SynQor MPFC-115-270-QP Internal inrush current limit Datasheet

MPFC-115-270-QP
Power Factor Correction
Quarter-brick
Military Power Factor Correction Module
85-180Vrms
47 - 63Hz / 360 - 800Hz
270Vdc
350W
≥0.99
Up to 95%
Input Voltage
Input Frequency
Output Voltage
Output Power
Power Factor
Full Load Efficiency
The MPFCQor 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 MPFCQor 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 military and
aerospace environments.
-N-M
ON
5-270-QP
ORRECTI
MPFC-11Y POWER FACTOR C
MILITAR
Vdc 350W
rms 270
85-180V 360 - 800Hz
z/
47 - 63H
Operational Features
•
•
•
•
•
•
•
•
Input voltage range: 85-180Vrms
Universal input frequency range: 47 - 63Hz / 360 - 800Hz
350W output power
≥0.99 Power Factor
High efficiency: >95% (115Vrms)
Internal inrush current limit
Auxiliary 10V bias supply
Compatible with SynQor’s MCOTS DC-DC converters
and SynQor’s MCOTS AC line filters
Control Features
• PFC Enable
• Load Enable (also: Power Out Good signal)
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
Mechanical 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
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)
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-115-270-QP
Phone 1-888-567-9596
Contents
Page No.
Typical Application............................................................................2
Technical Specification.......................................................................3
Technical Diagrams...........................................................................5
Screening & Qualification Testing.......................................................7
Application Section............................................................................8
Encased Mechanical........................................................................14
Encased Mechanical with Flange......................................................15
Ordering Information......................................................................16
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Doc.# 005-0006727 Rev. B
03/31/2016
Page 1
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Typical Application of the MPFC Module
F1
L1
IN
MOV1
OUT
SynQor
MCOTS
AC Line Filter
GND
L2/N
L1
L1
IN
SynQor
MPFC
Module
TVS1
OUT
CHold-Up
SynQor
ON/ MCOTS
OFF DC-DC
Trim
Converter
-Sense
-Vout
-VIN
-Vout
CY1
ENABLE
F1:
MOV1, TVS1:
F2:
CHold-Up:
CY1-Y2:
+Sense
AUX
L2/N
+Vout
+V
IN
Load ENA
PFC ENA
L2/N
F2
+Vout
CY2
5A / 250V Fuse
Must prevent peak voltage from exceeding 450V during all transients.
Use fuse recommended in converter specification
100 - 1,000 μF (Dependent on Power Level and Line Frequency)
See “EMI Considerations” in application notes
Example Parts:
F1:
MOV1:
TVS1:
CHold-Up:
CY1:
CY2:
250VAC, 5A; Littelfuse 0216005.MXEP
210VAC, 80J; EPCOS S14K210E2
300V, 3J; two VISHAY 1.5KE150CA devices connected in series
Two 315V, 220uF; Nichicon UVZ 2F221MRD in parallel (-40C)
Two 200V, 820uF; Cornell Dubilier MLS821M200EB0C in series (-55C)
3.3nF, 500VAC; Vishay VY1332M59Y5UQ6TV0
10nF, 300VAC; Vishay VY2103M63Y5US63V7
Figure A: Typical Application of the MPFCQor module to create an AC-DC Power Supply
Product # MPFC-115-270-QP
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Page 2
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Technical Specification
MPFC-115-270-QP Electrical Characteristics
Operating conditions of 115Vrms, 60Hz input, 350W output, 400uF 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 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
180
Vrms
AC Input 100ms Transient
40
180
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, min 200W output
0.97
400Hz, min 200W 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
385
W
Arms
Maximum Input Current
4.8
85 VAC in
OUTPUT CHARACTERISTICS
Output Voltage Set Point
265
270
275
Vdc
Output Voltage Regulation
Over Line
±0.3
%
Vin <160Vrms
Over Load
±2
%
Over Temperature
±1.5
%
Total Output Voltage Range
260
270
275
V
Output Voltage Ripple and Noise
60Hz, see Note 1
Peak-to-Peak
