Cosel TUNS50F User manual

The information contained in this document has been carefully researched and is, to the best
of our knowledge, accurate. However, we assume no liability for any product failures or
damages, immediate or consequential, resulting from the use of the information provided
herein. Our products are not intended for use in systems in which failures of product could
result in personal injury. All trademarks mentioned herein are property of their respective
owners. All specifications are subject to change without notice.
Instruction Manual
TUNS-Series
Cosel
Our company network supports you worldwide with offices in ermany, Austria,
Switzerland, reat Britain and the USA. For more information please contact:
FORTEC Elektronik AG
Hauptniederlassung
Lechwiesenstr. 9
86899 Landsberg am Lech
Telefon: [phone]
Telefax: [phone]
E-Mail: [email protected]
Internet: www.fortecag.de
FORTEC Elektronik AG
Büro Nord
Am Hasenkamp 36
22457 Hamburg
Telefon: [phone]
Telefax: [phone]
E-Mail: [email protected]
Internet: www.fortecag.de
FORTEC Elektronik AG
Büro West
Hohenstaufenring 55
50674 Köln
Telefon: [phone]
Telefax: [phone]
E-Mail: [email protected]
Internet: www.fortecag.de
FORTEC Elektronik AG
Büro Wien
Nuschinggasse 12
A-1230 Wien
Telefon: [phone]
Telefax: [phone]
E-Mail: [email protected]
Internet: www.fortec.at
ALTRAC AG
(Tochter der FORTEC):
Bahnhofstraße 3
CH-5436 Würenlos
Telefon: [phone]
Telefax: [phone]
E-Mail: [email protected]
Internet: www.altrac.ch

TUNS-12
Basic Characteristics Data
Basic Characteristics Data
Model Circuit method
Switching
frequency
[kHz]
Input
current
[A]
* 1
Inrush
current
protection
circuit
PCB/Pattern
Series/Parallel
operation availability
Material
Single
sided Double sided Series operation Parallel operation
TUNS50F
Active filter 80-600 0.67 Thermistor Aluminum Yes Yes
* 2
Flyback converter 100-300
TUNS100F
Active filter 80-600 1.3 Thermistor Aluminum Yes Yes
* 2
Forward converter 300
TUNS300F
Active filter 100 3.6 SCR Aluminum Yes Yes
* 2
Half-bridge converter 400
TUNS500F
Active filter 100 6.0 SCR Aluminum Yes Yes
* 2
Half-bridge converter 400
TUNS700F
Active filter 100 8.6 SCR Aluminum Yes Yes
* 2
Half-bridge converter 400
*1The value of input current is at ACIN 100V and rated load.
*2Refer to instruction manual.
TUNS

1 1Pin Connection Pin Connection
TUNS-14 TUNS-21
2 2 Connection for Standard Use Connection for Standard Use
TUNS-14 TUNS-21
6.1 Mounting method
6.2 Stress to the pins
6.3 Cleaning
6.4 Soldering temperature
6.5 Derating
6.6 Heat sink (Optional parts)
6.1 Mounting method
6.2 Stress to the pins
6.3 Cleaning
6.4 Soldering temperature
6.5 Derating
TUNS-18
TUNS-18
TUNS-18
TUNS-18
TUNS-18
TUNS-19
TUNS-26
TUNS-26
TUNS-26
TUNS-26
TUNS-26
4.1 Input voltage range
4.2 Overcurrent protection
4.3 Overvoltage protection
4.4 Thermal protection
4.5 Remote sensing
4.6 Adjustable voltage range
4.7
Withstanding Voltage/Isolation Voltage
4.1 Input voltage range
4.2 Overcurrent protection
4.3 Peak current protection
4.4 Overvoltage protection
4.5 Thermal protection
4.6 Remote ON/OFF
4.7 Remote sensing
4.8 Adjustable voltage range
4.9 Inverter operation monitor (IOG)
4.10
Withstanding Voltage/Isolation Voltage
5
5
Series and Parallel Operation
Series and Parallel Operation
TUNS-17
TUNS-25
5.1 Series operation
5.2 Parallel operation
5.1 Series operation
5.2 Parallel operation
5.3 N+1 redundant operation
6
6
Implementation-Mounting Method
Implementation-Mounting Method
TUNS-18
TUNS-26
TUNS-16
TUNS-16
TUNS-16
TUNS-16
TUNS-16
TUNS-17
TUNS-17
TUNS-23
TUNS-23
TUNS-23
TUNS-23
TUNS-23
TUNS-23
TUNS-24
TUNS-24
TUNS-25
TUNS-25
TUNS-17
TUNS-17
TUNS-25
TUNS-25
TUNS-26
3 3 Wiring Input/Output Pin Wiring Input/Output Pin
TUNS-15 TUNS-22
3.1 Wiring input pin
3.2 Wiring output pin
3.3 Wiring +BC/-BC pins
3.1 Wiring input pin
3.2 Wiring output pin
3.3 Wiring +BC/-BC pins
TUNS-15
TUNS-15
TUNS-15
TUNS-22
TUNS-22
TUNS-22
4 Function TUNS-16 4 Function TUNS-23
7 Peak current TUNS-27
7
8
Lifetime expectancy depends on
stress by temperature difference
Lifetime expectancy depends on
stress by temperature difference
TUNS-20
TUNS-28
AC-DC Power Supplies Bus Converter.Power Module Type
TUNS-13
TUNS
Instruction Manual
TUNS50F, TUNS100F TUNS300F, TUNS500F, TUNS700F

