MPFC‑U‑390‑HP

MPFC-U-390-HP
Power Factor Correction
Half-brick
Military Power Factor Correction Module
85-264Vrms
47 - 63Hz / 360 - 800Hz
390Vdc
700W
≥0.99
Up to 95%
Input Voltage
Input Frequency
Output Voltage
Output Power
Power Factor
Full Load Efficiency
The MPFCQor Military 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 MCOTS DC-DC converters and
SynQor’s MCOTS AC line filter, the MPFCQor will draw
a nearly perfect sinusoidal current (PF>0.99) from
a single phase AC input. A version capable of being
paralleled for higher power levels is available. The
module is supplied completely encased to provide
protection from the harsh environments seen in
many industrial and transportation environments.
RRECTION
90-HP-N-M
MPFC-U-3 POWER FACTOR CO
Y
W
R
0
70
MILITA
s 390 Vdc
85-264Vrm360 - 800Hz
/
47 - 63Hz
Designed and manufactured in the USA
Operational Features
•
•
•
•
•
•
•
•
•
Input voltage range: 85-264Vrms
Universal input frequency range: 47 - 63Hz / 360 - 800Hz
700W output power
≥0.99 Power Factor
High efficiency: >95% (230Vrms)
Internal inrush current limit
Auxiliary 10V bias supply
Can be paralleled with current sharing
Compatible with SynQor’s MCOTS DC-DC converters
and SynQor’s MCOTS AC line filters
Mechanical Features
•
•
•
•
Industry standard half-brick pin-out
Size: 2.386” x 2.486” x 0.512” (60.6 x 63.1 x 13.0 mm)
Total weight: 4.9 oz (139 g)
Flanged baseplate version available
Safety Features
•
•
•
•
•
Input/Output to baseplate isolation 2150Vdc
UL 60950-1/R:2011-12
CAN/CSA-C22.2 No. 60950-1/A1:2011
EN60950-1/A2:2013
CE Marked
Product MPFC-U-390-HP
Phone 1-888-567-9596
Control Features
•
•
•
•
•
PFC Enable
Load Enable (also: Power Out Good signal)
AC Power Good Signal
Clock synchronization
Output current monitor / Active current sharing
Protection Features
•
•
•
•
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
Designed to meet these standards when used with
SynQor MACF Filters & MCOTS DC-DC Converters.
• MIL-STD-461(A-F)
• MIL-STD-1399
• MIL-STD-704-2, -704-4, & -704-6* (see 704 app section)
Contents
Page No.
Typical Application............................................................................2
Standards & Qualification Testing.......................................................7
Application Section............................................................................8
Encased Mechanical........................................................................16
Encased Mechanical with Flange......................................................17
Ordering Information......................................................................18
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 1
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Typical Application of the MPFC Module
F2
F1
L1IN
CLK Sync
SynQor
MCOTS
AC Line
Filter
MOV1
L1
L1OUT
TVS1
+Vout
SynQor
MPFC Module
IMON
GND
AC Good
L2/NOUT
L2/NIN
+Vout
ON/
OFF
+Sense
SynQor
MCOTS
DC-DC
Converter Trim
CHold-Up
Load ENA
PFC ENA
+VIN
AUX
L2/N
-Sense
-Vout
CY1
ENABLE
F1:
MOV1, TVS1:
F3
10A / 250V Fuse
Must prevent peak voltage from exceeding 575V during all
transients.
