage, if the AC source voltage drops
below its rated under-voltage value for 1 second or more, the
PFCQor will shut down.
After any shutdown the PFCQor will automatically return to
the beginning of the STARTUP SEQUENCE described above.
Output Over-Voltage:
If the output voltage exceeds its specified maximum limit, the
PFCQor’s boost converter will shutdown. However, under
this condition the PFCQor’s pre-charge circuit will continue
to deliver 100mA of current to the output whenever the AC
source voltage is higher than the dc output voltage. Care must
be taken to insure this condition does not allow the output
voltage to rise high enough to damage the PFCQor or the
load converters.
Output Current Limit & Short-Circuit
Shutdown:
5k
CLK SYNC
VOUT-
• The PFCQor performs optimally with a 200kHz
switching frequency. Deviation from this frequency will
result in a reduction of maximum output power. Consult
factory for details.
If the PFCQor’s output is overloaded such that its output
current limit becomes activated, the output voltage will fall as
the excess load current discharges the hold-up capacitor. The
PFCQor will continue to deliver power into this overload
condition for 100 ms, after which the unit will shut down
and automatically return to the beginning of the STARTUP
SEQUENCE described above. If at any point the output
voltage falls below the peak of the AC source voltage, the
PFCQor will immediately shut down and return to the
STARTUP SEQUENCE.
Over Temperature:
If the internal temperature of the PFCQor reaches
130°C the PFCQor will turn off its boost converter. The
LOAD ENABLE output will simultaneously be de-asserted
high. When the internal temperature falls below 110°C,
the PFCQor will return to the beginning of the STARTUP
SEQUENCE described above.
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Doc.# 005-0006254 Rev. D05/13/2014
Page 11
PFCU390HPx07
Power Factor Correction
Half-brick
Application Section
Energy Storage Hold-Up Capacitor
The hold-up capacitor performs two functions:
• It handles the cyclic imbalance between the flow of energy
drawn from the AC source and the flow of energy delivered
to the DC-DC converters. In doing so, the voltage across
the hold-up capacitor has a ripple at a frequency twice that
of the AC source voltage (e.g. 120Hz for a 60Hz input). The
larger the hold-up capacitor, or the higher the frequency of
the AC source, the smaller this ripple will be.
• It provides a source of energy so that the DC-DC converters
can continue to deliver load power during a temporary
brownout or dropout of the AC source. The larger the
hold-up capacitor the longer it can provide this energy.
Often it will be made large enough to allow the load to be
gracefully shutdown after the AC source has been outside of
its normal range for a set amount of time. A typical “holdup time” would be in the 20 ms range for a 50/60 Hz system.
The total energy stored in a hold-up capacitor having
capacitance C at any given voltage V is:
E = ½CV 2
The amount of energy, ∆E, which can be drawn from this
capacitor depends on the capacitor’s starting voltage, Vs ,
and its final voltage, Vf , where Vs is the PFCQor’s nominal
regulated output voltage and Vf is the PFCQor’s minimum
output voltage limit. This energy equals the amount of power,
P, which the DC-DC converters draw from the hold-up
capacitor times the length of time, ∆t, which it takes for the
hold-up capacitor’s voltage to drop from Vs to Vf . This energy
can be equated to the hold-up capacitance according to the
following formula:
∆E = P∆t = ½C(Vs2- Vf2)
This formula can be rearranged to find the minimum
required value for C to provide the hold-up time desired for
a given power level (note: this power level P is not the load
power, but rather the load power divided by efficiency of the
DC-DC converters):
Cmin = 2P∆t ⁄ ( Vs2- Vf2)
For example, is we assume P = 600W, ∆t = 20ms, Vs = 400V and
Vf = 200V, then we would want a hold-up capacitance of at
least 200µF.
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During the start-up sequence the PFCQor will pre-charge
the hold-up capacitor with approximately 100mA of current
until it has reached a voltage about 10V below the peak of the
AC source voltage. The time it takes for this to occur can be
calculated using the following formula:
t = CV/100mA
For example, if the AC source voltage is 230Vrms (Vpk =
325V) and the hold-up capacitor is 200µF, this length of time
will be approximately 0.6 seconds. The larger the hold-up
capacitor, the longer it will take.