1 Pin Connection
¿TUNS50F
5+VOUT
3+BC 4-BC
6TRM
7-VOUT
2AC2
1AC1
2-FG
¿TUNS100F
4-BC3+BC 4-FG
5+VOUT
6+S
7TRM
8-S
1AC1 9-VOUT
2AC2
Fig.1.1 Pin connection (bottom view)
Table 1.1 Pin connection and function
No. Pin
Connection Function
TUNS50F TUNS100F
11AC1 AC input
2 2 AC2
3 3 +BC +BC output
4 4 -BC -BC output
5 5 +VOUT +DC output
7 9 -VOUT -DC output
-8-S Remote sensing (-)
-6+S Remote sensing (+)
6 7 TRM Adjustment of output voltage
- - FG Mounting hole (FG)
2 Connection for Standard Use
¡To use TUNS series, connection shown in Fig.2.1 and external
components are required.
¡This product uses conduction cooling method (e.g. heat radiation
from the aluminum base plate to the attached heat sink).
Reference: 6.5 ”Derating”
Load
FG
+
+
F1 TH1
FG FG
CY
Co
C1
+BC -BC
Cbc
AC IN
AC1
AC2
+VOUT
-VOUT
-S
+S
TUNS50F
TUNS100F
Noise
filter
Heatsink
C2
+S, -S : TUNS100F
Fig.2.1 Connection for standard use
Table 2.1 External components
No. Symbol Components Reference
1 F1 Input fuse
3.1 “Wiring input pin (1)”
2 C1 Input Capacitor 3.1 “Wiring input pin (2)”
3 - Noise Filter
3.1 “Wiring input pin (3)”
4 CY Y capacitor
5 TH1
Inrush current protection thermistor 3.1 “Wiring input pin (4)”
6 Co Output capacitor 3.2 “Wiring output pin (1)”
7 Cbc Smoothing Capacitor for boost voltage 3.3 “Wiring +BC/-BC pins (1)”
8 C2 Capacitor for boost voltage 3.3 “Wiring +BC/-BC pins (2)”
9 - Heatsink 6.6 “Heat sink”
AC-DC Power Supplies Bus Converter.Power Module Type TUNS50F, TUNS100F
Instruction Manual
TUNS-14
TUNS

3 Wiring Input/Output Pin
3.1 Wiring input pin
(1) F1 : External fuse
¡Fuse is not built-in on input side. In order to protect the unit, install
the slow-blow type fuse on input side (as shown in Table 3.1).
Table 3.1 Recommended fuse (Slow-blow type)
Model TUNS50F TUNS100F
Rated current 2A 3.15A
(2) C1 : External Capacitor for input side
¡-
tance and ripple current capability are above the values shown in
Table 3.2.
¡Use a safety approved capacitor with 250V ac rated voltage.
¡If C1 is not connected, it may cause the failure of the power sup-
ply or external components.
Table 3.2 Input Capacitor C1
No. Model Voltage Capacitance Rated ripple
current
1 TUNS50F AC250V  3A or more
2 TUNS100F  3A or more

¡
 -
tor CY for low line noise and stable operation of the power supply.
¡The operation of the power supply may be unstable due to the

¡Install a correspondence filter, if it is required to meet a noise
standard or if the surge voltage may be applied to the unit.
¡Install a primary decoupling capacitor CY, with more than 470pF,
near the input pins (within 50mm from the pins).
¡When the total capacitance of the primary decoupling capacitor is

be met by the Hi-Pot test between input and output. A capacitor
should be installed between output and FG.
(4) TH1 : Inrush current limiting thermistor
¡It has a possibility that internal components fail by inrush current,
so please use power thermistor or inrush current limiting circuit to
keep input current below 60A.
¡If you use power thermistor and turn the power ON/OFF repeat-
edly within a short period of time, please have enough intervals
so that a power supply cools down before being turned on. And
appropriate intervals should be set even if inrush current limiting
circuit except power thermistor is used.
¡The output voltage may become unstable at low temperature due
to the ESR of power thermistor. In this case, increase the capaci-
tance of Cbc more than recommended value or connect same
capacitors in parallel. Please evaluate before use.
3.2 Wiring output pin
(1) Co : Output capacitor
¡Install an external capacitor Co between +VOUT and -VOUT pins
for stable operation of the power supply (Fig.2.1).
Recommended capacitance of Co is shown in Table 3.3.
¡Select the high frequency type capacitor. Output ripple and start-

the wiring impedance.
¡Install a capacitor Co near the output pins (within 50mm from the
pins).
¡When the power supply is used under 0Cambient temperature,
output ripple voltage increases. In this case, connect 3 capacitors
Co in parallel connection.

Model Temperature of base plate
Tc=0 to +100CTc=-40 to +100C
Output voltage
(V) TUNS50F TUNS100F TUNS50F TUNS100F
5 2200 2200 2200×3 2200×3
12 470 470 470×3 470×3
24 220 220 220×3 220×3

introduced in Fig.3.1.
C4 :
5V,12V 10mF
24V 4 .7mF
FG
+
F1 TH1
FG FG
CY
C1
+BC -BC
Cbc
AC IN
AC1
AC2
+VOUT
-VOUT
-S
+S
TUNS50F
TUNS100F
C2
Load
C4
R
C
+
Co
50mm
Oscilloscope
BW:100MHz
1.5m
50W
Coaxial
Cable R=50W
C=0.01mF
Noise
filter
+S, -S : TUNS100F
Fig.3.1 Method of Measuring Output Ripple and Ripple Noise
3.3 Wiring +BC/-BC pins
(1) Cbc : Smoothing capacitor for boost voltage
¡In order to smooth boost voltage, connect Cbc between +BC and
-BC. Recommended capacitance of Cbc is shown in Table3.4.
¡Note that +BC and -BC terminals have high voltage (DC385V typ).
¡Keep the capacitance within the allowable external capacitance.
¡Select a capacitor of which the boost voltage ripple voltage does
not exceed 30Vp-p.
¡When the power supply is operated under -20C, it may make
the boost voltage unstable due to the characteristic of equivalent
series resistor. Please choose the capacitor which has more than
recommended capacitance.
TUNS50F, TUNS100F AC-DC Power Supplies Bus Converter.Power Module Type
Instruction Manual
TUNS-15
TUNS