100 - 1,000 µF (Dependent on Power Level and Line Frequency)
CY1-Y4:
See “EMI Considerations” in application notes
●
●
●
ON/
OFF
CY2
+Vout
+VIN
F2, F3 :
CHold-Up:
-Vout
-VIN
+Sense
SynQor
MCOTS
DC-DC
Trim
Converter
-Sense
Example Parts:
250VAC, 10A; Littelfuse 0216010.MXEP
F1:
MOV1:
300VAC, 60J; EPCOS S10K300E2
TVS1:
400V, 3J; Two VISH
CHold-Up:
-VIN
-Vout
CY3
AY 1.5KE200CA devices connected in series
CY4
One 450V, 330uF; EPCOS B43508B5337M (-40C)
Two 250V, 560uF ; Cornell Dubilier MLS561M250EB0C in series (-55C)
CY1, CY3:
CY2, CY4:
3.3nF, 500VAC; Vishay VY1332M59Y5UQ6TV0
10nF, 300VAC; Vishay VY2103M63Y5US63V7
Isolated AC Good
Figure A: Typical Application of the MPFCQor module to create a multiple-ouput AC-DC Power Supply
Product # MPFC-U-390-HP
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 2
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Technical Specification
MPFC-U-390-HP Electrical Characteristics
Operating conditions of 115Vrms, 60Hz input, 700W output, 370uF bulk capacitance, and baseplate temperature = 25°C unless otherwise noted; full
operating baseplate temperature range is -55 °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
-55
100
°C
Baseplate temperature
Storage Temperature
-65
125
°C
Voltage at AC GOOD and 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
Voltage at CLK SYNC In
-2
5.5
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 <85 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 400W output
Total Harmonic Distortion of AC Input Current
3
%
Inrush of AC Input Current
When used with Synqor MACF 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
775
W
Arms
Maximum Input Current
9.5
85 VAC in
OUTPUT CHARACTERISTICS
Output Voltage Set Point
385
390
395
Vdc
Output Voltage Regulation
Over Line
±0.3
%
Vin <240 Vrms, see Figure 10
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 370uF hold-up capacitor
V
RMS
4
Operating Output Current Range
0
1.8
A
Output Over-Voltage Shutdown Threshold
440
460
V
Output (Hold-up) Capacitance
100
1,000
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: 300 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 MPFCQor 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 # MPFC-U-390-HP
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 3
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Technical Specification
MPFC-U-390-HP Electrical Characteristics (continued)
Operating conditions of 115Vrms, 60Hz input, 700W output, 370uF bulk capacitance, and baseplate temperature = 25°C unless otherwise noted; full
operating baseplate temperature range is -55 °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
200
kHz
Each of 4 interleaved phases
Clock Synchronization Input (CLK SYNC)
Frequency Range
150
250
kHz
Logic Level High
2
V
Logic Level Low
0.8
V
Duty Cycle
20
80
%
IMON
Output voltage (no load)
0
V
Output voltage (700W load)
2
V
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
AC Good (AC GOOD)
AC Input Voltage for AC Good
119
375
Vpk
Pull-down resistance
20
Ω
Open collector
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 (MIL-217) MIL-HDBK-217F
2000
kHrs
Ground Benign, Tb = 70°C
Calculated MTBF (MIL-217) MIL-HDBK-217F
200
kHrs
Ground Mobile, Tb = 70°C
Product # MPFC-U-390-HP
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 4
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Technical Specification
100
60
95
50
Power Dissipation (W)
Efficiency (%)
90
85
80
75
115 Vin
230 Vin
70
40
30
20
115 Vin
230 Vin
10
90 Vin
90 Vin
65
0
0
100
200
300
400
500
600
700
0
100
200
Output Power (W)
300
400
500
600
700
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).
700
115Vrms, 400Hz
700
115Vrms, 400Hz
600
230Vrms, 60Hz
600
400
300
200
500
115Vrms, 60Hz
400
300
200
100
100
0
1
0.99
0.98
0.97
0.96
0.95
0.94
0.93
0.92
0.91
0.9
0
1
Leading Power Factor
Figure 5: Output power vs. leading power factor, MPFC module only
Product # MPFC-U-390-HP
Phone 1-888-567-9596
MPFC Output Power (W)
500
115Vrms, 60Hz
MPFC Output Power (W)
230Vrms, 60Hz
0.95
0.9
0.85
0.8
0.75
0.7
0.65
0.6
Leading Power Factor
Figure 6: Output power vs. leading power factor, MPFC module with SynQor
MACF AC line filter
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 5
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Technical Specification
Figure 7: Output voltage ripple with 370μF Hold-up capacitor at full rated power
(115VAC, 60Hz) Vout (2V/div), Timebase: (5ms/div)
Figure 8: Output voltage startup waveform with 390uF hold-up capacitor, no load