After the hold-up capacitor’s voltage has reached this
level, and assuming the PFCQor has been enabled, the boost
converter in the PFCQor will quickly charge the hold-up
capacitor to the nominal regulated output voltage level.
NOTE: The PFCQor is able to operate with a minimum of
100uF of hold-up capacitance, but Synqor recommends at
least 330uF if the power system will be required to conform
to lightning surge standards. This is because the PFCQor
relies on the hold-up capacitor to absorb most of the energy
from a lightning surge.
NOTE: Even though the PFCQor limits the inrush
current drawn from the AC source during its STARTUP
SEQUENCE, it will not necessarily limit this current at the
end of a temporary brownout or dropout of the AC source
when the hold-up capacitor’s voltage has not dropped below
its minimum output voltage limit. In such a condition the
PFCQor will not reinitiate a STARTUP SEQUENCE and
it will therefore not limit the current flowing through it. If
the peak of the AC source voltage is greater than the holdup capacitor’s voltage at the end of the brownout/dropout
period, there will be a large inrush current for one half-cycle
as the hold-up capacitor’s voltage is charged up to the peak of
the AC source voltage. The larger the hold-up capacitor the
larger this inrush current will be. To keep this inrush current
within a reasonable limit, the maximum capacitance of the
hold-up capacitor is limited as specified in the Technical
Specifications table.
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Doc.# 005-0006254 Rev. D05/13/2014
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PFCU390HPx07
Power Factor Correction
Half-brick
Application Section
If it is desired to have a hold-up time longer than can be
achieved with this maximum specified hold-up capacitance,
then the circuit shown below can be used.
VOUT+
PFC Module
In this case, the hold-up capacitor would require a minimum
ripple current rating of 1.3Arms, and the output voltage would
have a pk-pk ripple voltage of 4.8V.
Rc
C1
C2
Safety Notes
VOUT-
In this circuit the total hold-up capacitance is (C1 + C2),
and it can be made as large as desired as long as C1 does not
exceed the maximum capacitance specified in the Technical
Specifications table. The resistor, Rc, in series with C2 is
present to limit the current that will charge this capacitor after
a temporary brownout/dropout event. Its resistance should be
large enough to limit the charging current to a fraction of the
PFCQor’s rated output current. The diode in parallel with the
resistor permits the load converters to draw whatever energy
they need from C2 without being hindered by the resistor.:
Output Ripple Considerations:
The hold-up capacitor must have a ripple current rating high
enough to withstand the ripple current generated on the output
of the PFCQor. Ripple current amplitude is dependent only
upon the total PFCQor output power, PDC, and the operating
output voltage VO. It can be calculated using the following
formula:
The output of the PFCQor is not isolated from the AC source, and
it is therefore a hazardous voltage. Care must be taken to avoid
contact with this voltage, as well as with the AC source voltage.
The PFCQor must have a fuse in series with its AC source.
The rating for this fuse is given in the Technical Specification
table. If multiple PFCQors are paralleled, there should be a
fuse for each PFCQor.
Thermal Consideration
The maximum operating base-plate temperature, TB, is 100 ºC.
Refer to the thermal derating curves to see the allowable power
output for a given baseplate temperature and input voltage.
A power derating curve can be calculated for any heatsink
that is attached to the base-plate of the converter. It is only
necessary to determine the thermal resistance, RTHBA, of the
chosen heatsink between the base-plate and the ambient air for
a given airflow rate. The following formula can then be used to
determine the maximum power the converter can dissipate for
a given thermal condition:
max
P diss =
The AC line frequency, fac, bulk capacitance, C, operating
output voltage, and output power will determine the amplitude
of the voltage ripple present on the output of the PFCQor. It
can be calculated with:
TB - TA
RTHBA
This value of power dissipation can then be used in
conjunction with the data shown in the figures to determine
the maximum load power that the converter can deliver in the
given thermal condition.
