Cosel TUHS Series Instructions for use

2019/7/25Rev. 1.10E
Applications Manual
TUHS series

Applications Manual for TUHS series
1. Pin Assignment
Pin assignment
2. Connection for Standard Use
Connection for standard use
Input fuse ：F1
Smoothing capacitor for input voltage ：Cbc
Inrush current limiting resistor ：R1
Input capacitor (TUHS25) ：C1
Varistor ：SK1
Output capacitor ：Co
AC line filter ：L1
Y capactor ：C11,C12,C13
3. Derating
Output current derating
Input voltage derating
4. Operation under low temperature condition A-10
Outline of unstable operation at low temperature
and countermeasures
5. Holdup time
Holdup time
Holdup voltage
6. Board layout
Caution points of board layout
Reference PCB layout
Note：Information contained in this document is subject to change without notice for improvement.
The materials are intended as a reference design, component values and circuit examples
described in this document varies depending on operating conditions and component variations.
Please select the components and design under consideration of usage condition etc.
5.2 A-13
A-93.2
6.2 A-16
6.1 A-14
2.1
2.4 A-6
2.5
2.8
A-1
A-2
A-4
A-2
A-7
2.3 A-4
A-7
2.6 A-7
A-7
3.1
A-125.1
A-14
Contents
Page
A-1
2.2
1.1
2.7
A-12
2.9 A-7
A-104.1
A-8
A-8

1.1 Pin Assi
g
nment
Fig.1.1 ●TUHS3/TUHS5 ●TUHS10/TUHS15 ●TUHS25
Pin Assignment
(top view)
Table.1.1
Pin connection
and function
Fig.1.2
Block Diagram
6
1 AC1
4
5
-BC
Pin
Connection
2
3
FunctionNo.
-DC output
AC input
AC2
+BC +BC output
-BC output
+VOUT +DC output
-VOUT
A-1
2.1 Pin configuration
1 Pin Assignment
AC2
AC1
+BC -BC
-Vout
+Vout
AC2
AC1
+BC -BC
-Vout
+Vout
AC2
AC1
+BC -BC
-Vout
+Vout
Applications Manual
TUHS series
→
AC1
AC2
-BC +BC
+Vout
-Vout