4.4 Thermal protection
¡When the power supply temperature is kept above 100C, the
thermal protection will be activated and simultaneously shut down
the output.
When the thermal protection is activated, shut off the input voltage
and eliminate all the overheating conditions. To recover the output
voltage, keep enough time to cool down the power supply before
turning on the input voltage again.
4.5 Remote sensing
¿TUNS50F
¡Remote sensing is not built-in.
¿TUNS100F
¡Remote sensing is built-in.
(1) When the remote sensing function is not in use
+S
+VOUT
-S
-VOUT
+Co
Short at pin root
Load
TUNS100F
Fig. 4.1 Connection when the remote sensing is not in use
¡When the remote sensing function is not in use, it is necessary to


¡
possible.
Loop wiring should be avoided.
This power supply might become unstable by the noise coming
from poor wiring.
(2) When the remote sensing function is in use
+S
Co
-S
+VOUT
-VOUT
+
Wire as close as possible
Load
TUNS100F
Fig. 4.2 Connection when the remote sensing is in use
¡Twisted-pair wire or shield wire should be used for sensing wire.
¡Thick wire should be used for wiring between the power supply
and a load.
Line drop should be less than 0.5V.
Voltage between +VOUT and -VOUT should remain within the
output voltage adjustment range.
¡If the sensing patterns are short, heavy-current is drawn and the
pattern may be damaged.
The pattern disconnection can be prevented by installing the pro-
tection parts as close as a load.
Table 3.4 Recommended capacitance Cbc
No. Model Voltage Cbc Allowable
capacitance range
1 TUNS50F DC420V
or more
 
2 TUNS100F  
(2) C2 : Capacitor for boost voltage
¡Install external capacitors C2 with capacitance shown in table 3.5.
¡If capacitors C2 are not installed, it may cause the failure of the
power supply or external components.
Table 3.5 Recommended capacitance C2
No. Model Voltage Capacitance Rated ripple
current
1 TUNS50F DC450V  1A or more
2 TUNS100F  1A or more
4 Function
4.1 Input voltage range
¡The input voltage range is from 85 VAC to 264 VAC.
¡In cases that conform with safety standard, input voltage range is
AC100-AC240V(50/60Hz).
¡Be aware that use of voltages other than those listed above may

cause damage. Avoid square waveform input voltage, commonly
used in UPS units and inverters.
4.2 Overcurrent protection
¡Overcurrent protection is built-in and comes into effect at over
105% of the rated current.
Overcurrent protection prevents the unit from short circuit and
overcurrent condition. The unit automatically recovers when the
fault condition is cleared.
¡When the output voltage drops at overcurrent, the average output
current is reduced by intermittent operation of power supply.
4.3 Overvoltage protection
¡Overvoltage protection circuit is built-in. If the overvoltage protec-
tion circuit is activated, shut down the input voltage, wait more
than 3 minutes and turn on the AC input again to recover the out-
put voltage. Recovery time varies depending on such factors as
input voltage value at the time of the operation.
Remarks:
Please note that devices inside the power supply might fail when
voltage of more than rated output voltage is applied to output ter-
minal of the power supply. This could happen when the customer
tests the overvoltage performance of the unit.
To check the function of overvoltage protection, adjust the output
voltage by changing TRM voltage. Please contact us for details.
AC-DC Power Supplies Bus Converter.Power Module Type TUNS50F, TUNS100F
Instruction Manual
TUNS-16
TUNS

¡As wiring or load impedance may generate oscillation or large
fluctuations in output voltage, make sure enough evaluation is
given advance.
4.6 Adjustable voltage range
¡Output voltage between +VOUT and -VOUT can be adjusted by
connecting external resistors to TRM.
¡When the output voltage adjustment is not used, open the TRM
pin respectively.
¡When the output voltage adjustment is used, note that the over-
voltage protection circuit operates when output voltage is set too
high.
¡The wiring to the potentiometer should be as short as possible.

depending on the types of resistors and potentiometers, please

Resistors.............
 ± 100ppm/C
Potentiometers ... C
¡Output voltage can be adjusted by connecting an external potenti-
ometer (VR1) and resistors (R1 and R2) as shown in Fig. 4.3.
Output voltage will increase if the resistance between 2and 3is
reduced by turning the potentiometer.
Recommended values for external components are shown in
Table 4.1.

+VOUT
-VOUT
-S
+S
TRM
External Resistor R1
External VR1
External Resistor R2
1
25kW
3
TUNS50F
TUNS100F
+S, -S : TUNS100F
Fig. 4.3 Connecting External Devices (TUNS50F/TUNS100F)
Table 4.1 Recommended Values of External Resistors (TUNS50F, TUNS100F)
No. Output
Voltage
Adjustable Range
VOUT±5% VOUT±10%
R1 R2 R1 R2
1 5V 10kW2.7kW4.7kW1kW
2 12V 12kW2.2kW5.6kW560W
3 24V 27kW1.8kW15kW470W
4.7 Withstanding Voltage / Isolation Voltage
¡When testing the withstanding voltage, make sure the voltage
is increased gradually. When turning off, reduce the voltage
gradually by using the dial of the hi-pot tester. Do not use a
voltage tester with a timer as it may generate voltage several
times as large as the applied voltage.
5 Series and Parallel
Operation
5.1 Series operation
¡Series operation is available by connecting the outputs of two or
more power supplies as shown below. Output current in series
connection should be lower than the lowest rated current in each
unit.
Load
Load
Power
Supply
Power
Supply
Load
Power
Supply
Power
Supply
(a)
(b)
Fig. 5.1 Examples of series operation
5.2 Parallel operation
¡Parallel operation is not possible.
¡Redundancy operation is available by wiring as shown below.
+S
+VOUT
-S
-VOUT
+S
+VOUT
-S
-VOUT
Load
I
I
1I3
2
+S, -S : TUNS100F
Fig. 5.2 Example of Redundancy Operation
¡Even a slight difference in output voltage can affect the balance
between the values of I1and I2.
Please make sure that the value of I3does not exceed the rated
current of a power supply.
I3the rated current value
TUNS50F, TUNS100F AC-DC Power Supplies Bus Converter.Power Module Type
Instruction Manual
TUNS-17
TUNS