At 60 Hz:
For example, to calculate voltage and current ripple for a
PFCQor with a 700W output, 500uF hold-up capacitor, and a
60Hz fundamental AC line frequency:
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Doc.# 005-0006254 Rev. D05/13/2014
Page 13
PFCU390HPx07
Power Factor Correction
Half-brick
Application Section
AC Line Filter
An AC line filter is needed to attenuate the differential- and
common-mode voltage and current ripples created by the
PFCQor, the DC-DC converters and the load such that the
system will comply with EMI requirements. The filter also
provides protection for the PFCQor from high frequency
transients in the AC source voltage. SynQor has a family of AC
line filters that will provide these functions. It is recommended
that a metal-oxide varistor (MOV) be placed from line-to-line
on the input of the filter, and a TVS diode be placed from lineto-line on the output of the filter in order to keep the PFCQor
input voltage from exceeding 575V during all transients. See
Figure A for suggested parts. If a non-SynQor AC line filter is
used, the use of an MOV on the input and a TVS diode on the
output of the filter is still recommended.
EMI Considerations
To meet various conducted line emission standards, additional
Y-capacitors may be needed to attenuate common-mode noise.
Synqor recommends that saftey-rated ceramic capacitors be
placed across any isolated DC-DC converters on the output of
the PFC from Vin- to Vout- and Vout- to ground. See “Typical
Application of the PFC Module” (Figure A) for a diagram and
suggested parts.
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Paralleling Multiple PFCQors
In higher power applications, multiple units can be used in
parallel as shown below.
• To balance load currents evenly between PFCQor modules, a
0.1 ohm resistor must be placed in series with Vout- on each
module. The parallel diagram below shows correct placement
of the resistors in relation to other circuitry. Resistors must
be rated to handle RMS load return current.
• PFC ENABLE may be driven with a common signal, but a
100 ohm resistor should be placed in series with each input
before being connected to the common node.
• AUX Bias outputs can be directly connected together as shown.
• AC GOOD can drive a common signal, but a 100 ohm
resistor should be placed in series with each output before
being connected to the common node.
• The loads should only be enabled when all the individual
LOAD ENABLE outputs have been asserted low. The
circuit shown below combines the individual LOAD
ENABLE outputs into a single master LOAD ENABLE to
achieve this requirement.
• Active current sharing is accomplished by connecting all
IMON pins directly together. The voltage at the IMON
pins is then indicative of the average output current. Again,
any circuit used to monitor the IMON voltage should have
high input impedance.
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Doc.# 005-0006254 Rev. D05/13/2014
Page 14
PFCU390HPx07
Power Factor Correction
Half-brick
Application Section
Parallel Diagram
L1
F1
F3
L1
VOUT+
AC GOOD
TVS1
IMON
100
L2/N
PFC #1
VIN+
100
Load 1
AUX
50k
ENABLE
50k
PFC ENA
L2/N
MASTER
LOAD ENABLE
C1
LOAD ENABLE
R1
VOUT-
VIN-
0.1
ENABLE
F2
F4
L1
VOUT+
AC GOOD
TVS2
IMON
100
PFC #2
Load 2
AUX
ENABLE
50k
PFC ENA
L2/N
VIN+
100
LOAD ENABLE
VOUT-
R2
0.1
VIN5k
AC GOOD
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Page 15
PFCU390HPx07
Power Factor Correction
Half-brick
Encased Mechanical
2.486
.020 [63,14 0,5]
2.00 [50,8]
SIDE VIEW
1.400 [35,56]
1.000 [25,4]
+.002
.512
-.005
+0,05
13
-0,12
OVERALL HEIGHT
.700 [17,78]
.400 [10,16]
9
2.386
[60,6
[
.243 .020
[6,17 0,5]
.020
0,5]
6
7
8
5
]
.163
[4,15]
.243 .020
[6,17 0,5]
TOP VIEW
1.90
[48,3]
1.900
[48,26]
.233 .020
[5,92 0,5]
1
2
A
B
3
4
.400 [10,16]
THRU HOLE
M3 (SEE NOTE 2 AND 8)
STANDOFFS (4)
.800 [20,32]
1.000 [25,4]
.543 .020
[ 13,79 0,5]
1.400 [35,56]
NOTES
1. Baseplate flatness tolerance is 0.004” (.10 mm) TIR
for surface.
