Power Factor Correction Module

PFCU390QPx04
Power Factor Correction
Quarter-Brick
Power Factor Correction Module
85-264Vrms
Input Voltage
47 - 63Hz / 360 - 800Hz
Input Frequency
390Vdc
350W
Output Voltage
Output Power
The PFCQor Power Factor Correction module
is an essential building block of an AC-DC
power supply. Used in conjunction with a holdup capacitor, SynQor’s 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 module is supplied
completely encased to provide protection from
the harsh environments seen in many industrial
and transportation environments.
≥0.99
Power Factor
Up to 95%
Full Load Efficiency
SRS-G
0QPC04
CTION
PFCU39 ACTOR CORRE
F
50W
3
R
E
c
d
W
V
O
0
P
rms 39
85-264V 360 - 800Hz
z/
47 - 63H
Control Features
• PFC Enable
• Load Enable (also: Power Out Good signal)
Operational Features
•
•
•
•
•
•
•
Input voltage range: 85-264Vrms
Universal input frequency range: 47 - 63Hz / 360 - 800Hz
350W output power
≥0.99 Power Factor
High efficiency: >95% (230Vrms)
Internal inrush current limit
Auxiliary 10V bias supply
•
•
•
•
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
Mechanical Features
•
•
•
•
Protection Features
Industry standard quarter-brick pin-out
Size: 1.54” x 2.39” x 0.50” (39.0 x 60.6 x 12.7 mm)
Total weight: 3.07 oz. (87 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
Safety Features
•
•
•
•
•
Input/Output to baseplate isolation 2150Vdc - pending
UL 60950-1:2007 - pending
CAN/CSA-C22.2 No. 60950-1:2007 - pending
EN60950-1/A12:2011 - pending
CE Marked - pending
Product # PFCU390QPx04
Phone 1-888-567-9596
Page No.
Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Standards & Qualification Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Application Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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Doc.# 005-0006788 Rev. 1 09/09/2015
Page 1
Technical Specification
PFCU390QPx04
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
Typical Application of the PFC Module
F1
L1
OUT
SynQor
AC Line Filter
MOV1
GND
L2/N
L1
L1
IN
IN
SynQor
PFC
Module
TVS1
PFCENA
L2/N
OUT
L2/N
+Sense
SynQor
ON/ DC-DC Trim
OFF Converter
AUx
-Sense
F1:
5A / 250V Fuse
Must prevent peak voltage from exceeding 575V during all transients
F2:
CHold-Up:
Usefuserecommendedinconverterspecification
CY1-Y2:
IN
LoadENA
-Vout
O
+Vout
+V
CHold-Up
ENABLE
MOV1, TVS1:
F2
+Vout
-Vout
-VIN
CY1
CY2
50–500μF(DependentonPowerLevelandLineFrequency)
See “EMI Considerations” in application notes
ExampleParts:
F1:
MOV1:
TVS1:
CHold-Up:
CY1:
CY2:
250VAC,5A;Littelfuse0216005.MXEP
300VAC,80J;EPCOSS10K300E2
300V,3J;twoVISHAY1.5KE200CAdevicesconnectedinseries
One 450V, 330uF; EPCOS B43508B5337M (-40C)
Two 250V, 560uF; Cornell Dubilier MLS561M250EB0C in series (-55C)
3.3nF,500VAC;VishayVY1332M59Y5UQ6TV0
10nF,300VAC;VishayVY2103M63Y5US63V7
Typical Application of the PFCQor module to create a multiple-ouput AC-DC Power Supply
Product # PFCU390QPx04
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Page 2
Technical Specification
PFCU390QPx04
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
PFCU390QPx04 Electrical Characteristics
Operating conditions of 115Vrms, 60Hz input, 350W output, 200uF 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 & Conditions
ABSOLUTE MAXIMUM RATINGS
Input Voltage (L1 to L2/N)
575
Isolation Voltage (Input / Output to Baseplate)
2150
Vdc
Operating Temperature
-40
100
°C
Baseplate temperature
Storage Temperature
-45
125
°C
Voltage at LOAD ENA pins
-0.3
16
V
Relative to Vout- pin
Current drawn from AUX pin
0
10
mADC
Voltage at PFC enable pin
-2
575
V
Relative to Vout- pin
INPUT CHARACTERISTICS (L1 to L2/N)
Operating Input Voltage Range