6.3 Cleaning
¡Clean the product with a brush. Prevent liquid from getting into
the product.
Do not soak the product into liquid.
¡Do not stick solvent to a name plate or a resin case.
(If solvent sticks to a name plate or a resin case, it will cause
to change the color of the case or to fade letters on name plate
away.)
¡After cleaning, dry them enough.
6.4 Soldering temperature
¡Flow soldering: 260Cfor up to 15 seconds.
¡Soldering iron (26W): 450Cfor up to 5 seconds.
6.5 Derating
(1) Input voltage derating curve
Input voltage derating curve is shown in Fig.6.2.
85 90
80
100


Fig. 6.2 Input voltage derating curve
(2) Output voltage derating curve
¡Use the power modules with conduction cooling (e.g. heat dissipa-
tion from the aluminum base plate to the attached heat sink).
Fig. 6.3 shows the derating curves with respect to the aluminum
base plate temperature. Note that operation within the hatched

¡Please measure the temperature on the aluminum base plate
edge side when you cannot measure the temperature of the cen-
ter part of the aluminum base plate.
In this case, please take 5deg temperature margin from the derat-
ing characteristics shown in Fig.6.3.
 -
sible when the up and down of the temperature are frequently
generated.
Contact us for more information on cooling methods.
6 Implementation-
Mounting Method
6.1 Mounting method
¡The unit can be mounted in any direction. When two or more
power supplies are used side by side, position them with proper
intervals to allow enough air ventilation. Aluminum base plate tem-
perature of each power supply should not exceed the temperature
range shown in derating curve.
¡Avoid placing the AC input line pattern layout underneath the unit.
It will increase the line conducted noise. Make sure to leave an
ample distance between the line pattern layout and the unit. Also
avoid placing the DC output line pattern underneath the unit be-
cause it may increase the output noise. Lay out the pattern away
from the unit.
¡Avoid placing the signal line pattern layout underneath the unit
because the power supply might become unstable. Lay out the
pattern away from the unit.
¡High-frequency noise radiates directly from the unit to the atmo-
sphere. Therefore, design the shield pattern on the printed circuit
board and connect it to FG.
The shield pattern prevents noise radiation.
¡
-
ing a M3 tap on the heat sink.
Please make sure a mounting hole will be connected to a grounding
capacitor CY.

Mounting hole
Standard M3 tapped
Optional : -T f3.4 thru
6.2 Stress to the pins
¡When too much stress is applied to the pins may damage internal
connections. Avoid applying stress in excess of that shown in Fig.
6.1.
¡The pins are soldered onto the internal PCB.
Therefore, Do not bend or pull the leads with excessive force.
¡Mounting hole diameter of PCB should be 3.5mm to reduce the
stress to the pins.
¡

Others+VOUT, -VOUT
Less than
39.2N(4kgf)
Less than
39.2N(4kgf)
Less than
39.2N(4kgf)
Less than
19.6N(2kgf)
Less than
19.6N(2kgf)
Less than
19.6N(2kgf)
Fig. 6.1 Stress to the pins
AC-DC Power Supplies Bus Converter.Power Module Type TUNS50F, TUNS100F
Instruction Manual
TUNS-18
TUNS

-40-20 020406080 100
0
50
100
Load Factor [%
Aluminum base plate temperature Tc [C
(85)
(75)
1
1TUNS50F/TUNS100F
TUNS5T0F UNS100F
Tc
Measuring point
Fig.6.3 Derating curve
6.6 Heat sink (Optional parts)
¡The power module works with conduction cooling and needs heat
dissipation using heat sinks. Optional heat sinks are available for
TUNS50F/TUNS100F Series. Refer to Table 6.1 and Table 6.2 for
details on the thermal resistance of heat sinks.
¿TUNS50F
Table 6.1 Types of Heat Sinks Available
No. Model

Thermal resistance[
C

Style
H W D
Convection
(0.1m/s)
Forced Air
1 F-QB-F1 12.7 58.4 37.6 14.0
Refer Fig.6.5
Horizontal
2 F-QB-F2 12.7 58.7 37.3 Vertical
3 F-QB-F3 25.4 58.4 37.6 7.5 Horizontal
4 F-QB-F4 25.4 58.7 37.3 Vertical
5 F-QB-F5 38.1 58.4 37.6 5.0 Horizontal
6 F-QB-F6 38.1 58.7 37.3 Vertical
W
D
DH
H
W
Vertical
Horizontal
Fig.6.4 Heat Sink Types
0
2
4
6
8
10
0.00.5 1.01.5 2.02.5 3.0
Wind velocity(m/s)
Thermalresistance(/w)
F-QB -F1/F2
F- QB -F3/F4
F-QB -F5/F6
C
Fig.6.5 Thermal Resistance of Heat Sink(Forced Air)
¿TUNS100F
Table 6.2 Types of Heat Sinks Available
No. Model

Thermal resistance[
C

Style
H W D
Convection
(0.1m/s)
Forced Air
1 F-CBS-F1 12.7 57.9 61.5 7.5
Refer Fig.6.7
Horizontal
2 F-CBS-F2 12.7 58.4 61.0 Vertical
3 F-CBS-F3 25.4 57.9 61.5 4.6 Horizontal
4 F-CBS-F4 25.4 58.4 61.0 Vertical
5 F-CBS-F5 38.1 57.9 61.5 3.0 Horizontal
6 F-CBS-F6 38.1 58.4 61.0 Vertical
W
D D
W
VerticalHorizontal
H H
Fig. 6.6 Heat Sink Types
0
1
2
3
4
5
6
0.00.5 1.01.5 2.02.5 3.0
Wind velocity(m/s)
Thermalresistance(/w)
F-CBS-F1/F2
F-
CBS
-F3/F4
F-CBS-F5/F6
C
Fig.6.7 Thermal Resistance of Heat Sink(Forced Air)
TUNS50F, TUNS100F AC-DC Power Supplies Bus Converter.Power Module Type
Instruction Manual
TUNS-19
TUNS