2.1 Connection for Standard Use
■To use the TUHS series, connection shown in Figure 2.1 and external components are required.
Fig. 2.1
Connection for
standard use
■Parts name are shown in Table 2.1 as reference.
■External parts should be changed according to the ambient temperature, and input and output
conditions. For details, refer to the selection method of individual parts.
■Depending on the wiring conditions, a capacitor C14 between the primary and secondary may
be required for line conduction. If mounted, please use reinforced insulation (Y1 class certified).
Table 2.1
Parts name
※ Thermistor R1 recommended by TUHS25 can be used with other models
A-2
2.1 Pin configuration
2 Connection for Standard Use
Load
Applications Manual
TUHS series
C14
C1
Rating Part name Rating Part name
1F1 AC250V/2A SLT 250V 2A
（Nippon Seisen Cable.,Ltd.）AC250V/2A SLT 250V 2A
（Nippon Seisen Cable.,Ltd.）
A2JD-100J
（Uchihashi Estec Co.,Ltd.）
A2JD-100J
（Uchihashi Estec Co.,Ltd.）
CWFS23C□□□□100J
（KOA Corporation）
CWFS23C□□□□100J
（KOA Corporation）
3Cbc DC400V/18uＦEKXJ401□□□180□□□□S
（Nippon Chemi-Con）DC400V/22uＦEKXJ401□□□220□□□□S
（Nippon Chemi-Con）
4SK1 AC385V S10K385E2K1
（TDK EPCOS）AC385V S10K385E2K1 （TDK EPCOS）
5C1 AC250V ECQU3A104MG
（Panasonic）AC250V ECQU3A104MG （Panasonic）
6C14 AC250V/1000pF DE1E3RA102M
（Murata Manufacturing）AC250V/1000pF DE1E3RA102M （Murata Manufacturing）
Rating Part name Rating Part name
1F1 AC250V/2A SLT 250V 2A
（Nippon Seisen Cable.,Ltd.）AC250V/2A SLT 250V 2A （Nippon Seisen Cable.,Ltd.）
A2JD-100J
（Uchihashi Estec Co.
,
Ltd.）
CW3C□□□□□10R0J
（KOA Cor
p
oration）
CWFS23C□□□□100J
（KOA Cor
p
oration）
CWFS23C□□□□100J
（KOA Cor
p
oration）
3Cbc DC400V/47uＦEKXJ401□□□470□□□□S
（Nippon Chemi-Con）DC400V/68uＦEKXJ401□□□680□□□□S （Nippon Chemi-Con）
4SK1 AC385V S10K385E2K1
（TDK EPCOS）AC385V S10K385E2K1
（TDK EPCOS）
5C1 AC250V ECQU3A104MG
（Panasonic）AC250V ECQU3A104MG
（Panasonic）
6C14 AC250V/1000pF DE1E3RA102M
（Murata Manufacturing）AC250V/1000pF DE1E3RA102M
（Murata Manufacturing）
Rating Part name
1F1 AC250V/3.15A SLT 250V 3.15A
（Nippon Seisen Cable.,Ltd.）
2R1 10Ω 10D2-08LC
（SEMITEC）
3Cbc DC400V/120uＦEKXJ401□□□121□□□□S
（Nippon Chemi-Con）
4SK1 AC385V S10K385E2K1
（TDK EPCOS）
5C1 AC250V ECQU3A104MG
（Panasonic）
6C14 AC250V/1000pF DE1E3RA102M
（Murata Manufacturing）
R1 Inrush current
limiting Resistor
Primary to secondary
capacitor
Primary to secondary
capacitor
No. TUHS3 symbol Item
Varistor
Item
No. symbol
2R1 Inrush current
limiting Resistor 10Ω
2
No. symbol
Varistor
Primary to secondary
capacitor
Input fuse
Smoothing capacitor
for input voltage
Varistor
Input capacitor
Smoothing capacitor
for input voltage
Item TUHS25
Input fuse
Inrush current
limiting Resistor
Smoothing capacitor
for input voltage
TUHS5
Input fuse
TUHS15TUHS10
10Ω 10Ω
10Ω
Input capacitor
Input capacitor

■When connect the output to FG of an equipment, a noise may become big. The noise can be
reduced by connecting external filter and grounding capacitor on the input side. Refer to Fig2.2.
■Parts name are shown in Table 2.2 as reference of connecting output to FG.
Fig. 2.2
Recomemended
circuit of connect
output to FG
Table 2.2
Parts name
(connect output
to FG)
※Refer to Table 2.1 for F1, R1, Cbc, SK1,and C1.
■When using multiple power supplies, a noise filter separately from the above circuit may be required
A-3
Applications Manual
TUHS series
Rating Part name Rating Part name
1L1 25.0mH/0.4A SU10VFC-R04250
（TOKIN
)
25.0mH/0.4A SU10VFC-R04250
（TOKIN
)
2 C11,C12 AC250V/2200pF CD45-E2GA222M
（TDK）AC250V/2200pF CD45-E2GA222M （TD
K
）
3C13 AC250V/0.022u F LE223
(Okaya Elecotric Industries) AC250V/0.022uF LE223 (Okaya Elecotric Industries)
Rating Part name Rating Part name
1L1 25.0mH/0.4A SU10VFC-R04250
（TOKIN
)
35.0mH/0.5A SS11VL-R05350
（TOKIN ）
2 C11,C12 AC250V/2200pF CD45-E2GA222M
（TDK）AC250V/2200pF CD45-E2GA222M （TD
K
）
3C13 AC250V/0.022u F LE223
(Okaya Elecotric Industries) AC250V/0.022uF LE223 (Okaya Elecotric Industries)
Rating Part name
1L1 35.0mH/0.5A SS11VL-R05350
（TOKIN ）
2 C11,C12 AC250V/2200pF CD45-E2GA222M
（TDK）
3C13 AC250V/0.022u F LE223
(Okaya Elecotric Industries)
No.
Y capacitors
symbol Item
No. s ymbol TUHS3
Y capacitors
Ite m
AC line filter
AC line filter
TUHS 15TUHS1 0
TUHS 5
Y capacitors
No. s ymbol Item TUHS2 5
AC line filter