AC Input Continuous
85
264
Vrms
AC Input 100ms Transient
40
290
Vrms
Available output power reduced when <90 Vrms
Input Under-Voltage Lockout
30
Vrms
>1s Duration
Operating Input Frequency
47
63
Hz
50/60Hz range
360
800
Hz
400Hz range
Power Factor of AC Input Current
0.99
50/60Hz
0.97
400Hz, min 200W output
Total Harmonic Distortion of AC Input Current
3
%
Inrush of AC Input Current
When used with SynQor AC line filter
50/60Hz
10
Apk
Apk
400Hz
20
Enabled AC Input Current (no load)
50
80
mArms
Disabled AC Input Current
30
50
mArms
Maximum Input Power
385
W
Arms
Maximum Input Current
4.8
85 VAC in
OUTPUT CHARACTERISTICS
Output Voltage Set Point
385
390
395
Vdc
Output Voltage Regulation
Over Line
±0.3
%
Vin <240Vrms
Over Load
±2
%
Over Temperature
±1.5
%
Total Output Voltage Range
380
390
395
V
Output Voltage Ripple and Noise
60Hz, see Note 1
Peak-to-Peak
10
V
With 200uF hold-up capacitor
V
RMS
4
Operating Output Current Range
0
0.9
A
Output Over-Voltage Shutdown Threshold
440
460
V
Output (Hold-up) Capacitance
50
500
µF
See Note 2
Efficiency
50% Load
94
%
See Figure 1 for efficiency curve
100% Load
95
%
See Figure 1 for efficiency curve
Note 1: 200 µF electrolytic hold-up capacitor having a typical ESR of 0.5Ω. Ripple amplitude dependent on capacitance and ESR of hold-up capacitor.
Note 2: The PFCQor is able to operate with a minimum of 50uF 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 # PFCU390QPx04
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Doc.# 005-0006788 Rev. 1 09/09/2015
Page 3
Technical Specification
PFCU390QPx04
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
PFCU390QPx04 Electrical Characteristics (continued)
Operating conditions of 115Vrms, 60Hz input, 350W output, 200uF 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 & Conditions
DYNAMIC CHARACTERISTICS
Turn-On Transient
Start-up Inhibit Time
10
ms
Turn-On Time
2
s
Output Voltage Overshoot
0
2
%
ISOLATION CHARACTERISTICS (Input/output to baseplate)
Isolation Voltage
2150
V
Isolation Resistance
100
MΩ
Isolation Capacitance
100
pF
TEMPERATURE LIMITS FOR POWER DERATING CURVES
Semiconductor Junction Temperature
125
°C
Board Temperature
125
°C
Transformer Temperature
125
°C
Maximum Baseplate Temperature, Tb
100
°C
FEATURE CHARACTERISTICS
Output Precharge
Output Current
100
mA
Output Short-Circuit Withstand
indefinite
s
Free Running Switching Frequency
250
kHz
Each of 2 interleaved phases
PFC Enable (PFC ENA)
V
Off-State Voltage
2
V
On-State Voltage
0.8
V
Internal Pull-Up Voltage
5
V
Internal Pull-Up Resistance
10
kΩ
Load Enable
Pull-down resistance
20
Ω
Open collector
Output Voltage for Load Enable (Good) State
Rising / Startup
360
V
Falling / Shutdown
200
V
Over-Temperature Trip Point
130
°C
At internal PCB
Auxiliary Bias Supply
Voltage Range (≤3 mA Load)
7
11
V
Maximum Source Current
10
mA DC
Equivalent Series Resistance
1
kΩ
RELIABILITY CHARACTERISTICS
Calculated MTBF (Telcordia) TR-NWT-000332
TBD
106 Hrs. Tb = 70°C
Calculated MTBF (MIL-217) MIL-HDBK-217F
TBD
106 Hrs. Tb = 70°C
Field Demonstrated MTBF
TBD
106 Hrs. See our website for details
Product # PFCU390QPx04
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Doc.# 005-0006788 Rev. 1 09/09/2015
Page 4
Technical Specification
98.00
30
96.00
25
Power Dissipation (W)
Efficiency (%)
94.00
92.00
90.00
230Vrms
88.00
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
90Vrms
115Vrms
230Vrms
20
15
10
115Vrms
5
90Vrms
86.00
PFCU390QPx04
0
84.00
0
50
100
150
200
250
300
0
350
50
100
150
200
250
300
350
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 full rated power
(115Vrms, 60Hz) Top: Vin (100V/div), Bottom: Iin (5A/div), Timebase: (5ms/
div).