7 Lifetime expectancy depends on
stress by temperature difference
¡Regarding lifetime expectancy design of solder joint, following
contents must be considered.
It must be careful that the soldering joint is stressed by tempera-
ture rise and down which is occurred by self-heating and ambient
temperature change.
The stress is accelerated by thermal-cycling, therefore the tem-
perature difference should be minimized as much as possible if
temperature rise and down is occurred frequently.
¡Product lifetime expectancy depends on the aluminum base plate
central temperature difference (DTc) and number of cycling in a
day is shown in Fig.7.1.
If the aluminum base plate center part temperature changes fre-
quently by changing output load factor etc., the above the lifetime
expectancy design should be applied as well.
Please contact us for details.
0
5
10
25 30 35 40 45 50 55 60 65 7
0
1time ON/OFF /1day
2times ON/OFF /1day
3times ON/OFF /1day
4times ON/OFF /1day
5times ON/OFF /1day
The aluminum base
p
late central tem
p
erature differenceDTc
[
C

Lifetime expectancy [years
Fig.7.1 Lifetime expectancy against rise/fall temperature difference
Application manuals available at our website.
Recommended external components are also introduced for your
reference.
AC-DC Power Supplies Bus Converter.Power Module Type TUNS50F, TUNS100F
Instruction Manual
TUNS-20
TUNS

1 Pin Connection
¿TUNS300F/TUNS500F/TUNS700F
7-VOUT
6+VOUT
2AC2
1AC1
8-S
9+S
0TRM
å IOG
3R5-BC 4+BC 4-FG
Fig.1.1 Pin connection (bottom view)
Table 1.1 Pin connection and function
No.
Pin
Connection
Function
1AC1 AC input
2AC2
3
R External resistor for inrush current protection
4
+BC +BC output
5
- BC - BC output
6+VOUT +DC output
7
- VOUT - DC output
8
- S Remote sensing ( - )
9+S Remote sensing (+)
0TRM Adjustment of output voltage
åIOG Inverter operation monitor
∫RC1 Remote ON/OFF (Option)
çRC2
- FG Mounting hole (FG)
¿TUNS700FOO-P (OPTION)
7-VOUT
6+VOUT
2AC2
1AC1
8-M
9+M
0NC
å IOG
3R5-BC 4+BC 4-FG
Fig.1.2 Pin connection (bottom view)
Table 1.2 Pin connection and function
No.
Pin
Connection
Function
8
- MOutput voltage monitor terminal
9+M
0NC No connection
Other than the above are the same as standard products.
Please refer to Table 1.1.
2 Connection for Standard Use
¡To use TUNS series, connection shown in Fig.2.1 and external
components are required.
¡This product uses conduction cooling method (e.g. heat radiation
from the aluminum base plate to the attached heat sink).
Reference: 6.5 ”Derating”
Heatsink
Load
FG
Co
+
+
R
C1
F1
FG
AC IN
FG
TFR1
CY
C3 C2
+BC
+S
-BC
-S
Cbc
AC1
AC2
+VOUT
-VOUT
Noise
filter
TUNS300F
TUNS500F
TUNS700F
Fig.2.1 Connection for standard use
Table 2.1 External components
No. Symbol Components Reference
1 F1 Input fuse
3.1 “Wiring input pin (1)”
2 C1 Input Capacitor 3.1 “Wiring input pin (2)”
3 - Noise Filter
3.1 “Wiring input pin (3)”
4 CY Y capacitor
5 Co Output capacitor
3.2 “Wiring output pin (1)”
6 Cbc Smoothing Capacitor for boost voltage 3.3 “+BC/-BC pins (1)”
7 C2,C3 Capacitor for boost voltage 3.3 “+BC/-BC pins (2)”
8 TFR1 Inrush current protection resistor 3.3 “+BC/-BC pins (3)”
9 - Heatsink -
TUNS300F, TUNS500F, TUNS700F AC-DC Power Supplies Bus Converter.Power Module Type
Instruction Manual
TUNS-21
TUNS

3 Wiring Input/Output Pin
3.1 Wiring input pin
(1) F1 : External fuse
¡Fuse is not built-in on input side. In order to protect the unit, install
the slow-blow type fuse on input side (as shown in Table 3.1).
Table 3.1 Recommended fuse (Slow-blow type)
Model TUNS300F TUNS500F/TUNS700F
Rated current 10A 15A
(2) C1 : External Capacitor for input side
¡-
tance and ripple current capability are above the values shown in
Table 3.2.
¡Use a safety approved capacitor with 250V ac rated voltage.
¡If C1 is not connected, it may cause the failure of the power sup-
ply or external components.
Table 3.2 Input Capacitor C1
No. Model Voltage Capacitance Rated ripple
current
1 TUNS300F
AC250V
 5A or more
2 TUNS500F  5A or more
3 TUNS700F  5A or more

¡
 -
tor CY for low line noise and stable operation of the power supply.
¡The operation of the power supply may be unstable due to the

¡Install a correspondence filter, if it is required to meet a noise
standard or if the surge voltage may be applied to the unit.
¡Install a primary decoupling capacitor CY, with more than 470pF,
near the input pins (within 50mm from the pins).
¡When the total capacitance of the primary decoupling capacitor is

be met by the Hi-Pot test between input and output. A capacitor
should be installed between output and FG.
3.2 Wiring output pin
(1) Co : Output capacitor
¡Install an external capacitor Co between +VOUT and -VOUT pins
for stable operation of the power supply (Fig.2.1).
Recommended capacitance of Co is shown in Table 3.3.
¡Select the high frequency type capacitor. Output ripple and start-

the wiring impedance.
¡Install a capacitor Co near the output pins (within 50mm from the
pins).
¡When the power supply is used under 0Cambient temperature,
output ripple voltage increases. In this case, connect 3 capacitors
Co in parallel connection.