2.2 In
p
ut fuse ：F1
■No protective fuse is preinstalled on the input side. To protect the unit, install a slow-blow
type fuse shown in Table 2.2 in the input circuit.
■In the case of using DC input, please use a DC fuse.
The reference DC fuse type name is shown follow.
DC fuse type nameꞏ ꞏ ꞏBD2
0
(DC400V 2A)
(Daito Communication Apparatus Co., Ltd.)
■When the fuse is blown out, the input voltage is applied to the both ends of fuse terminals.
If the TUHS is used in the equipment which need to comply safety standard certification,
please keep the distance (2.5mm or more) between the terminals of fuse to satisfy the
requirement of safety standard.
Table 2.3
Recommended
fuse
2.3 Smoothing capacitor for input voltage: Cbc
■In order to smooth input voltage, connect aluminum electrolytic capacitor Cbc between +BC and -BC.
Recommended capacitance of Cbc is shown in Table 2.4.
■Please select the voltage rating of the aluminum electrolytic capacitor to match the specification
of the input voltage range.
AC100V system ꞏ ꞏ ꞏ DC200V or more
AC200V system ꞏ ꞏ ꞏ DC400V or more
■Ripple voltage and hold-up time will vary depending on input and output conditions
Please select the smoothing capacitor capacity refer to the table 2.4.
■Please do not exceed allowable capacity of Cbc to avoid the power supply failure.
■If you would like to confirm hold-up time for selecting the capacity of Cbc, please refer to Section 5
Hold-up Time.
■When the power supply is operated under -2
0
℃, it may cause the smoothing capacitor rippl
e
voltage increase due to the characteristic of equivalent seies resistor.
Choose the capacitor which has 3 times or more than recommended capacitance.
■When a small capacitor than the recommended capacity is selected, ripple voltage of the smoothin
g
voltage will increase.
Select a capacitor of which the ripple voltage does not exceed 25 Vp-p.
There is a possibility of more than ripple current rating of the smoothing capacitor, please parts
selection after confirming the allowable ripple current of the capacitor.
Table 2.4
Recommended
capacitance
Cbc
※1 Including wide input of AC100V/AC200
V
Model
TUHS3 15uＦ
18uＦ
15uＦ
AC100V system ※147uＦ
AC100V system ※1
Only AC200V system
22uＦ
TUHS5
47uＦ
22uＦ
15uＦ
TUHS10
22uＦ
68uＦ
Allowable max
capacitance
Recommended capacitance（Ta>=-20℃、20msec or more on AC100V）
Input condition Io<=100%
AC100V system ※1
Io<=50% Io<=75%
33uＦ
10uＦ
68uF
150uF 10uＦ15uＦ18uＦ
27uＦ
4.7uＦ
AC100V system ※110uＦ
33uＦ
27uＦ33uＦ
Only AC200V system
4.7uＦ
18uＦ
10uＦ
TUHS15 220uF
33uＦ47uＦ
2A 2ADC Rated current
6.8uＦ
Io<=25%
Only AC200V system
2A
TUHS3 TUHS5
AC Rated current
Item TUHS10
2A 2A2A
2.2uＦ
68uF 18uＦ
68uＦ
Only AC200V system 15uＦ
22uＦ
4.7uＦ6.8uＦ10uＦ
22uＦ
TUHS15
A-4
2A 2A
TUHS25
3.15A
2A
TUHS25 390uF AC100V system ※147uＦ68uＦ82uＦ120uＦ
Only AC200V system
Applications Manual
TUHS series