+.007
.022
-.010
+0,17
0,55
-0,25
[
]
PIN DESIGNATIONS
Pin Name
Function
1
L1
AC Line 1
2
CLK SYNC
Clock Synchronization Input
3. Pins 1-4, 6-8, and B are 0.040" (1.02mm) diameter,
with 0.080" (2.03mm) diameter standoff shoulders.
B
IMON
Output Current Monitor / Current Share
3
PFC ENA
Negative Logic PFC Enable
4. Pins 5 and 9 are 0.080" (2.03 mm) diameter with
0.125" (3.18 mm) diameter standoff shoulders.
4
L2/N
AC Line 2 / Neutral
5
VOUT(-)
Negative Output Voltage
5. All Pins: Material - Copper Alloy; Finish - Matte Tin
over Nickel plate
6
AUX
Auxiliary Bias power supply
7
LOAD ENA Negative Logic load enable and power
out good signal
8
AC GOOD
Negative Logic AC good signal
9
VOUT (+)
Positive Output voltage
2. Applied torque per screw should not exceed 6in-lb.
(0.7 Nm).
6. Undimensioned components are shown for visual
reference only.
7. Weight: 4.9 oz (139 g)
8. Threaded and Non-Threaded options available
9. All dimensions in inches (mm).
Tolerances:
x.xx +/-0.02 in. (x.x +/-0.5mm)
x.xxx +/-0.010 in. (x.xx +/-0.25mm)
unless otherwise noted.
10.Workmanship: Meets or exceeds IPC-A-610C Class II
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Doc.# 005-0006254 Rev. D05/13/2014
Page 16
PFCU390HPx07
Power Factor Correction
Half-brick
Encased Mechanical with Flange
3.15 [80]
2.486
.020 [63,14
0,5]
SIDE VIEW
1.400
[35,56]
1.000
[25,4]
.700
[17,78]
.400
[10,16]
USE W/ 4-40 OR
M3 SCREW (6x)
RECOM. TORQUE
3 in.lb
.13[3,3]
7
8
9
6
.500 .025
[12,7 0,63]
OVERALL
HEIGHT
.18 [4,6]
SEE NOTES 5 & 6
5
.010 [0,2]
1.900
[48,26]
TOP VIEW
1.61
[40,9]
1.87
[47,4]
2.386 .020
[60,6 0,5]
.31
.96 [7,9]
[24,4]
2
1
A
B
3
4
.400[10,16]
.600[10,16]
1.000[25,4]
.027
[0,69
.020
0,5]
.125
[3,18]
1.400[35,56]
.543
.020 [13,79
0,5]
.775
.020 [19,69
0,5]
.875
.020 [22,23
0,5]
2.175
.020 [55,25 0,5]
NOTES
1. Applied torque per screw should not exceed 5in-lb.
(3in-lb recommended).
PIN DESIGNATIONS
Pin Name
Function
1
L1
AC Line 1
2
CLK SYNC
Clock Synchronization Input
3. Pins 1-4, 6-8, and B are 0.040" (1.02mm) diameter,
with 0.080" (2.03mm) diameter standoff shoulders.
B
IMON
Output Current Monitor / Current Share
3
PFC ENA
Negative Logic PFC Enable
4. Pins 5 and 9 are 0.080 (2.03 mm) diameter with 0.125"
(3.18 mm) diameter standoff shoulders.
4
L2/N
AC Line 2 / Neutral
5
VOUT(-)
Negative Output Voltage
5. All Pins: Material - Copper Alloy; Finish - Matte Tin
over Nickel plate
6
AUX
Auxiliary Bias power supply
7
LOAD ENA Negative Logic load enable and power
out good signal
8
AC GOOD
Negative Logic AC good signal
9
VOUT (+)
Positive Output voltage
2. Baseplate flatness tolerance is 0.010" (.10 mm) TIR
for surface.