10
V
With 400uF hold-up capacitor
V
RMS
4
Operating Output Current Range
0
1.3
A
Output Over-Voltage Threshold
320
330
V
See application section
Output (Hold-up) Capacitance
100
1,000
µF
See Note 2
Output Common-Mode Capacitance
20
nF
See “EMI Considerations” in application notes
Efficiency
50% Load
94
%
See Figure 1 for efficiency curve
100% Load
95
%
See Figure 1 for efficiency curve
Note 1: 400 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 660uF 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-115-270-QP
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Doc.# 005-0006727 Rev. B
03/31/2016
Page 3
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Technical Specification
MPFC-115-270-QP Electrical Characteristics (continued)
Operating conditions of 115Vrms, 60Hz input, 350W output, 400uF 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
50
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
250
V
Falling / Shutdown
100
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
1260
kHrs
Ground Benign, Tb = 70°C
Calculated MTBF (MIL-217) MIL-HDBK-217F
150
kHrs
Ground Mobile, Tb = 70°C
Product # MPFC-115-270-QP
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Doc.# 005-0006727 Rev. B
03/31/2016
Page 4
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Technical Diagrams
98.00
30
96.00
25
Power Dissipation (W)
Efficiency (%)
94.00
92.00
90.00
140Vrms
88.00
115Vrms
115Vrms
140Vrms
20
15
10
5
90Vrms
86.00
90Vrms
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 140Vrms (60Hz) input voltage at Tb = 25°C.
Figure 2: Power dissipation at nominal output voltage vs. load power for 90Vrms,
115Vrms and 140Vrms (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).
350
310
305
115Vrms, 60Hz
250
200
150
100
0.98
0.97
0.96
0.95
0.94
0.93
0.92
0.91
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285
280
275
270
265
255
250
245
0.9
85
Leading Power Factor
Figure 5: Output power vs. leading power factor, MPFC module only
Min
290
260
0
0.99
Typical
295
50
1
Max
300
Output Voltage (V)
300
MPFC Output Power (W)
115Vrms, 400Hz
95
105
115
125
135
145
155
165
175
Input Voltage (Vrms)
Figure 6: DC output voltage range vs. input voltage
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Doc.# 005-0006727 Rev. B
03/31/2016
Page 5
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Technical Specification
Figure 8: Output voltage startup waveform with 400uF hold-up capacitor, no load
(115VAC, 60Hz), (50V/div), Timebase: (500ms/div)
400
400
350
350
300
300
Output Power (W)
Power Output (W)
Figure 7: Output voltage ripple with 400μF Hold-up capacitor at full rated power
(115VAC, 60Hz) Vout (5V/div), Timebase: (5ms/div)
250
200
85 Vac
150
>100 Vac
250
200
150
100
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 # MPFC-115-270-QP
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60
80
100
120
140
160
180
200
Input Voltage (Vrms)
Figure 10: Output power vs. input voltage, output turn-on threshold is 85Vrms
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Doc.# 005-0006727 Rev. B
03/31/2016
Page 6
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Screening & Qualification Testing
Mil-COTS Qualification
Test Name
Details
# Tested
(# Failed)
Consistent with
MIL-STD-883F Method
Life Testing
Visual, mechanical and electrical testing before, during and after 1000 hour burn-in
@ full load
15
(0)
Method 1005.8
Shock-Vibration
Visual, mechanical and electrical testing before, during and after shock and
vibration tests
5
(0)
MIL-STD-202,
Methods 201A & 213B
Humidity
+85˚C, 95% RH, 1000 hours, 2 minutes on / 6 hours off
Temperature
Cycling
500 cycles of -55˚C to +100˚C
(30 minute dwell at each temperature)
Solderability
15 pins
DMT
-65˚C to +110˚C across full line and load specifications in 5˚C steps
Altitude
70,000 feet (21 km), see Note
8
(0)
10
(0)
15
(0)
7
(0)
2
(0)
Method 1004.7
Method 1010.8, Condition A
Method 2003
Note: A conductive cooling design is generally needed for high altitude applications because of naturally poor convective cooling at rare atmospheres.