■Electrolytic capacitor has lifetime. So make sure that the lifetime is no problem under the usage
condition.
■Detail formula is different by capacitor manufacturer.
When calculating the lifetime, follow the instruction of capacitor manufacturers.
■The temperature of the electrolytic capacitor is required for lifetime calculation.
■Please measure the point of the electrolytic capacitor at which the temperature is maximum.
■High frequency ripple current does not flow through to Cbc.
The ripple current which has twice of input frequency and depends on the output load
(shown in Fig2.3) flows into Cbc.
■The relationship between effective ripple current of Cbc and load factor is shown in
Fig2.4 (A),(B),(C),(D),(E).
■The ripple current changes approximately 1.5 times depending on PCB patterns, external parts,
ambient temperature, etc.
If the ripple current value which 1.5 times of the data shown in Fig.2.4, exceed the allowable ripple
current of electrolytic capacitor, please measure the actual ripple current value, then calculate the lifetime.
Fig. 2.3
Current
of Cbc
Fig. 2.4
Effective ripple
current of Cbc
A-4
(A) TUHS3(Reference) 120Hz (B) TUHS5(Reference) 120Hz
(D) TUHS15(Reference) 120Hz(C) TUHS10(Reference) 120Hz
Load factor[%]
ripple current [mArms]
Applications Manual
TUHS series
Load factor[%]
ripple current [mArms]
Load factor[%]
ripple current [mArms]
Load factor[%]
ripple current [mArms]
(E) TUHS25(Reference) 120Hz
Load factor[%]
ripple current [mArms]

2.4 Inrush current limitin
g
Resistor: R1
■The TUHS series have no internal inrush current limiting circuit.
■Connect resistor R1 between AC input and power supply to limit inrush current up to
50A(TUHS3/5/10/15) and 60A(TUHS25). Select a resistor which has enough permissible
current capability.
■Fomula of inrush current is shown below. Please calculate the inrush current from this equation.
■Inrush current prevention element has power loss and genetates heat by input current.
Please select the power thermistor if the power loss of the resistor and efficiency drop are not
acceptable.
■When a power thermistor is used, inrush current will increase at high ambient temperature
because of the reduction of the resistance of the thermistor. Please do not turn on/off the input
repeatedly within a short period of time. Keep appropriate intervals to allow the power supply
to cool down sufficiently before turning on.
■The inrush current value, with the parts shown in Table 2.1, shown in Fig 2.5.
Fig. 2.5
Inrush current
values
■Available AC voltage for inrush current prevention element varies by the smoothing capacitor value.
The relationship between the value of smoothing capacitor and AC voltage of the recommended
inrush current prevention element to reference is shown in Figure 2.6.
Fig. 2.6
Characteristics of
power thermistor
resistor
R1
■Under low temperature conditions, the output of power supply may be unstable due to high ESR values
of the power thermistor and Cbc. Check with the actual device before use.
※Refer to page A-8 for operation under low temperature conditions.
A-6
L
in
p
RR
V
I
1
2*
Ip ：Inrush current[peak]
Vin：Input voltage[rms]
R1 ：Inrush current limiting Resistor
AC200Vin
Ta：85ºC
Ta：25ºC
Ta：-20ºC
23A
21A
7A
TUHS5F24
セメント抵抗(1K100JA)使用
TUHS5F24
Use resistor (1K100JA)
AC200Vin
Ta：85ºC
Ta：25ºC
Ta：-20ºC
48A
24A
4A
TUHS25F24
サーミスタ(10D2-08LC)使用
TUHS25F24
Use thermistor (10D2-08LC)
Applications Manual
TUHS series