Model Temperature of base plate
Tc=0 to +100CTc=
- 40 to +100C
Output voltage
(V)
TUNS300F/TUNS500F
TUNS700F
TUNS300F/TUNS500F
TUNS700F
12 2200 2200×3
28 1000 1000×3
48 470 470×3

introduced in Fig.3.1.
+
R
C1
F1
FG
AC IN
FG
TFR1
CY
C3 C2
+BC
+S
-BC-S
Cbc
AC1
AC2
+VOUT
-VOUT
TUNS300F
TUNS500F
TUNS700F
R
C
Load
C4
+
Co
50mm
Noise
filter
Oscilloscope
BW:100MHz
1.5m
50W
Coaxial
Cable R=50W
C=0.01mF
C4 :
12V 10mF
28V 4.7mF
48V 2.2mF
Fig.3.1 Method of Measuring Output Ripple and Ripple Noise
3.3 Wiring +BC/-BC pins
(1) Cbc : Smoothing capacitor for boost voltage
¡In order to smooth boost voltage, connect Cbc between +BC and
-BC. Recommended capacitance of Cbc is shown in Table3.4.
¡Note that +BC and -BC terminals have high voltage (DC380V typ).
¡Keep the capacitance within the allowable external capacitance.
¡Select a capacitor of which the boost voltage ripple voltage does
not exceed 30Vp-p.
¡When the power supply is operated under -20C, it may make
the boost voltage unstable due to the characteristic of equivalent
series resistor. Please choose the capacitor which has more than
recommended capacitance.
Table 3.4 Recommended capacitance Cbc
No. Model Voltage Cbc Allowable
capacitance range
1 TUNS300F DC420V
or more
 
2 TUNS500F X2
3 TUNS700F X2
(2) C2, C3 : Capacitor for boost voltage
¡Install external capacitors C2, C3 with capacitance shown in table
3.5.
¡If capacitors C2, C3 are not installed, it may cause the failure of
the power supply or external components.
Table 3.5 Recommended capacitance C2 and C3
No. Model Voltage Capacitance Rated ripple
current
1 TUNS300F
DC450V
 3A or more
2 TUNS500F  3A or more
3 TUNS700F  3A or more
AC-DC Power Supplies Bus Converter.Power Module Type TUNS300F, TUNS500F, TUNS700F
Instruction Manual
TUNS-22
TUNS

Remarks:
Please note that devices inside the power supply might fail when
voltage of more than rated output voltage is applied to output ter-
minal of the power supply. This could happen when the customer
tests the overvoltage performance of the unit.
4.5 Thermal protection
¡When it exceeds the Derating (Section 6.5), the thermal protection
will be activated and simultaneously shut down the output.
When the thermal protection is activated, shut off the input voltage
and eliminate all the overheating conditions. To recover the output
voltage, keep enough time to cool down the power supply before
turning on the input voltage again.
4.6 Remote ON/OFF
¿-R1
¡Remote ON/OFF is possible by applying a voltage between RC1
and RC2 pin. External DC power source is necessary to operate
remote control.
External current limiting resistor Rrc is necessary.
¡When power supply shut off by over voltage protection or
overheating protection, it can be recovered by toggling Remote
ON/OFF signal.

No. ITEM RC1, RC2
1 Function Output is OFF in ”L”
2 Base pin RC2
3 Output ON SW OPEN
(0.5V max, 0.1mA max)
4 Output OFF SW SHORT
(5mA typ, 3mA min)
¡Sink current of RC1 must be kept up to 12mA.
RC1150
RC2
12mA max
Rrc
OUTSIDE OF TUNS INSIDE OF TUNS
Vrc
SW
VfN1.0V
Fig .4.1 RC Connection Example
*Please be careful not to connect RC1 and RC2 opposite.
It may cause a failure of power supply.
¡Remote ON/OFF circuit (RC1, RC2) is isolated from the input and
output and FG.
¿-R2
¡”-R2” can reduce standby power than “-R1”.
¡The usage is same as option “-R1”.
Please refer to option “-R1”

0.5Wtyp (AC100V), 1.2Wtyp (AC200V)
(3) TFR1 : Inrush current limiting resistor 4.7ohm - 22ohm
¡Connect a resistor between R pin and +BC pin for inrush cur-
rent protection. The surge capacity is required for TFR1, please
contact component mfg. Wirewound resistor with thermal cut-offs
type is required.
4 Function
4.1 Input voltage range
¡The input voltage range is from 85 VAC to 264 VAC.
¡In cases that conform with safety standard, input voltage range is
AC100-AC240V(50/60Hz).
¡Be aware that use of voltages other than those listed above may

cause damage. Avoid square waveform input voltage, commonly
used in UPS units and inverters.
4.2 Overcurrent protection
¿TUNS300F/TUNS700F
¡Overcurrent protection is built-in and comes into effect at over
105% of the rated current.
Overcurrent protection prevents the unit from short circuit and
overcurrent condition. The unit automatically recovers when the
fault condition is cleared.
¡When the output voltage drops at overcurrent, the average output
current is reduced by intermittent operation of power supply.
¿TUNS500F
¡Overcurrent protection is built-in and comes into effect at over
101% of the peak current.
Overcurrent protection prevents the unit from short circuit and
overcurrent condition. The unit automatically recovers when the
fault condition is cleared.
¡When the output voltage drops at overcurrent, the average output
current is reduced by intermittent operation of power supply.
4.3 Peak current protection
¿TUNS500F
¡Peak current protection is built-in. When the power supply is op-
erated at over peak load based on section 7 (Peak current), this
function comes into effect and reduce the output.
¡A few seconds later, a unit automatically recovers. But if the over-
current condition has not been released, the output will reduced
again (intermittent operation mode).
4.4 Overvoltage protection
¡Overvoltage protection circuit is built-in. If the overvoltage protec-
tion circuit is activated, shut down the input voltage, wait more
than 3 minutes and turn on the AC input again to recover the out-
put voltage. Recovery time varies depending on such factors as
input voltage value at the time of the operation.
TUNS300F, TUNS500F, TUNS700F AC-DC Power Supplies Bus Converter.Power Module Type
Instruction Manual
TUNS-23
TUNS

4.7 Remote sensing
¡Remote sensing is built-in.
(1) When the remote sensing function is not in use
+S
+VOUT
-S
-VOUT
+Co
Short at pin root
Load
TUNS300F
TUNS500F
TUNS700F
Fig. 4.2 Connection when the remote sensing is not in use
¡When the remote sensing function is not in use, it is necessary to