Mil-COTS Converter and Filter Screening
Screening
Process Description
S-Grade
M-Grade
Baseplate Operating Temperature
-55˚C to +100˚C
-55˚C to +100˚C
Storage Temperature
-65˚C to +135˚C
-65˚C to +135˚C
●
●
Pre-Cap Inspection
IPC-A-610, Class III
Temperature Cycling
MIL-STD-883F, Method 1010, Condition B, 10 Cycles
Burn-In
100˚C Baseplate
12 Hours
96 Hours
100%
25˚C
-55˚C, +25˚C, +100˚C
MIL-STD-883F, Method 2009
●
●
Final Electrical Test
Final Visual Inspection
●
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: 70,000 ft / 2 hr duration
500.5 - Procedure II
Operating: 70,000 ft / 2 hr duration; Ambient Temperature
Rapid Decompression
500.5 - Procedure III
Storage: 8,000 ft to 40,000 ft
Acceleration
513.6 - Procedure II
Operating: 15 g
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: -65°C / 4 hrs
502.5 - Procedure II
Operating: -55°C / 3 hrs
Temperature Shock
503.5 - Procedure I - C
Storage: -65°C to 135°C; 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 (54.6 grms), duration = 1 hr/axis
516.6 - Procedure I
20 g peak, 11 ms, 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, 4 hrs/axis, 20 g (sine sweep from 10 - 500 Hz)
Blowing Dust
510.5 - Procedure II
Blowing Sand
Altitude
High Temperature
Low Temperature
Shock
Sinusoidal vibration
Sand and Dust
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Page 7
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
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 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
Product # MPFC-115-270-QP
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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 50mA. 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
50mA 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.
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03/31/2016
Page 8
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Application Section
Brownout/Dropout Sequence
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 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.
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
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 2):
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.
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Page 9
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Application Section
LOAD_ENABLE
(also: POWER OUT GOOD signal) (Pin 6):
The MPFCQor 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
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.
Input Over- and Under-Voltage:
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 50mA 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.
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.
Output Over-Voltage:
• For high-side or remotely switched loads, an optoisolator can
be employed as shown below.
Product # MPFC-115-270-QP
Phone 1-888-567-9596
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 MPFCQor’s pre-charge circuit
will continue to deliver 50mA 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.
www.synqor.com
Doc.# 005-0006727 Rev. B
03/31/2016
Page 10
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Application Section
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:
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 deasserted high. When the internal temperature falls below
110°C, the MPFCQor 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 # MPFC-115-270-QP
Phone 1-888-567-9596
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 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, if we assume P = 350W, ∆t = 20ms, Vs =
270V and Vf = 150V, then we would want a hold-up
capacitance of at least 280µF.
NOTE: The MPFCQor is able to operate with a minimum of
100µF of hold-up capacitance, but SynQor recommends at least
660µF 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 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 with 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.# 005-0006727 Rev. B
03/31/2016
Page 11
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Application Section
For example, to calculate voltage and current ripple for a
MPFCQor with a 350W output, 400µF 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 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 V O. It can be
calculated using the following formula:
𝑃𝑃𝐷𝐷𝐷𝐷
𝑃𝑃𝐷𝐷𝐷𝐷
𝐼𝐼𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 =
=
√2 ∙ 𝑉𝑉𝑂𝑂 382
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-115-270-QP
𝑃𝑃𝐷𝐷𝐷𝐷
1.02 ∙ 105 ∙ 𝐶𝐶
Phone 1-888-567-9596
𝑉𝑉𝑝𝑝𝑝𝑝−𝑝𝑝𝑝𝑝 =
350𝑊𝑊
= 0.9𝐴𝐴𝑟𝑟𝑟𝑟𝑟𝑟
382
350𝑊𝑊
= 8.6𝑉𝑉𝑝𝑝𝑝𝑝−𝑝𝑝𝑝𝑝
2𝜋𝜋 ∙ 60𝐻𝐻𝐻𝐻 ∙ 400 ∙ 10−6 𝐹𝐹 ∙ 270𝑉𝑉
In this case, the hold-up capacitor would require a minimum
ripple current rating of 0.9Arms, and the output voltage would
have a pk-pk ripple voltage of 8.6V.
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.