(115VAC, 60Hz) Vout (100V/div), Timebase: (500ms/div)
435
800
430
700
425
420
Output Voltage (V)
Power Output (W)
600
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
120
375
85
Base Plate Temperature (ºC)
Figure 9: Output power vs. baseplate temperature derating curve
Product # MPFC-U-390-HP
Phone 1-888-567-9596
110
135
160
185
210
235
260
285
Input Voltage (Vrms)
Figure 10: DC output voltage range vs. input voltage
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 6
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Standards & Qualification Testing
STANDARDS COMPLIANCE
Input/Output to baseplate isolation 2150Vdc
CAN/CSA-C22.2 No. 60950-1/A1:2011
EN60950-1/A2:2013
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 Test Conditions
QUALIFICATION TESTING
Life Test
Vibration
Mechanical Shock
Temperature Cycling
Power/Thermal Cycling
Design Marginality
Humidity
Solderability
Altitude
32
5
5
10
5
5
5
15 pins
2
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 and y axis, 1 drop in 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, 85% RH, 1000 hours, continuous Vin applied except 5 min/day
MIL-STD-883, method 2003
70,000 (21km), see Note
Mil-COTS MIL-STD-810G Qualification Testing
MIL-STD-810G Test
Fungus
Method
508.6
Description
Table 508.6-I
500.5 - Procedure I
Storage: 70,000ft. / 2 Hr. duration
500.5 - Procedure II
Operating; 70,000ft. / 2 Hr. duration; Ambient Temperature
Rapid Decompression
500.5 - Procedure III
Storage: 8,000ft. to 40,000ft.
Acceleration
513.6 - Procedure II
Operating - 15g’s
Salt Fog
509.5
Storage
501.5 - Procedure I
Storage: 135°C / 3 hrs
501.5 - Procedure II
Operating: 100°C / 3 hrs
502.5 - Procedure I
Storage: -65C / 4 hrs
502.5 - Procedure II
Operating: -55C / 3 hrs
Temperature Shock
503.5 - Procedure I - C
Storage: -65C to 135C; 12 cycles
Rain
506.5 - Procedure I
Wind Blown Rain
Immersion
512.5 - Procedure I
Non-Operating
Humidity
507.5 - Procedure II
Aggravated cycle @ 95% RH (Figure 507.5-7 aggravated temp - humidity cycle, 15 cycles)
Random Vibration
514.6 - Procedure I
10-2000 Hz, PSD level of 1.5 g2/Hz(54.6grms), duration = 1 hr/axis
516.6 - Procedure I
20g’s peak, 11ms, Functional Shock (Operating no load) (saw tooth)
516.6 - Procedure VI
514.6 - Category 14
510.5 - Procedure I
Bench Handling Shock
Rotary wing aircraft - helicopter, 4hrs/axis, 20g’s (sine sweep from 10 - 500HZ)
Blowing Dust
510.5 - Procedure II
Blowing Sand
Altitude
High Temperature
Low Temperature
Shock
Sinusoidal vibration
Sand and Dust
Product # MPFC-U-390-HP
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 7
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Application Section
Basic Operation & Features
The MPFCQor 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 MCOTS AC Line Filter, a
SynQor MPFCQor module, an energy storage hold-up
capacitor and one or more SynQor MCOTS 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 MPFCQor 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 MPFCQor
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 MPFCQor 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 MPFCQor
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 MPFCQor 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
Product # MPFC-U-390-HP
Phone 1-888-567-9596
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
MPFCQor .
StartUp Sequence
When the AC source voltage is first applied, regardless of
whether the MPFCQor is enabled or disabled through its
PFC_ENABLE pin, the MPFCQor 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 MPFCQor is therefore disabled, the MPFCQor
will remain in this pre-charged state indefinitely.
NOTE: During both this pre-charging time and for
whatever time afterwards that the MPFCQor remains disabled
it is essential that all the load converters connected to the
output of the MPFCQor be disabled so that the total load
current seen by the MPFCQor is only a small fraction of the
100mA charging current. To help facilitate this requirement,
the MPFCQor’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 MPFCQor will start operating and the
MPFCQor ’s output voltage will be increased to its nominal
regulated value.
After this regulated voltage level is achieved, the MPFCQor
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 MPFCQor .
If the PFC_ENABLE input is de-asserted (pulled high or
allowed to float), the boost converter in the MPFCQor 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 MPFCQor is disabled as long as the AC
source voltage is present.