¡
possible.
Loop wiring should be avoided.
This power supply might become unstable by the noise coming
from poor wiring.
(2) When the remote sensing function is in use
TUNS300F
TUNS500F
TUNS700F
+S
Co
-S
+VOUT
-VOUT
+
Wire as close as possible
Load
Fig. 4.3 Connection when the remote sensing is in use
¡Twisted-pair wire or shield wire should be used for sensing wire.
¡Thick wire should be used for wiring between the power supply
and a load.
Line drop should be less than 0.5V.
Voltage between +VOUT and -VOUT should remain within the
output voltage adjustment range.
¡If the sensing patterns are short, heavy-current is drawn and the
pattern may be damaged.
The pattern disconnection can be prevented by installing the pro-
tection parts as close as a load.
¡As wiring or load impedance may generate oscillation or large
fluctuations in output voltage, make sure enough evaluation is
given advance.
4.8 Adjustable voltage range
¡Output voltage between +VOUT and -VOUT can be adjusted by
connecting external resistors to TRM.
¡When the output voltage adjustment is not used, open the TRM
pin respectively.
¡When the output voltage adjustment is used, note that the overvolt-
age protection circuit operates when output voltage is set too high.
¡The wiring to the potentiometer should be as short as possible.

depending on the types of resistors and potentiometers, please

Resistors.............
 ± 100ppm/C
Potentiometers ... C
¡Output voltage can be adjusted by connecting an external potenti-
ometer (VR1) and resistors (R1 and R2) as shown in Fig. 4.4.
Output voltage will increase if the resistance between 2and 3is
reduced by turning the potentiometer.
Recommended values for external components are shown in
Table 4.2.

+VOUT
-VOUT
-S
+S
TRM
External Resistor R1
External VR1
External Resistor R2
1
25kW
3
TUNS300F
TUNS500F
TUNS700F
Fig. 4.4 Connecting External Devices (TUNS300F/TUNS500F/TUNS700F)
Table 4.2 Recommended Values of External Resistors (TUNS300F/TUNS500F/TUNS700F)
No. Output
Voltage
Adjustable Range
VOUT±5% VOUT±10%
R1 R2 R1 R2
1 12V 12kW
2.2kW
6.8kW
1.0kW 2 28V 39kW27kW
3 48V 68kW47kW
¿-Y1
¡Adjustable voltage range of 48V output is changed to ± 20%.
*Adjustable voltage range of standard type except 48V output is
±20%.
¡Safety standard, is considered as Non-SELV output.
AC-DC Power Supplies Bus Converter.Power Module Type TUNS300F, TUNS500F, TUNS700F
Instruction Manual
TUNS-24
TUNS

4.9 Inverter operation monitor (IOG)
¡By using the inverter operation monitor (IOG), condition of the in-
verter can be monitored.
The following 1or 2conditions make the IOG signal turns “H”
from “L” within 1 second.
1Malfunction of inverter
2Output voltage is rapidly dropped by adjusting output voltage
 

No. Item IOG
1 Function Normal operation "L"
Malfunction of inverter "H"
2 Base pin -S
3 Level voltage "L" 0.5V max at 10mA
4 Level voltage "H" Open corrector
5 Maximum sink current 10mA max
6 Maximum applied voltage 35V max
4.10 Withstanding Voltage / Isolation Voltage
¡When testing the withstanding voltage, make sure the voltage
is increased gradually. When turning off, reduce the voltage
gradually by using the dial of the hi-pot tester. Do not use a
voltage tester with a timer as it may generate voltage several
times as large as the applied voltage.
5 Series and Parallel
Operation
5.1 Series operation
¡Series operation is available by connecting the outputs of two or
more power supplies as shown below. Output current in series
connection should be lower than the lowest rated current in each
unit.
Load
Load
Power
Supply
Power
Supply
Load
Power
Supply
Power
Supply
(a)
(b)
Fig. 5.1 Examples of series operation
5.2 Parallel operation
¡Parallel operation is not possible.
¿–P (TUNS700F)
¡This option is for parallel operation.
¡Sensing and adjustment of the output voltage are not possible at
the time of the use with this option.
¡As variance of output current drew from each power supply is
maximum 10%, the total output current must not exceed the value
determined by the following equation.
(Output current in parallel operation)
=(the rated current per unit) x (number of unit) x0.9
Total number of units should be no more than 5 pieces.
¡To improve the load sharing of each unit, please use the same
length from each unit to the load.
¡Connect each input pin for the lowest possible impedance.
When the number of the units in parallel operation increases, input
current increases. Adequate wiring design for input circuitry such
as circuit pattern, wiring and current for equipment is required.
¡If temperatures of aluminum base plates are different in the power
supply for parallel operation, values of output current will change
greatly.
Design radiation to equalize plate temperatures by attaching the
same heatsinks.
Load
FG
Co
+
+
R
C1
F1
FG
AC IN
FG
TFR1
CY
C3 C2
+BC
+M
-BC
-M
Cbc
AC1
AC2
+VOUT
-VOUT
Noise
filter
FG
Co
+
+
R
C1
F1
FG
FG
TFR1
CY
C3 C2
+BC
+M
-BC
-M
Cbc
AC1
AC2
+VOUT
-VOUT
Noise
filter
FG
Co
+
+
R
C1
F1
FG
FG
TFR1
CY
C3 C2
+BC
+M
-BC
-M
Cbc
AC1
AC2
+VOUT
-VOUT
Noise
filter
Fig. 5.2 Parallel operation
¡Please refer to the application manuals for details of -P type.
Application manual is on our web site.
TUNS300F, TUNS500F, TUNS700F AC-DC Power Supplies Bus Converter.Power Module Type
Instruction Manual
TUNS-25
TUNS