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
𝑚𝑚𝑚𝑚𝑚𝑚
𝑃𝑃𝑑𝑑𝑖𝑖𝑖𝑖𝑖𝑖
=
𝑅𝑅𝑇𝑇𝑇𝑇𝐵𝐵𝐵𝐵
www.synqor.com
Doc.# 005-0006727 Rev. B
03/31/2016
Page 12
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Application Section
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.
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. The MPFC’s
maximum output power complies with this requirement.
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.
•
•
•
•
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 MPFCQor 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 nonSynQor 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 safteyrated ceramic capacitors be placed across any isolated DCDC converters on the output of the PFC from Vin- to Voutand Vout- to ground. However, the total capacitance from
the PFC output leads to earth ground should not be more
than 20nF if one of the PFC input leads is connected to
earth ground. See “Typical Application of the PFC
Module” (Figure A) for a diagram and suggested parts.
CFILT = MACF filter effective capacitance
CPFC = MPFC effective capacitance
RPFC = MPFC load
POUT = MPFC total output power
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
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
Product # MPFC-115-270-QP
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006727 Rev. B
03/31/2016
Page 13
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Encased Mechanical
1.536 [39.01]
1.030 [26.16]
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]
2
3
1
0.215
[5.46]
1
BOTTOMSIDE CLEARANCE
0.005 0.010
[ 0.13 0. 25]
THREADED INSERT
SEE NOTE 1
(4 PLCS)
NOTES
0.300 [7.62]
0.600 [15.24]
PIN DESIGNATIONS
1)Applied torque per screw should not exceed 6in-lb. (0.7 Nm). Screw
should not exceed 0.100” (2.54mm) depth
below the surface of the baseplate.
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)All dimensions in inches (mm).
Tolerances:
Pin
1
2
3
Name
L1
PFC ENA
L2/N
4
-VOUT
5
6
8
AUX
LOAD ENA
+VOUT
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
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 # MPFC-115-270-QP
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006727 Rev. B
03/31/2016
Page 14
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Encased Mechanical with Flange
SEATING PLANE HEIGHT
.500 .025
[12.7 0.63]
2.200 [55.88]
2.000 [50.80]
1.536 [39.01]
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]
FLANGE THICKNESS
0.125
[3.2]
.130 [3.30]
SEE NOTE 1
(6 PLCS)
1)Applied torque per screw should not exceed 6in-lb. (0.7 Nm).
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)All Pins: Material - Copper Alloy; Finish - Matte Tin over Nickel plate
6)Undimensioned components are shown for visual reference only.
7)Weight: 3.32 oz. (94 g)
8)All dimensions in inches (mm).
Tolerances:
1
0.300 [7.6]
BOTTOMSIDE CLEARANCE
.010 .010
[0.51 0.25]
NOTES
2
0.600 [15.2]
PIN DESIGNATIONS
Pin
1
2
3
Name
L1
PFC ENA
L2/N
4
-VOUT
5
6
8
AUX
LOAD ENA
+VOUT
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
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 # MPFC-115-270-QP
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-0006727 Rev. B
03/31/2016
Page 15
MPFC-115-270-QP
Input:85-180Vrms
Output:270Vdc
Power:350W
Ordering Information
Ordering Information / Part Numbering Scheme
Family
Input Voltage
Output Voltage
Package Size
MPFC
115: 85-180V
270: 270V
QP: Quarter-brick Peta
Thermal Design
Screening Level
N: Encased
S: S-Grade
M: M-Grade
F: Encased with Flanged Baseplate
Example: MPFC-115-270-QP-N-M
PART NUMBERING SYSTEM
The part numbering system for SynQor’s ac-dc converters follows the format
shown in the example.
APPLICATION NOTES
A variety of application notes and technical white papers can be downloaded in pdf format from our website.
STANDARDS COMPLIANCE
Input/Output to baseplate isolation 2150Vdc
Basic Insulation to Baseplate
CAN/CSA-C22.2 No. 60950-1/A1:2011
EN60950-1/A2:2013
CE Marked
Contact SynQor for further information and to order:
Phone:
Toll Free:
Fax:
E-mail:
Web:
Address:
Product # MPFC-115-270-QP
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
PATENTS
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
9,143,042
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.# 005-0006727 Rev. B
03/31/2016
Page 16