Figure 4: Typical Input Voltage and Current waveforms at full rated power
(115Vrms, 400Hz). Top: Vin (100V/div), Bottom: Iin (5A/div), Timebase: (1ms/
div).
435
350
430
300
115Vrms, 400Hz
425
230Vrms, 60Hz
150
100
50
0
1
0.99
0.98
0.97
0.96
0.95
0.94
0.93
0.92
0.91
0.9
Output Voltage (V)
200
420
MPFC Output Power (W)
250
115Vrms, 60Hz
Max
415
Typical
410
Min
405
400
395
390
385
380
375
85
Figure 5: Output power vs. leading power factor, PFC module only
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110
135
160
185
210
235
260
285
Input Voltage (Vrms)
Leading Power Factor
Figure 6: DC output voltage range vs. input voltage
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Doc.# 005-0006788 Rev. 1 09/09/2015
Page 5
Technical Specification
400
400
350
350
300
300
250
85 Vac
200
105 Vac
150
>115 Vac
100
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
Figure 8: Output voltage startup waveform with 200uF hold-up capacitor, no
load (115VAC, 60Hz) Vout (100V/div), Timebase: (500ms/div)
Power Output (W)
Power Output (W)
Figure 7: Output voltage ripple with 200μF Hold-up capacitor at full rated
power (115VAC, 60Hz) Vout (10V/div), Timebase: (5ms/div)
PFCU390QPx04
250
200
150
100
50
50
0
0
70
80
90
100
110
40
Base Plate Temperature (ºC)
Figure 9: Output power vs. baseplate temperature derating curve
Product # PFCU390QPx04
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65
90
115
140
165
190
215
240
265
290
Input Voltage (Vrms)
Figure 10: Output power vs. input voltage, output turn-on threshold is 85Vrms
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Doc.# 005-0006788 Rev. 1 09/09/2015
Page 6
Standards & Qualification Testing
PFCU390QPx04
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
Standards Compliance, Qualification Testing & EMC Characteristic
Parameter
Notes & Conditions
STANDARDS COMPLIANCE
UL 60950-1:2007
CAN/CSA-C22.2 No. 60950-1:2007
EN60950-1/A12:2011
CE Marked
Pending
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
QUALIFICATION TESTING
Life Test
Vibration
Mechanical Shock
Temperature Cycling
Power/Thermal Cycling
Design Marginality
Humidity
Solderability
# Units Test Conditions
32
5
5
10
5
5
5
15 pins
95% rated Vin and load, units at derating point, 1000 hours
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
-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
Tmin-10 °C to Tmax+10 °C, 5 °C steps, Vin = min to max, 0-105% load
85 °C, 95% RH, 1000 hours, continuous Vin applied except 5 min/day
MIL-STD-883, method 2003
EMC CHARACTERISTICS (With SynQor AC Line Filter)
Conducted emissions
Line frequency harmonics
Voltage fluctuations
ESD air
Radiated immunity
Fast transients
Line surge immunity
Conducted immunity
Power freq. mag. field
Voltage dip immunity
Product # PFCU390QPx04
Phone 1-888-567-9596
EN55011 and EN55022, FCC PART 15
EN61000-3-2
EN61000-3-3
EN61000-4-2
EN61000-4-3
EN61000-4-4
EN61000-4-5
EN61000-4-6
EN61000-4-8
EN61000-4-11
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Doc.# 005-0006788 Rev. 1 09/09/2015
Page 7
Application Section
PFCU390QPx04
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
Basic Operation & Features
StartUp Sequence
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 below the levels called for in MIL-STD-1399. The
total harmonic distortion of the AC current waveform is less than
8%.