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 8
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Application Section
Brownout/Dropout Sequence
If the AC source voltage falls below the MPFCQor’s specified
continuous minimum input voltage, the AC_GOOD output will
de-assert (it will become a logic high), although the MPFCQor
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 MPFCQor 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 MPFCQor’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 holdup 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 MPFCQor to return to
the beginning of the startup sequence described above.
NOTE: Regardless of what happens to the MPFCQor’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 MPFCQor 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 MPFCQor 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 MPFCQor’s
specified continuous operating range for at least one cycle of the
source waveform, the AC_GOOD output will again be asserted
low.
Product # MPFC-U-390-HP
Phone 1-888-567-9596
Control Features
Auxiliary Power Supply (AUX) (Pin 6):
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
MPFCQor, such as the circuits shown earlier in this section.
The AUX power supply is present and regulated
whenever the MPFCQor’s output voltage is greater than
approximately 75V. The AUX bias power supply is
unspecified when MPFCQor’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 MPFCQor uses the following circuit for this input
logic signal:
• If this input is floating or tied high the MPFCQor’s boost
converter is disabled and the LOAD_ENABLE output signal
is de-asserted high.
• If this input is pulled low the MPFCQor’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.
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 9
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Application Section
LOAD_ENABLE
(also: POWER OUT GOOD signal) (Pin 7):
The MPFCQor uses the following circuit for this output
logic signal:
• When the LOAD_ENABLE pin is internally pulled LOW the
load converters are permitted to draw power from the
MPFCQor ’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 MPFCQor ’s output based on the status of the
LOAD_ENABLE signal, as shown below.
• For high-side or remotely switched loads, an optoisolator can
be employed as shown below.
AC_GOOD (Pin 8):
The MPFCQor uses this circuit for this output logic
signal:
• The AC_GOOD signal is internally pulled low whenever the
AC source voltage is within the MPFCQor ’s continuous
operating range for at least one cycle of the source waveform,
regardless of whether the MPFCQor 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).
Product # MPFC-U-390-HP
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 10
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Application Section
Output Current Monitor (Pin B):
The MPFCQor uses this circuit for this output analog signal:
• 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 MPFCQor uses the following circuit for this input
logic signal.
• The MPFCQor performs optimally with a 200kHz switching
frequency. Deviation from this frequency will result in a
reduction of maximum output power. Consult factory for details.
Protection Features
If the AC source voltage exceeds the maximum peak voltage
rating defined in the electrical specifications, the MPFCQor will
shut down. However, under this condition the MPFCQor’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
MPFCQor or the load converters.
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Output Over-Voltage:
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 over-voltage threshold.
Under this condition, the MPFCQor’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
MPFCQor or the load converters.
Output Current Limit and Short-Circuit
Shutdown:
If the MPFCQor’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 MPFCQor 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 MPFCQor
will immediately shut down and return to the startup
sequence.
Over Temperature:
Input Over- and Under-Voltage:
Product # MPFC-U-390-HP
If a brownout or dropout of the AC source voltage occurs, and if
it lasts long enough for the MPFCQor ’s output voltage to drop
below its specified minimum limit, the MPFCQor will shut
down. Furthermore, regardless of what happens to the
MPFCQor’s output voltage, if the AC source voltage drops
below its rated under-voltage value for 1 second or more, the
MPFCQor will shut down.
After any shutdown, the MPFCQor will automatically return to
the beginning of the startup sequence described above.
If the internal temperature of the MPFCQor reaches 130°C,
the MPFCQor 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
MPFCQor will return to the beginning of the startup sequence
described above.
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 11
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
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 “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
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 MPFCQor’s nominal regulated
output voltage and Vf is the MPFCQor’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:
For example, if we assume P = 600W, ∆t = 20ms, Vs = 390V
and Vf = 200V, then we would want a hold-up capacitance of
at least 215µF.
NOTE: The MPFCQor 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 MPFCQor relies on
the hold-up capacitor to absorb most of the energy from a
lightning surge.
NOTE: Even though the MPFCQor 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 MPFCQor 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 holdup 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 with a resistor
and diode as shown below.
∆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)
Product # MPFC-U-390-HP
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Doc.# 005-0006642 Rev. B
05/14/2015
Page 12
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Application Section
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.
