TDK PFH05W Series Supplement

TDK-Lambda Americas Inc. 2019
1
PFH05W Evaluation
Test Board
Application notes
Version 1.05
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Table of Contents
1.0 Getting Started .................................................................................................................................. 5
1.1 Test Equi ment ............................................................................................................................. 6
1.2 Test Setu ..................................................................................................................................... 7
1.3 Test Points ..................................................................................................................................... 9
1.4 PMBus and Remote On/Off Functions ........................................................................................ 10
1.5 Setting the PMBus Address ......................................................................................................... 11
1.6 Turning PFH Module On/Off ....................................................................................................... 12
2.0 Electrical Schematic Drawing .......................................................................................................... 13
3.0 Bill of Material ................................................................................................................................. 14
4.0 Board Files ....................................................................................................................................... 15
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BEFORE U ING THE POWER UPPLY UNIT
Be sure to read and understand this instruction manual thoroughly before using this roduct. Pay attention to all cautions and warnings before
using this roduct. Incorrect usage could lead to an electrical shock, damage to the unit or a fire hazard.
DANGER
Never use this roduct in locations where flammable gas or ignitable substances are resent. There are risks of igniting these substances and
ex loding by arcing.
WARNING
•Do not touch this roduct or its internal com onents while circuit is live, or shortly after shut down. There may be high voltage or high
tem erature resent and you may receive an electric shock or burn.
•While this roduct is o erating, kee your hands and face away from it as you may be injured by an unex ected situation.
•Do not make unauthorized changes to this roduct, otherwise you may receive an electric shock and void your warranty.
•Do not dro or insert anything into the roduct. It might lead to a failure, fire or electric shock.
•Do not use this roduct if abnormal conditions such as emission of smoke and/or abnormal smell or audible noise, etc… are resent. It might
lead to fire and/or electric shock. In such cases, lease contact TDK Lambda. Do not attem t re air by yourself, as it is dangerous for the user.
•Do not o erate these roducts in the resence of condensation. It might lead to fire or electric shock.
CAUTION
•This ower su ly is designed and manufactured for use within an end roduct such that it is accessible only to trained SERVICE ENGINEERS.
•Confirm that the connections to in ut/out ut terminals, and signal terminals are correct as s ecified in this instruction manual before turning
on the ower.
•In ut voltage, Out ut current, Out ut ower, ambient tem erature, case tem erature, and ambient humidity should be ke t within the
s ecifications, otherwise the roduct may be damaged.
•Do not o erate and store this roduct in an environment where condensation might occur. In such case, water roof treatment is necessary.
•The equi ment has been evaluated for use in a Pollution Degree 2 environment.
•Do not use this roduct in environment with a strong electromagnetic field, corrosive gas or conductive substances.
•For a lications, which require very high reliability, such as nuclear related equi ment, medical equi ment, traffic control equi ment, etc.,
it is necessary to rovide a fail-safe mechanism in the end equi ment.
•Do not inject abnormal voltages into the out ut terminal or signal terminal of this roduct. The injection of reverse voltage or over voltage
exceeding nominal out ut voltage into the out ut terminal or signal terminal might cause damage to internal com onents.
•Never o erate the roduct under the over-current or short circuit conditions. Failure or other damage may occur.
•The out ut voltage of this ower su ly unit is considered to be a hazardous energy level (The voltage is 2V or more and the electric ower
is 240W or more). It must not be made accessible to users. Protection must be rovided for Service Engineers against indirect contact with
the out ut terminals and/or to revent tools being dro ed across them. While working on this roduct, the AC in ut ower must be switched
off, and the in ut, out ut, +VBus, and -VBus terminal voltages should be at a safe level.
•The a lication circuits and their arameters are for reference only. Be sure to verify effectiveness of these circuits and their arameters
before finalizing the circuit design.
•Use a Fast-Blow external fuse to each module to ensure safe o eration and com liance with the safety standards to which it is a roved. The
recommended in ut fuse rating within the instructions is as follows: 10A, 250V fast acting fuse. The breaking ca acity and voltage rating of
this fuse may be subject to the end use a lication.
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Reference Documents:
1.) PFH Instruction Manual
2.) PFH PMBus S ecification Customer Release
3.) PFH500F-## Evaluation Re ort
4.) PFH GUI Interface
Note: ## - Denotes out ut voltage of PFH modules (e.g. “28” for 28Vdc)
CAUTION
•This information in this document is subject to change without rior notice. Please refer to the latest version of the data sheet, etc., for the
most u -to date s ecifications of the roduct.
•No art of this document may be co ied or re roduced in any form without rior written consent TDK-Lambda.