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, highfrequency “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.
In addition, the PFCQor has input and output control signals
that include PFC_ENABLE, and LOAD_ENABLE, (which doubles
as a POWER_OUT_GOOD signal). Both 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.
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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Page 8
Application Section
Brownout/Dropout Sequence
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 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.
PFCU390QPx04
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
Control Features
Auxiliary Power Supply (AUX) (Pin 5):
The circuit shown below is an effective model for the
AUX bias power supply:
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 2):
The PFCQor uses the following circuit for this input
logic signal:
• 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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Page 9
Application Section
PFCU390QPx04
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
LOAD_ENABLE
(also: POWER OUT GOOD signal) (Pin 6):
The PFCQor uses the following circuit for this output logic
signal:
Protection Features
• 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.
• 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.
Input Over- and Under-Voltage:
If the AC source voltage exceeds the maximum peak voltage
rating defined in the electrical specifications, the PFCQor will
shut down. However, under this condition the PFCQor’s precharge 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 undervoltage 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:
• For high-side or remotely switched loads, an optoisolator can
be employed as shown below.
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If the output voltage exceeds its specified maximum limit, the
MPFC will remain active, but will stop delivering power through
its main boost stage until the output voltage falls below the overvoltage threshold.
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 ensure this
condition does not allow the output voltage to rise high
enough to damage the PFCQor or the load converters.
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Page 10
Application Section
Output Current Limit and Short-Circuit
Shutdown:
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.
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 “hold-up 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 = ½CV2
Product # PFCU390QPx04
Phone 1-888-567-9596
PFCU390QPx04
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
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 DCDC 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, if we assume P = 350W, ∆t = 20ms, Vs =
390V and Vf = 200V, then we would want a hold-up
capacitance of at least 125µF.
NOTE: The PFCQor is able to operate with a minimum of
50µF of hold-up capacitance, but SynQor recommends at least
330µF 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 hold-up 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 limit inrush
current during this event, limit the charging current of additional
hold-up capacitance a resistor and diode as shown below.
If it is desired to have a hold-up time longer than can be
achieved with the maximum specified hold-up capacitance, then
the circuit shown below can be used.
www.SynQor.com
Doc.# 005-0006788 Rev. 1 09/09/2015
Page 11
Application Section
PFCU390QPx04
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
For example, to calculate voltage and current ripple for a
PFCQor with a 350W output, 250µF hold-up capacitor, and a
60Hz fundamental AC line frequency:
𝐼𝐼𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 =
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:
𝑃𝑃𝐷𝐷𝐷𝐷
𝑃𝑃𝐷𝐷𝐷𝐷
𝐼𝐼𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 =
=
√2 ∙ 𝑉𝑉𝑂𝑂 551
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:
𝑃𝑃𝐷𝐷𝐷𝐷
𝑉𝑉𝑝𝑝𝑝𝑝−𝑝𝑝𝑝𝑝 =
2𝜋𝜋 ∙ 𝑓𝑓𝑎𝑎𝑎𝑎 ∙ 𝐶𝐶 ∙ 𝑉𝑉𝑂𝑂
𝐴𝐴𝐴𝐴 60 𝐻𝐻𝐻𝐻: 𝑉𝑉𝑝𝑝𝑝𝑝−𝑝𝑝𝑝𝑝 =
Product # PFCU390QPx04
𝑃𝑃𝐷𝐷𝐷𝐷
1.47 ∙ 105 ∙ 𝐶𝐶
Phone 1-888-567-9596
𝑉𝑉𝑝𝑝𝑝𝑝−𝑝𝑝𝑝𝑝 =
350𝑊𝑊
= 0.6𝐴𝐴𝑟𝑟𝑟𝑟𝑟𝑟
551
350𝑊𝑊
= 9.6𝑉𝑉𝑝𝑝𝑝𝑝−𝑝𝑝𝑝𝑝
2𝜋𝜋 ∙ 60𝐻𝐻𝐻𝐻 ∙ 250 ∙ 10−6 𝐹𝐹 ∙ 390𝑉𝑉
In this case, the hold-up capacitor would require a minimum
ripple current rating of 0.6Arms, and the output voltage would
have a pk-pk ripple voltage of 9.6V.
