PFC-650 Series 650 Watt PFC Front End Univerter® Power Factor Correction Module The Univerter PFC-650 Power Factor Correction modules are AC to DC converters that operate from wide range AC input voltages and frequencies with extremely high conversion ef f iciency and near unit y power f act or , producing an output of 375VDC. The PFC650U operates from the universal input voltage range of 90 to 265VAC and input frequencies in the range of 47 to 440Hz making it ideal for applications requiring Power Factor Correction the world over. Model PFC-650W is optimized for input voltages in the 90 to 180VAC range and input frequencies in the range of 330 to 880Hz making it an ideal choice for both military and commercial aircraft applications. These compact power modules use advanced electrical design and thermal management techniques that make them suitable for rugged, environmentally challenged applications . FEATURES Extremely High Efficiency – 94% typ Near Unity Power Factor – 0.99 typ. High Power Density – 150W/in³ -40ºC to +100 ºC Operation Standard -55ºC to +100 ºC Operation Optional Extremely Low Thermal Resistance Conduction Cooled Rugged Encapsulated Package Active Inrush Current Limiting LD ENA Signal Controls Downstream Converters MIL-STD-704/DO-160 Compatible Compact ¾ Brick Package 3.6 x 2.4 x 0.5 in. MODEL SELECTION MODEL Input Voltage, VAC Input Frequency, Hz PFC-650U 90 - 265 47 - 440 PFC-650W 90 - 180 330 - 880 Typical Application: Astrodyne USA: 1-800-823-8082 Astrodyne Pacific: 886-2-26983458 PFC-650 Series 650 Watt Power Factor Correction Module 375 VDC Output, ¾ Brick Package ABSOLUTE MAXIMUM RATINGS Exceeding absolute maximum ratings may cause permanent damage or reduce reliability PARAMETER OPTION MINIMUM MAXIMUM UNITS CONDITIONS Input Voltage (AC1 to AC2) 265 VAC Continuous Input Voltage (AC1 to AC2) 280 VAC 100ms max. 15.0 Vdc 2500 Vdc LD ENA Voltage (LD ENA to -Vout) -0.3 Circuit-to-Case Voltage Storage Temperature Operating Temperature Standard -55 110 °C T -55 110 °C E -55 125 °C Standard -40 100 °C Baseplate T -55 100 °C Baseplate E -55 125 °C Baseplate 260 °C < 5 sec Soldering Temperature SPECIFICATIONS Electrical specifications apply for Vin = 115VAC, 60Hz (400Hz for PFC-650W model) Full Load, Tc=25 °C unless specified otherwise INPUT SPECIFICATIONS MINIMUM TYPICAL MAXIMUM UNITS PFC-650U 90 115/230 265 VAC PFC-650W 90 115 180 VAC PFC-650U 47 50/60/400 440 Hz PFC-650W 330 400/600 880 Hz CONDITIONS Input Voltage Input Line Frequency Power Factor PFC-650U 0.999 Vin = 115VAC, 60 Hz, Full Load PFC-650U 0.990 Vin = 230VAC, 50 Hz, Full Load PFC-650W 0.980 Vin =115VAC, 400 Hz, Full Load Astrodyne Corp. 1-800-823-8082 PFC-650 Datasheet 04-16-12 Page 2 of 7 PFC-650 Series 650 Watt Power Factor Correction Module 375 VDC Output, ¾ Brick Package SPECIFICATIONS (continued) Electrical specifications apply for Vin = 115VAC, 60Hz (400Hz for PFC-650W model) Full Load, Tc=25 °C unless specified otherwise Total Harmonic Distortion PFC-650U TBD PFC-650W TBD Maximum Input Current 8.1 6.2 Arms Vin = 90VAC, Full Load, Tc = 25°C Arms Vin = 115VAC, Tc = 100°C Inrush Current PFC-650U 25 PFC-650W 10 Input-to-Case Leakage Current Using 15Ω external Rss. A TBD µArms Start-up Voltage 70 80 85 VAC Input Under Voltage 65 75 85 VAC Ride Through Time OUTPUT SPECIFICATIONS TBD Vin = 115VAC, Single Ø with one lead earthed ms MINIMUM TYPICAL MAXIMUM Output Voltage 370 375 Output Current 0 Output Current Limit 115VAC, 400Hz UNITS CONDITIONS 380 Vdc Vin = 115VAC, Tc = 25°C 1.75 ADC NONE Ripple PFC-650U 30 V p-p Vin = 115VAC, 60Hz, C hold up = 440uF PFC-650W 30 V p-p Vin = 115VAC, 400Hz, C hold up = 136uF Hold Up Capacitance PFC-650U 220 1000 µF PFC-650W 40 220 µF Efficiency PFC-650U 0.990 Vin = 115VAC, 60 Hz, Full Load PFC-650U 0.999 Vin = 230VAC, 50 Hz, Full Load PFC-650W 0.94 Vin =115VAC, 400 Hz, Full Load Astrodyne Corp. 1-800-823-8082 PFC-650 Datasheet 04-16-12 Page 3 of 7 PFC-650 Series 650 Watt Power Factor Correction Module 375 VDC Output, ¾ Brick Package SPECIFICATIONS (continued) Electrical specifications apply for Vin = 115VAC, 60Hz (400Hz for PFC-650W model) Full Load, Tc=25 °C unless specified otherwise CONTROL SPECIFICATIONS MINIMU M TYPICAL MAXIMUM UNITS CONDITIONS LD ENA Threshold (Vout rising) 320 360 Vdc LD ENA threshold (Vout falling) 205 235 Vdc LD ENA Logic Low Current 20 mA LD ENA Logic Low Voltage 0.5 Vdc LD ENA LOGIC LOW SINK CURRENT = 10mA UNITS CONDITIONS ISOLATION SPECIFICATIONS MINIMU M Input-to-Output Isolation TYPICAL MAXIMUM Non-isolated Vdc Input-to-Case Isolation 2500 Vdc Output-to-Case Isolation 2500 Vdc Circuit-to-Case Capacitance THERMAL/ MECHANICAL SPECIFICATIONS TBD MINIMU M TYPICAL pF MAXIMUM UNITS CONDITIONS Thermal Shutdown Temperature 105 °C Baseplate temp Thermal Shutdown Restart Temperature 85 °C Baseplate