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1.0 Getting Started
PFH05W##-100-EVK-S1 & PFH05W##-1D0-EVK-S1 Evaluation Boards
NOTE: ## - Denotes out ut voltage of PFH modules (e.g. “28” for 28Vdc)
PFH05W-001-EVK-S0 Evaluation Board
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1.1 Test Equipment
1.) AC Voltage Source: Capable of single-phase output, AC voltage range 85 V AC - 265 V AC , 47 Hz
- 63 Hz, adjustable. AC Source should be adequately sized to support the PFH module’s
operation.
2.) DC Multimeter: capable of 0V to 500V input range.
3.) Output Load: DC load capable of 60 V DC or greater, DC Load current up to 42A or greater
(12V/42A, 28V/18A, or 48V/10.5A), and 500 W or greater, with display such as load current and
load power.
4.) Fan: Airflow is required to be directed across the mounted heatsink of the PFH module.
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1.2 Test Setup
1.) Electrical In ut Connections: CONN1: LINE, In ut Line Connection
CONN2: NEUT, In ut Neutral Connection
CONN3: EGND, Earth Ground Connection
NOTE: Refer to the PFH Datasheet for s ecific module’s AC In ut Current
requirement when sizing wire gauge and cable length.
2.) Electrical Out ut Connection: CONN5 +Vout, Out ut Load Connections
(Red Cable)
CONN4 -Vout, Out ut Load Return Connections
(Black Cable)
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WARNING
Make sure ALL input and output cables are de-energized before making electrical connections to the
Evaluation Test Board
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1.3 Test Points
1.) Secondary Test Points: TP201 Vout+, Monitor Out ut Voltage
TP204 Vout(-), Monitor Out ut Voltage return
TP202 RS(+), Out ut Remote Sense (+) connection
TP203 TRIM, Trim Test connection
WARNING HAZARD US V LTAGE
2.) Primary Test Points: TP103 +BUS, Monitor 400Vdc
TP104 -BUS, Monitor 400Vdc return
TP101 LINE, Monitor AC Line In ut
TP102 NEUT, Monitor AC Neutral In ut
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1.4 PM us and Remote On/Off Functions
1.) PMBus Connections (J301)
NOTE:
1. 3.3Vdc is su lies by the interface module
To communicate with the PFH module via PMBus, use the Texas Instruments Interface Ada ter EVM
(P/N#: USB-TO-GPIO). This ada ter is available from,
•TI
•Digi-Key
•Newark Element
•Mouser Electronics
•Arrow
Pin #:
Descri tion:
1
Not Used
2
Not Used
3
Not Used
4
Not Used
5
USB 3.3Vdc
1
6
SGND
7
Not Used
8
PMB
us
Alert
9
PMB
us
Clock
10
PMB
us
Data
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WARNING When AC voltage is applied to the Evaluation Test Board the 450V bulk capacitors ARE
energized at ALL time
2.) Remote On/Off (SW200) SW200, Will either turn the module On or ut it into Standby
3.) Auxiliary Voltage (DS301) DS301, The LED will Turn-On when the 450Vdc bulk ca acitors
are energized above 70Vdc
4.) Power Good (DS300) DS300, The LED will Turn-On once the module’s out ut has
been Turned-On
5.) Test Points TP301 Monitor Auxiliary Voltage
TP302 Monitor Power Good Signal
1.5 Setting the PM us Address
•The PMBus address setting on the Evaluation Test Board comes with the Factory default setting,
Address: 0x33 (Hex) (R318 & R319 are o ulated with 41.2K)
•To change PMBus address to a different address R318 (AD1) and R319 (AD2) must be o ulated
with a ro riate resistor values located in “PFH PMBus S ecification Customer Release”
document.
Example: Su ose a PMBus address of 0x51 was desired instead of 0x33.
R318 (PMBus AD1): Remove 41.2K (0805 Resistor) Po ulate with 14K (0805 Resistor)
R319 (PMBus AD2): Remove 41.2K (0805 Resistor)  Po ulate with 69.8K (0805 Resistor)
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1.6 Turning PFH Module On/Off
1.) Before a lying AC voltage to the module make sure,
a. The surface under the test fixture is a non-conductive surface
b. Securely connect In ut and Out ut cables to the test board
c. Securely connect all monitoring devices to test board
WARNING When AC voltage is applied to the Evaluation Test Board the 450V bulk capacitors ARE
energized at ALL time
2.) A ly AC in ut voltage to test fixture
a. AC in ut voltage range 100Vac – 265Vac
b. AC in ut voltage range < 100Vac, out ut load is de-rated 6.7W/V
c. Once AC in ut voltage is a lied, Auxiliary Voltage LED (DS301) will Turn-On
3.) Turning On PFH module can be accom lished 1 of 2 ways,
i. Remote On/Off
ii. PMBus
a. The method chosen to turn On PFH has to be the AME method to turn Off PFH
i. Exam le: If Remote On/Off turns On PFH, then PMBus cannot turn it Off, only
Remote On/Off can turn Off PFH.