Safety Notes
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.
Thermal Consideration
The maximum operating base-plate temperature, TB, is
100ºC. 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 baseplate 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:
𝑇𝑇𝐵𝐵 − 𝑇𝑇𝐴𝐴
𝑚𝑚𝑎𝑎𝑎𝑎
𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
=
𝑅𝑅𝑇𝑇𝑇𝑇𝐵𝐵𝐵𝐵
This value of power dissipation can then be used in
conjunction with the data shown in the figures to determine
www.SynQor.com
Doc.# 005-0006788 Rev. 1 09/09/2015
Page 12
Application Section
PFCU390QPx04
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
the maximum load power that the converter can deliver in the
given thermal condition.
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 line-to-line on the output of the filter in
order to keep the PFCQor input voltage from exceeding
450V during all transients, except when the PFC is disabled,
when the input can tolerate 575V transients for up to
100ms. See Figure A for example 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.
Product # PFCU390QPx04
Phone 1-888-567-9596
www.SynQor.com
Doc.# 005-0006788 Rev. 1 09/09/2015
Page 13
Standard Mechanical Diagram
1.536 [39.01]
1.030 [26.16]
PFCU390QPx04
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
PIN EXTENSION
0.180
[4.57]
SEATING PLANE HEIGHT
0.500 0.025
[12.7 0.63]
0.450 [11.43]
4
TOP VIEW
5
6
8
0.004 [0.10]
1.860 2.386
[47.24] [60.60]
2.000
[50.80]
0.080
[2.03]
3
1
0.215
[5.46]
1)Applied torque per screw should not exceed 6in-lb. (0.7 Nm).
2)Baseplate flatness tolerance is 0.004” (.10 mm) TIR for surface.
3)Pins 1-3, 5-6 are 0.040” (1.02mm) diameter, with 0.080”
(2.03mm) diameter standoff shoulders.
4)Pins 4 and 8 are 0.062” (1.57 mm) diameter with 0.100”
(2.54 mm) diameter standoff shoulders.
5)All Pins: Material - Copper Alloy; Finish - Matte Tin over Nickel plate
6)Undimensioned components are shown for visual reference only.
7)Weight: 3.07 oz. (87 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
Phone 1-888-567-9596
1
BOTTOMSIDE CLEARANCE
0.005 0.010
[ 0.13 0. 25]
THREADED INSERT
SEE NOTE 1
(4 PLCS)
NOTES
Product # PFCU390QPx04
2
0.300 [7.62]
0.600 [15.24]
PIN DESIGNATIONS
Pin
Name
1
L1
PFC ENA
2
3
L2/N
4
-VOUT
5
AUX
6 LOAD ENA
8
+VOUT
www.SynQor.com
Function
AC Line 1
Negative Logic PFC Enable
AC Line 2 / Neutral
Negative Output Voltage
Auxiliary Bias power supply
Negative Logic load enable and power out good signal
Positive Output voltage
Doc.# 005-0006788 Rev. 1 09/09/2015
Page 14
Flanged Mechanical Diagram
2.200 [55.88]
2.000 [50.80]
1.536 [39.01]
SEATING PLANE HEIGHT
.500 .025
[12.7 0.63]
PFCU390QPx04
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
PIN EXTENSION
0.180
[4.6]
0.450 [11.4]
0.010 [0.25]
4 5 6
8
TOP VIEW
2.000
[50.8]
1.300 2.066 2.386
[33.02] [52.48] [60.60]
0.36
[9.1]
3
1
0.70
[17.8]
.130 [3.30]
SEE NOTE 1
(6 PLCS)
FLANGE THICKNESS
0.125
[3.2]
BOTTOMSIDE CLEARANCE
.010 .010
[0.51 0.25]
NOTES
1)Applied torque per screw should not exceed 5in-lb.