temp Thermal Resistance, Case to Ambient 4.2 °C/W Natural Convection in Free Air, No Heatsink, Tc = 100°C 0.5 x 2.4 x 3.6 (12.7 x 61.0 x 91.4) in (mm) 3/4 Brick, See Outline Drawing 5.7 (161) oz. (gm) Size, l x w x h Weight EMC COMPLIANCE EXTERNAL FILTER COMPLIANCE MIL-STD-461E FA250-6 YES RTCA DO-160E TBD RELIABILITY MTBF Prediction Astrodyne Corp. 1-800-823-8082 MINIMU M TYPICAL MAXIMUM 1.8 PFC-650 Datasheet 04-16-12 UNITS CONDITIONS M hrs MIL-217F GB 25°C Page 4 of 7 PFC-650 Series 650 Watt Power Factor Correction Module 375 VDC Output, ¾ Brick Package Outline Drawing Pin Function/Description AC1, AC2 These are the AC input terminals. The input should be connected to a suitable input filter in order to for the PFC module to perform properly and reliably and to comply with applicable EMI performance standards. +Out This is the positive output terminal. It should be connected to the positive terminal of the hold up capacitor. The 375 VDC output will appear here w.r.t the –Out terminal. Hold-up capacitor value ranges are provided in the specifications. The hold- Astrodyne Corp. 1-800-823-8082 up capacitor must be located in close proximity to the PFC output terminals. LD ENA This terminal provides logic control to downstream DC/DC converters. The LD ENA signal will be a logic low during PFC start up and will switch logic state (to open collector) upon the PFC output reaching 340 VDC. If AC input power is lost, the LD ENA will again go low when the PFC output drops to 220 VDC. For many RO DC/DC products, it is not necessary to use the LD ENA terminal. Please PFC-650 Datasheet 04-16-12 Page 5 of 7 PFC-650 Series 650 Watt Power Factor Correction Module 375 VDC Output, ¾ Brick Package see the applications notes or consult the factory for more information. RSS This terminal is internally connected to inrush control circuitry on model PFC-650U and is N/C on model PFC-650W. Model PFC-650W has a built in inrush limiting resistor whereas for model PFC-650U the resistor must be provided externally. For PFC650U, connect one end of the inrush limiting resistor to this terminal. The other end of the resistor will be connected to –Out. The external inrush resistor must be chosen to handle the inrush energy which is determined by the input voltage and hold-up capacitor value selected. The inrush connection diagram provides some specific recommendations. Consult the factory for assistance or additional information on selecting an inrush resistor. -Out This is the PFC negative output terminal. It should be connected to the negative terminal of the hold up capacitor. For model PFC-650U, connect one end of the inrush resistor to this terminal. Application Diagram The connection diagram below shows proper connections between PFC-650 modules, hold-up capacitor, inrush limiting resistor (if required) and DC/DC converters. For PFC-650W, the inrush limiting resistor is built-in and an external resistor is not required. The resistor is appropriately sized for a maximum input voltage of 180VAC and a maximum external hold-up capacitor value of 220uF. For PFC-650U, an external inrush limiting resistor must be provided and connected as shown in the connection diagram for PFC-650U. A resistor with high surge handling capability should be used. The maximum input voltage, external hold-up capacitor value and temperature must be considered in choosing a resistor. The maximum RMS input voltage and resistor value will determine the maximum inrush current. A resistor value between 10 and 20 ohms should be chosen. The surge energy in the resistor is that required to charge the hold- Connection Diagram for PFC-650U up capacitor up to the peak of the line. After that, internal circuitry will both bypass the external resistor with essentially a short circuit and limit additional inrush current. Astrodyne Corp. 1-800-823-8082 PFC-650 Datasheet 04-16-12 Page 6 of 7 PFC-650 Series 650 Watt Power Factor Correction Module 375 VDC Output, ¾ Brick Package PFC-650W Power Factor PFC-650U Power Factor 1.00 Power Factor Power Factor 0.98 230VAC, 50Hz 0.96 115VAC, 60Hz 0.94 0.92 1.00 0.98 0.96 0.94 0.92 0.90 0.88 0.86 0.84 0.82 0.80 115VAC, 400Hz 115VAC, 800Hz 0 0.90 0 100 200 300 400 500 100 600 200 300 400 Pout, Watts 500 600 Pout, Watts PFC-650U Efficiency PFC-650W Efficiency 100% 100% 230VAC, 50Hz 98% Efficiency, % Efficiency, % 98% 96% 94% 92% 115VAC, 400Hz 96% 94% 115VAC, 800Hz 92% 115VAC, 60Hz 90% 90% 0 100 200 300 400 500 600 0 100 Pout, Watts PFC-650U Power Loss 400 500 600 PFC-650W Power Loss 60 50 50 Power Loss, W Power Loss, W 300 Pout, Watts 60 40 115VAC, 60Hz 30 20 10 200 230VAC, 50Hz 0 115VAC, 800Hz 40 115VAC, 400Hz 30 20 10 0 0 100 200 300 400 500 600 0 Pout, Watts Astrodyne Corp. 1-800-823-8082 100 200 300 400 500 600 Pout, Watts PFC-650 Datasheet 04-16-12 Page 7 of 7