5.3 N+1 redundant operation
¡Redundancy operation is available by wiring as shown below.
+S
+VOUT
-S
-VOUT
+S
+VOUT
-S
-VOUT
Load
I
I
1I3
2
Fig. 5.3 Example of Redundancy Operation
¡Even a slight difference in output voltage can affect the balance
between the values of I1and I2.
Please make sure that the value of I3does not exceed the rated
current of a power supply.
I3the rated current value
6 Implementation-
Mounting Method
6.1 Mounting method
¡The unit can be mounted in any direction. When two or more
power supplies are used side by side, position them with proper
intervals to allow enough air ventilation. Aluminum base plate tem-
perature of each power supply should not exceed the temperature
range shown in derating curve.
¡Avoid placing the AC input line pattern layout underneath the unit.
It will increase the line conducted noise. Make sure to leave an
ample distance between the line pattern layout and the unit. Also
avoid placing the DC output line pattern underneath the unit be-
cause it may increase the output noise. Lay out the pattern away
from the unit.
¡Avoid placing the signal line pattern layout underneath the unit
because the power supply might become unstable. Lay out the
pattern away from the unit.
¡High-frequency noise radiates directly from the unit to the atmo-
sphere. Therefore, design the shield pattern on the printed circuit
board and connect it to FG.
The shield pattern prevents noise radiation.
¡
-
ing a M3 tap on the heat sink.
Please make sure a mounting hole will be connected to a grounding
capacitor CY.

Mounting hole
Standard M3 tapped
Optional : -T f3.4 thru
6.2 Stress to the pins
¡When too much stress is applied to the pins may damage internal
connections. Avoid applying stress in excess of that shown in Fig.
6.1.
¡The pins are soldered onto the internal PCB.
Therefore, Do not bend or pull the leads with excessive force.
¡Mounting hole diameter of PCB should be 3.5mm to reduce the
stress to the pins.
¡

Others+VOUT, -VOUT
Less than
39.2N(4kgf)
Less than
39.2N(4kgf)
Less than
39.2N(4kgf)
Less than
19.6N(2kgf)
Less than
19.6N(2kgf)
Less than
19.6N(2kgf)
Fig. 6.1 Stress to the pins
6.3 Cleaning
¡Clean the product with a brush. Prevent liquid from getting into
the product.
Do not soak the product into liquid.
¡Do not stick solvent to a name plate or a resin case.
(If solvent sticks to a name plate or a resin case, it will cause
to change the color of the case or to fade letters on name plate
away.)
¡After cleaning, dry them enough.
6.4 Soldering temperature
¡Flow soldering: 260Cfor up to 15 seconds.
¡Soldering iron (26W): 450Cfor up to 5 seconds.
6.5 Derating
(1) Intput voltage derating curve
¿TUNS700F
¡Input voltage derating curve is shown in Fig.6.2.

85 100
85
100
[%
Load factor
Fig. 6.2 Input voltage derating curve
AC-DC Power Supplies Bus Converter.Power Module Type TUNS300F, TUNS500F, TUNS700F
Instruction Manual
TUNS-26
TUNS

(2) Output voltage derating curve
¡Use the power modules with conduction cooling (e.g. heat dissipa-
tion from the aluminum base plate to the attached heat sink).
Fig.6.3 shows the derating curves with respect to the aluminum
base plate temperature. Note that operation within the hatched

¡Please measure the temperature on the aluminum base plate
edge side when you cannot measure the temperature of the cen-
ter part of the aluminum base plate.
In this case, please take 5deg temperature margin from the derat-
ing characteristics shown in Fig.6.3.
¡In case of forced air cooling, please measure the temperature on
the leeward side of aluminum base plate edge.
Especially, in case of using small heat sink, the temperature dif-
ference between the center and the edge side of the baseplate
becomes large.
In this case, 5deg temperature margin is not required.
¡-
sible when the up and down of the temperature are frequently
generated.
Contact us for more information on cooling methods.
Load Factor [%
1
1TUNS300F
-40-20 020406080 100
0
50
100
Aluminum base plate temperature Tc [C
Load Factor [%
12
1TUNS500F12
2TUNS500F28,TUNS500F48
-40-20 020406080 100
0
50
100
Aluminum base plate temperature Tc [C
(75)
Load Factor [%
1
2
1TUNS700F12
2TUNS700F28,TUNS700F48
-40-20 020406080 100
0
50
100
Aluminum base plate temperature Tc [C
(70)(50)
(75)
Tc
Measuring point
TUNS300F / TUNS500F / TUNS700F
Fig.6.3 Derating curve
7 Peak current
¿TUNS500F
¡The unit can generate the peak current under the following condi-
tions.
- t1[
- Ip[Rated peak current
- Iave[Rated current
- [35%

Output current
Ip : Peak current
Iave : Average current
t1 t2
Fig. 7.1 Peak current
¡When aluminum baseplate temperature Tc is higher than 95C,
Iave must be less than 95% of rated current. (TUNS500F28 and
TUNS500F48)
TUNS300F, TUNS500F, TUNS700F AC-DC Power Supplies Bus Converter.Power Module Type
Instruction Manual
TUNS-27
TUNS

8 Lifetime expectancy depends on
stress by temperature difference
¡Regarding lifetime expectancy design of solder joint, following
contents must be considered.
It must be careful that the soldering joint is stressed by tempera-
ture rise and down which is occurred by self-heating and ambient
temperature change.
The stress is accelerated by thermal-cycling, therefore the tem-
perature difference should be minimized as much as possible if
temperature rise and down is occurred frequently.
¡Product lifetime expectancy depends on the aluminum base plate
central temperature difference (DTc) and number of cycling in a
day is shown in Fig.8.1.
If the aluminum base plate center part temperature changes fre-
quently by changing output load factor etc., the above the lifetime
expectancy design should be applied as well.
Please contact us for details.
0
5
10
25 30 35 40 45 50 55 60 65 7
0
1time ON/OFF /1day
2times ON/OFF /1day
3times ON/OFF /1day
4times ON/OFF /1day
5times ON/OFF /1day
The aluminum base
p
late central tem
p
erature differenceDTc
[
C

Lifetime expectancy [years
Fig.8.1 Lifetime expectancy against rise/fall temperature difference
Application manuals available at our website.
Recommended external components are also introduced for your
reference.
AC-DC Power Supplies Bus Converter.Power Module Type TUNS300F, TUNS500F, TUNS700F
Instruction Manual
TUNS-28
TUNS

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