6. Undimensioned components are shown for visual
reference only.
7. Weight: 5.1 oz (145 g)
8. All dimensions in inches (mm).
Tolerances:
x.xx +/-0.02 in. (x.x +/-0.5mm)
x.xxx +/-0.010 in. (x.xx +/-0.25mm)
unless otherwise noted.
9. Workmanship: Meets or exceeds IPC-A-610C Class II
Product # PFCU390HPx07
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Page 17
PFCU390HPx07
Power Factor Correction
Half-brick
Ordering Information
Part Numbering Scheme
Family
PFC
Input Voltage Output
Performance
Package Size
Range
Voltage
Level
U: 85-264 Vrms
390: 390V
H: Half-brick
P: Peta
Thermal Design
Output
Power
C:Encased
D:Encased with
Non-threaded
Baseplate
V:Encased with
Flanged Baseplate
07: 700W
PART NUMBERING SYSTEM
The part numbering system for SynQor’s ac-dc converters follows the format
shown in the example below.
P FC U 390 H P C 0 7 S R S - G
6/6 RoHS
Options
(see Ordering Information)
Parallel
Capability
Input Phases Pin Style
S: Single-Phase
R: 0.180"
S: Supports
Parallel
Capability
ORDERING INFORMATION
The tables below show the valid model numbers and ordering options for
converters in this product family. When ordering SynQor converters, please
ensure that you use the complete 15 character part number consisting of
the 12 character base part number and the additional characters for options.
Add “-G” to the model number for 6/6 RoHS compliance.
Not all combinations make valid part numbers, please contact SynQor for
availability. See the Product Summary web page for more options.
Output Power
Thermal Design
Performance Level
Model Number
Input
Voltage
Output
Voltage
PFCU390HPC07SRS
85-264Vrms
390Vdc
Max Output
Power
Up to 700W
Package Size
APPLICATION NOTES
Output Voltage
A variety of application notes and technical white papers can be downloaded
in pdf format from our website.
Input Voltage Range
Product Family
The first 12 characters comprise the base part number and the last 3
characters indicate available options. The “-G” suffix indicates 6/6 RoHS
compliance.
RoHS Compliance: The EU led RoHS (Restriction of Hazardous
Substances) Directive bans the use of Lead, Cadmium, Hexavalent
Chromium, Mercury, Polybrominated Biphenyls (PBB), and Polybrominated
Diphenyl Ether (PBDE) in Electrical and Electronic Equipment. This SynQor
product is 6/6 RoHS compliant. For more information please refer to
SynQor’s RoHS addendum available at our RoHS Compliance / Lead Free
Initiative web page or e-mail us at [email protected].
PATENTS
SynQor holds the following U.S. patents, one or more of which apply to each product listed in
this document. Additional patent applications may be pending or filed in the future.
5,999,417
6,222,742
6,545,890
6,577,109
6,594,159
6,731,520
6,894,468
6,896,526
6,927,987
7,050,309
7,072,190
7,085,146
7,119,524
7,269,034
7,272,021
7,272,023
7,558,083
7,564,702
7,765,687
7,787,261
8,023,290
8,149,597
8,493,751
8,644,027
Contact SynQor for further information and to order:
Phone: ���������������������������� 978-849-0600
Toll Free:�������������������������� 888-567-9596
Fax:���������������������������������� 978-849-0602
E-mail:������������������������������ [email protected]
Web:�������������������������������� www.SynQor.com
Address:�������������������������� 155 Swanson Road
Boxborough, MA 01719 USA
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WARRANTY
SynQor offers a two (2) year limited warranty. Complete warranty
information is listed on our website or is available upon request from
SynQor.
Information furnished by SynQor is believed to be accurate and reliable.
However, no responsibility is assumed by SynQor for its use, nor for any
infringements of patents or other rights of third parties which may result
from its use. No license is granted by implication or otherwise under any
patent or patent rights of SynQor.
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