(3in-lb recommended).
2)Baseplate flatness tolerance is 0.010” (.2mm) TIR for surface.
3)Pins 1-3, 5-6 are 0.040” (1.02mm) diameter, with 0.080”
(2.03mm) diameter standoff shoulders.
4)Pins 4 and 8 are 0.062” (1.57 mm) diameter with 0.100”
(2.54 mm) diameter standoff shoulders.
5)Other Pin extensiom lengths available
6)All Pins: Material - Copper Alloy; Finish - Matte Tin over Nickel plate
7)Undimensioned components are shown for visual reference only.
8)Weight: 3.32 oz. (94 g)
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
Product # PFCU390QPx04
Phone 1-888-567-9596
2
1
0.300 [7.6]
0.600 [15.2]
PIN DESIGNATIONS
Pin
Name
1
L1
PFC ENA
2
3
L2/N
4
-VOUT
5
AUX
6 LOAD ENA
8
+VOUT
www.SynQor.com
Function
AC Line 1
Negative Logic PFC Enable
AC Line 2 / Neutral
Negative Output Voltage
Auxiliary Bias power supply
Negative Logic load enable and power out good signal
Positive Output voltage
Doc.# 005-0006788 Rev. 1 09/09/2015
Page 15
Ordering Information
Input Voltage
Family
Range
Output
Voltage
PFCU390QPx04
Package
Size
Part Numbering Scheme
Performance
Thermal Design
Level
Input:85-264Vrms
Output:390Vdc
Power:Up to 350W
Output
Power
Input Phases
Pin Style
Feature Set
04: 350W
S: Single-Phase
R: 0.180”
S: Standard
No Parallel
Capability
C: Encased
PFC
U: 85-264 Vrms
Q: Quarterbrick
390: 390V
P: Peta
V: Encased with
Flanged
Baseplate
PART NUMBERING SYSTEM
ORDERING INFORMATION
The part numbering system for SynQor’s dc-dc converters follows the format
shown in the example below.
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.
InQor units are only available with 6/6 RoHS compliance indicated by "-G".
PFC U 3 9 0 Q P C 0 4 S R S - G
6/6 RoHS
The following options must be included in place of the w x y z spaces in the
model numbers listed above.
Options
(see
Ordering Information)
Not all combinations make valid part numbers, please contact SynQor for
availability.
Output Power
Thermal Design
Performance Level
Application Notes
Package Size
A variety of application notes and technical white papers can be downloaded
in pdf format from our website.
Output Voltage
Input Voltage
RoHS Compliance: The EU led RoHS (Restriction of Hazardous
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.
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].
Contact SynQor for further information and to order:
PATENTS
Phone:
Toll Free:
Fax:
E-mail:
Web:
Address:
Product # PFCU390QPx04
978-849-0600
888-567-9596
978-849-0602
[email protected]
www.synqor.com
155 Swanson Road
Boxborough, MA 01719
USA
Phone 1-888-567-9596
SynQor holds numerous U.S. patents, one or more of which apply to most of its power converter
products. Any that apply to the product(s) listed in this document are identified by markings on
the product(s) or on internal components of the product(s) in accordance with U.S. patent laws.
SynQor’s patents include the following:
5,999,417
6,222,742
6,545,890
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
WARRANTY
SynQor offers a two (2) year limited warranty. Complete warranty information
is listed on our website or is available upon request from SynQor.
www.SynQor.com
Doc.# 005-0006788 Rev. 1 09/09/2015
Page 16