For example, to calculate voltage and current ripple for a
MPFCQor with a 700W output, 500uF hold-up capacitor, and a
60Hz fundamental AC line frequency:
𝐼𝐼𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 =
𝑉𝑉𝑝𝑝𝑝𝑝−𝑝𝑝𝑝𝑝 =
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 MPFCQor’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 MPFCQor. Ripple current amplitude is dependent only
upon the total MPFCQor 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 MPFCQor. It can be
calculated with:
𝑃𝑃𝐷𝐷𝐷𝐷
𝑉𝑉𝑝𝑝𝑝𝑝−𝑝𝑝𝑝𝑝 =
2𝜋𝜋 ∙ 𝑓𝑓𝑎𝑎𝑎𝑎 ∙ 𝐶𝐶 ∙ 𝑉𝑉𝑂𝑂
𝐴𝐴𝐴𝐴 60 𝐻𝐻𝐻𝐻: 𝑉𝑉𝑝𝑝𝑝𝑝−𝑝𝑝𝑝𝑝 =
Product # MPFC-U-390-HP
𝑃𝑃𝐷𝐷𝐷𝐷
1.47 ∙ 105 ∙ 𝐶𝐶
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700𝑊𝑊
= 1.3𝐴𝐴𝑟𝑟𝑟𝑟𝑟𝑟
551
700𝑊𝑊
= 9.6𝑉𝑉𝑝𝑝𝑝𝑝−𝑝𝑝𝑝𝑝
2𝜋𝜋 ∙ 60𝐻𝐻𝐻𝐻 ∙ 500 ∙ 10−6 𝐹𝐹 ∙ 390𝑉𝑉
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 9.6V.
Safety Notes
The output of the MPFCQor 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 MPFCQor must have a fuse in series with its AC source.
The rating for this fuse is given in the Technical Specification
table. If multiple MPFCQors are paralleled, there should be a fuse
for each MPFCQor.
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 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:
𝑇𝑇𝐵𝐵 − 𝑇𝑇𝐴𝐴
𝑚𝑚𝑚𝑚𝑚𝑚
𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
=
𝑅𝑅𝑇𝑇𝑇𝑇𝐵𝐵𝐵𝐵
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.
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 13
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Application Section
MIL-STD-704 Power Level & Power Factor
All versions of MIL-STD-704 state that single-phase loads must
draw less than 500VA of AC power. To meet this requirement,
the MPFC’s output power must be kept below approximately
450W.
Section 5.4.3 of MIL-STD-704F states that AC equipment
drawing greater than 100VA shall have no leading power factor.
Most electronic loads, including the SynQor MPFC, contain a
small amount of differential filter capacitance across the AC
input, which draws a small amount of leading reactive power.
This has a negligible effect on the power factor of the MPFC
when it is drawing significant real power. Regardless, a small
amount of leading power factor exists, and an exception to
MIL-STD-704F section 5.4.3 must be taken. Use Figures 5 & 6
to determine the amount of leading power factor and ensure
compatibility with the target AC power system.
•
•
•
•
To meet various conducted line emission standards, additional Ycapacitors 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.
Paralleling Multiple MPFCQors
In higher power applications, multiple units can be used in parallel
as shown below.
• To balance load currents evenly between MPFCQor 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.
CFILT = MACF filter effective capacitance
CPFC = MPFC effective capacitance
RPFC = MPFC load
POUT = MPFC total output power
• AUX Bias outputs can be directly connected together as shown.
This is an approximate representation of the input stage of the
MPFC and MACF filter for the purpose of calculating the
leading reactive power and power factor. The resistor represents
in-phase current and varies with the load power. The capacitors
represent the reactive current draw and are approximately
constant over load.
MCOTS AC Line Filter
EMI Considerations
• 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 of 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.
An AC line filter is needed to attenuate the differential- and
common-mode voltage and current ripples created by the
MPFCQor , the DC-DC converters, and the load, such that the
system will comply with EMI requirements. The filter also
provides protection for the MPFCQor 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 MPFCQor
input voltage from exceeding 575V during all transients. 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.