2.5 In
p
ut ca
p
acitor：C1
(
TUHS25
)
■To comply with conducterd noise CISPR22-B, EN55022-B, connect capacitor C1 which is 0.1μF
between AC input terminals.
■Use a capacitor with a rated voltage of AC250V which complies with the safety standards.
■If 0.11μF or more capacitor is connected, the discharge resistor is necessary in order to
comply UL60950-1. Please connect the discharge
r
esistor which satisfy the following formula.
2.6 Varistor：SK1
■In order to comply with IEC61000-4-5 Level 3 (surge immunity), coonnect a surge protective device.
■Overvoltage category changes depending on the location for installing the power supply.
Recommended components is complying to the overvoltage category II.
For example, home electronics and information equipment corresponds the installation category II.
And they are installed the primary part of the equipment which is connected to outlet by power cable.
If installation category III (required to connect distribution panel directly) is required, the varistor
must be bigger than recommended varistor.
Please confirm whether the components comply the standards.
2.7 Out
p
ut ca
p
acitor：Co
■In the TUHS series, the output capacitor is basically unnecessary. Reduce the ripple voltage or suppress
fluctuation in an output voltage by connecting the output electorolytic capacitor or ceramic capacitor.
The connection example is shown in Fig 2.7.
■When the pulse load is connected, the output voltage will change transiently.
Please check the level of the fluctuation in your situation.
And if the transient output voltage change is not acceptable, please connect the output capacitor Co
.
Fig.2.7
Connecting Example of
an External Capacitor
to the Output Side
Table 2.5
Recommended
capacitance
Co
2.8 AC line filter：L1
■The commom mode choke coil should be selected with confirmation because there are wire grade
and rated temperature of bobbin.
2.9 Y Ca
p
acitors：C11
,
C12
,
C13
■Please choose safety certified capacitor (Y1, Y2 class approved) to C11 and C12
.
However,
if secondary circuit is shorted to FG, not connected by capacitor, please choose Y1 class capacitor
as C11 and C12.
■During high voltage test, the voltage applied to C13 is determined by the value of C11, C12 and C13.
Please note the rated voltage of the capacitor. Fomula of the voltage applied to C13 is shown below.
■The noise reduction level depends on the location of the grounding capacitor.
Please connect the capacitor as close as possible to the power supply.
0～330μF
TUHS5 TUHS10 TUHS15
0～47μF 0～150μF
5V 0～100μF 0～100μF
TUHS25
-
A-7
12V 0～470μF0～47μF
Output voltage TUHS3
0～68μF 0～68μF
0～150μF
24V 0～22μF 0～22μF
15V 0～47μF 0～47μF 0～120μF 0～120μF 0～390μF
0～1000μF
0～220μF
42.4)2(Vlog
1
ine1
／
≦
uuC
R
test
CCC CC VV
312111
1211
C13
u


VC13 ：Voltage applied to C12
C11,C12 ：Y capacitor on the primary side
C13 ：Y capacitor on the secondary side
Vtest ：Test voltage
R ：Discharge resistor
C1：Input capacitance
Vin：Input voltage 120V or 240V[rms]
Load
Applications Manual
TUHS series

3.1 Out
p
ut current deratin
g
3.1 Out
p
ut deratin
g
■Please have sufficient ventilation to keep the temperature of point A in Fig.3.1 at Table 3.1
or below. Please also make sure that the ambient temperature does not exceed 85℃
■Derating curve is shown Fig.3.2.
Note: In the hatched area, the specification of Ripple, Ripple Noise is different form other area.
Table 3.1
Point A Temperature
Fig. 3.1
Temperature measuring
point on the case
(Top view)
Fig. 3.2
Output derating
A-8
Model TUHS3 TUHS5 TUHS10
Point A 105℃105℃105℃100℃95℃100℃
TUHS15 TUHS25
Output voltage all all all 12V,24V 15V all
2.1 Pin configuration
3.Derating
(A) TUHS3 Derating curve(Reference)
(B) TUHS5 Derating curve(Reference)
(C) TUHS10 Derating curve(Reference)
(D) TUHS15 Derating curve(Reference)
Point A(Center of the Case)
Applications Manual
TUHS series