b. Method 1: Toggle Remote On/Off,
I. Remote On/Off switch (SW200) On – Will turn PFH On
II. Remote On/Off switch (SW200) Off – Will turn PFH Off.
c. Method 2: PMBus,
I. Write CMD 0x01, Byte 0x80 – Turns PFH On
II. Write CMD 0x01, Byte 0x00 – Turn PFH Off
d. Once PFH is turned On, Power Good LED (DS300) will turn On
e. When PFH is turned Off, Power Good LED (DS300) will turn Off
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2.0 Electrical Schematic Drawing
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3.0 ill of Material
PFH05W-001-EVK- 0 Bill of Material
Part Reference Mfr Part Number1 Value Description Voltage Mfr1
BMPR1 BMPR2
BMPR3 BMPR4
BMPR5 BMPR6 SJ-5027 (BLACK)
Rubber
Bumper Bumper, Rubber, 0.63" Dia x 0.31" 3M
C100 C103 B32923C3105M2040 1uF Film Capacitor,305V, X2 Cap 250V TDK
C101 C102 CS45-E2GA332M-NKA 3.3nF Film Capacitor,305V, Y2 Cap 250V TDK
C104 B32923C3225M1040 2.2uF Film Capacitor,305V, X2 Cap 250V TDK
C105 C106
C213 C214 CS45-B2GA471K-NKA 470pF Film Capacitor,305V, Y2 Cap 250V TDK
C107 C108 B43508B5477M007 470uF Electrolytic Capacitor, 450V, 35X40 450V TDK
C200 C201 EEUFC2A471 470uF Electrolytic Capacitor, 100V, 16X40 100V Panasonic
C202 C203
C204 C205
C206 C207
C208 C209 C3225X7S2A475K200AB 4.7uF Ceramic Capacitor, 100V, 1210, 4.7uF 100V TDK
C212 C221 C2012X7R2A104K125AA 0.1uF Ceramic Capacitor, 100V, 0805 100V TDK
C222 C223 C3216X7R2A105MT 1.0uF Ceramic Capacitor,100V, 1206, 1.0uF 100V TDK
C301 C2012X7R1E105KT 1.0uF Ceramic Capacitor, 25V, 0805 25V TDK
CONN1 CONN2
CONN3 CONN4
CONN5 8196 PC Screw Terminal
CR100 CRH01 CRH01 PN Diode, Single Package, SMT TOSHIBA
DOC1 PFH500 PFH500 Evaluation Instruction Manual
DS300 DS301 5381H5 5381H5 LED, Green, Thru Hole
Chicago
Miniature Lamp
F100 F101 1A1907-03 1A1907-03 Fuse, Fuse holder, PWB BUSSMANN
F102 312010 312010 Fuse, 10A Fuse, Fast-Blow Littlefuse
J301 N2510-60XX
TI_USB_PMB
US .100" x .100" Four-Wall Header 3m
K100 JVN1A-12V-F JVN1A-12V-F RELAY SPST Panasonic
L100 L102 ARA00499 6.3mH Com Ind, 6325uH, Thru Hole TDK-Lambda
PWB100 ZB00511 ZB00511 PWB, (n) oz. Cu, .062"
R100 A5MC-220J 22.0 Res,22.0,5.0W 250V UCHIHASHI
R102 R103
R104 SPR2C474J 470K Res,470K,2.0W 250V KOA SPEER
R200 RK73Z2ATTE 0 Res,0,2.0A,70C,0805 N/A KOA SPEER
R300 R301 RK73H2ATTE1001F 1.00K Res,1.00K,0.125W,100ppm,70C,0805 150V KOA SPEER
R311 R312
R313 RK73H2ATTE1501F 1.50K Res,1.50K,0.125W,100ppm,70C,0805 150V KOA SPEER
R315 R316
R317 RK73H2ATTE30R1F 30.1 Res,30.1,0.125W,100ppm,70C,0805 150V KOA SPEER
R318 R319 RK73H2ATBK4122F 41.2K Res,41.2K, 0.125W,100ppm,70C,0805 150V KOA SPEER
SW200 T101SHCQE SPDT SPDT two position switch vertical (On None On) C&K
TP101 TP102
TP104 TP204 5011 5011 Test Point, Black, Thru Hole
Keystone
Electronics
TP103 TP201
TP202 5010 5010 Test Point, Red, Thru Hole
Keystone
Electronics
TP203 TP301
TP302 5014 5014 Test Point, Yellow, Thru Hole
Keystone
Electronics
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4.0 oard Files
FIGURE 1 To side Com onent Placement
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FIGURE 2 To Layer (Etch 1)
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FIGURE 3 Internal Layer (Etch 2)
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FIGURE 4 Internal Layer (Etch 3)
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FIGURE 5 Bottom Layer (Etch 4)
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FIGURE 6 Bottom side Com onent Placement
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