Product # MPFC-U-390-HP
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 14
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Application Section
PARALLEL DIAGRAM
Product # MPFC-U-390-HP
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 15
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Encased Mechanical
2.486 [63.14]
SEATING PLANE HEIGHT
0.512 0.005
[ 13.00 0.12]
2.000 [50.80]
PIN EXTENSION
0.163
[4.14]
0.700 [17.78]
5
6
7
8
9
TOP VIEW
0.004 [0.10]
1.900 2.386
[48.26] [60.60]
0.01
[0.3]
1.900
[48.26]
4
1
0.30
[7.6]
THRU HOLE STANDOFFS
SEE NOTE 1
(4 PLCS)
B
2
1
0.400
0.800
1.000
1.400
BOTTOMSIDE CLEARANCE
0.027 0.010
[ 0.69 0. 25]
NOTES
[10.16]
[20.32]
[25.40]
[35.56]
PIN DESIGNATIONS
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 1-4, 6-8, and B are 0.040” (1.02mm) diameter, with 0.080”
(2.03mm) diameter standoff shoulders.
4)Pins 5 and 9 are 0.080” (2.03 mm) diameter with 0.125”
(3.18 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: 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
Product # MPFC-U-390-HP
3
Phone 1-888-567-9596
Pin
1
2
B
Name
L1
CLK SYNC
IMON
3 PFC ENA
Function
AC Line 1
Clock Synchronization Input
Output Current Monitor / Current Share
4
5
6
7
AC Line 2 / Neutral
Negative Output Voltage
Auxiliary Bias power supply
Negative Logic load enable and power out good signal
L2/N
-VOUT
AUX
LOAD ENA
Negative Logic PFC Enable
8 AC GOOD
Negative Logic AC Good signal
9 +VOUT
Positive Output voltage
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 16
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Encased Mechanical with Flange
3.150 [80.01]
0.700 [17.78]
2.950 [74.93]
2.486 [63.14]
SEATING PLANE HEIGHT
0.495 0.025
[ 12.57 0.63]
PIN EXTENSION
0.180 [4.57]
5
TOP VIEW
7
6
8
9
0.010 [0.25]
1.900
[48.26]
1.300 1.866 2.386
[33.02] [47.40] [60.60]
0.31
[7.9]
4
3
B
2
1
1
0.775 0.020
[19.69 0.50]
FLANGE THICKNESS
0.125
[3.18]
.130 [3.30]
SEE NOTE 1
(6 PLCS)
BOTTOMSIDE CLEARANCE
0.005 0.010
[ 0.13 0. 25]
0.400 [10.16]
0.800 [20.32]
1.000 [25.40]
1.400 [35.56]
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 1-4, 6-8, and B are 0.040” (1.02mm) diameter, with 0.080”
(2.03mm) diameter standoff shoulders.
4)Pins 5 and 9 are 0.080” (2.03 mm) diameter with 0.125”
(3.18 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: 5.1 oz (145 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 # MPFC-U-390-HP
Phone 1-888-567-9596
PIN DESIGNATIONS
Pin
1
2
B
Name
L1
CLK SYNC
IMON
3 PFC ENA
Function
AC Line 1
Clock Synchronization Input
Output Current Monitor / Current Share
4
5
6
7
AC Line 2 / Neutral
Negative Output Voltage
Auxiliary Bias power supply
Negative Logic load enable and power out good signal
L2/N
-VOUT
AUX
LOAD ENA
Negative Logic PFC Enable
8 AC GOOD
Negative Logic AC Good signal
9 +VOUT
Positive Output voltage
www.synqor.com
Doc.# 005-0006642 Rev. B
05/14/2015
Page 17
MPFC-U-390-HP
Input:85-264Vrms
Output:390Vdc
Power:700W
Ordering Information
Ordering Information / Part Numbering Scheme
Family
Input Voltage
Output Voltage
Package Size
Thermal Design
Screening Level
N: Encased
MPFC
U: 85-264V
390: 390V
HP: Half-brick Peta
D: Encased with Non-threaded Baseplate
S: S-Grade
M: M-Grade
F: Encased with Flanged Baseplate
Example: MPFC-U-390-HP-N-M
PART NUMBERING SYSTEM
APPLICATION NOTES
Contact SynQor for further information and to order:
PATENTS
The part numbering system for SynQor’s ac-dc converters follows the format
shown in the example.
Phone:
Toll Free:
Fax:
E-mail:
Web:
Address:
Product # MPFC-U-390-HP
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
A variety of application notes and technical white papers can be downloaded in pdf format from our website.
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.# 005-0006642 Rev. B
05/14/2015
Page 18