Application Notes

EPM Series
Energy-Saving Power Module Series

Application Notes

EPM Series
Energy-Saving Power Module Series

Rev.3.1
Ｍay, 2013

Outline
The EPM Energy-Saving Power Module Series is a series of energy-saving switching power modules with built-in
switching transformers, control ICs, control circuits and switching elements (FET).
Attaching the input noise filter, the input rectifier diode and the output smoothing capacitor externally enables theeasy creation of power switching with high-efficiency, low-standby power.

Features・ Quasi-resonant operations for high efficiency.
・ Operations using both frequency reduction and bursts for generation of low-standby power.
・ Supports worldwide input and PFC output voltages (Vin: DC110V to 450V)・ Reinforced insulation between Primary and Secondary (AC3000V guaranteed for one minute).
・ Resin filling is available to reduce audible noise.
・ Compliant with all required safety standards for information equipment, AV equipment, industrial equipment, andhome appliance equipment.
・ Various built-in protection functions (overcurrent, overvoltage and overheating protection).

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EPM Series
1.

Application Notes

Selecting Externally Connected Equipment

The example of application circuits and parts value which are indicated to this application note aim at assistance ofa design. Therefore, external parts variation or user operating conditions are not fully taken into consideration.
Please take parts variation, operating conditions into consideration when designing.

1.1

Application Circuits●With FG (Class I Power Supply)
F101 TH101

R101 L101

D101

L

C102

M101

⑫ +DC IN

C10４
C101

N

C105

⑭ Drain

SecW ④⑪ Vcc+DC OUT ⑤

FG
Vin=85Vac～276Vac

L201
C201

⑧ FB

+DC
OUT

⑥
C202

⑩ -DC IN-DC
OUT

-DC OUT ⑦
C203●Without FG (Class II Power Supply)

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EPM Series
1.2

Application Notes

parts example
Output Specifications

Part

3.3V 1.0A

M101

EPM0310SJ

F101

250V 1.6A time-lag

TH1015Ω～10Ω

L101

22mH～47mH/ 0.2A

L201
C101

5V 1.0A

12V 0.5A

12V 1.0A

EPM1205SJ

EPM1210SJ

250V 1.6A time-lag

250V 1.6A time-lag

250V 1.6A time-lag

5Ω～10Ω

5Ω～10Ω

5Ω～10Ω

22mH～47mH/ 0.3A

22mH～47mH/ 0.3A

22mH～47mH/ 0.5A

2.2uH～10uH / 2A

2.2uH～10uH / 2A

2.2uH～10uH / 1A

2.2uH～10uH / 2A

0.1uH～0.22uH / 250V

0.1uH～0.22uH / 250V

0.1uH～0.22uH / 250V

0.1uH～0.22uH / 250V

C102

450V 15uF

450V 22uF

450V 22uF

450V 47uF

C103

470pF～2200pF classⅡ

470pF～2200pF classⅡ

470pF～2200pF classⅡ

470pF～2200pF classⅡ

C104、C105

470pF～2200pF classⅠ

470pF～2200pF classⅠ

470pF～2200pF classⅠ

470pF～2200pF classⅠ

C201、C202

10V 680uF

10V 680uF

25V 220uF

25V 330uF

C203

1kV

1kV

1kV

1kV

R101

3.3MΩ 500V

0.022uF

EPM0510SJ

0.022uF

3.3MΩ 500V

0.022uF

3.3MΩ 500V

0.022uF

3.3MΩ 500V

Output Specifications

Part

15V 0.5A

15V 1.0A

24V 0.5A

M101

EPM1505SJ

EPM1510SJ

EPM2405SJ

F101

250V 1.6A time lag

250V 1.6A time lag

250V 1.6A time lag

TH101

5Ω～10Ω

5Ω～10Ω

5Ω～10Ω

L101

22mH～47mH/ 0.3A

22mH～47mH/ 0.6A

22mH～47mH/ 0.5A

L201

2.2uH～10uH / 1A

2.2uH～10uH / 2A

2.2uH～10uH / 1A

C101

0.1uH～0.22uH / 250V

0.1uH～0.22uH / 250V

0.1uH～0.22uH / 250V

C102

450V 27uF

450V 47uF

450V 47uF

C103

470pF～2200pF classⅡ

470pF～2200pF classⅡ

470pF～2200pF classⅡ

C104、C105

470pF～2200pF classⅠ

470pF～2200pF classⅠ

470pF～2200pF classⅠ

C201、C202

25V 220uF

25V 330uF

35V 220uF

C203

1kV

1kV

R101

3.3MΩ 500V

Rev.3.1 May, 2013

0.022uF

0.022uF

3.3MΩ 500V

1kV

0.022uF

3.3MΩ 500V

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EPM Series
1.3

AC input

Application Notes

DC output

When using an AC input connector and DC output connector, pay attention to the rated voltage and rated currentof the connector.
Consider the input voltage, withstand voltage and safety standard demanded values and provide a clearance
between AC input connector pins.

1.4

Fuse (F101)

Since a fuse is not built into the module (M101), always install a fuse at the Live side to ensure safety.
Select the fuse by considering the normal current, in-rush current, ambient temperature, and other conditions.
(Discharge the capacitors in the circuit fully and consider the conditions at which the circuit impedance is lowest
when there is a thermistor or other element whose resistance value changes with temperature.)①Select a rated current of 2 or more times the normal current.
②Consider the rated current rate of change by ambient temperature.(At high temperature: Rated voltage drops)③Check that the in-rush current and normal current are within the blowout characteristic curve of the fuse.
④Select a fuse so that in-rush current and normal current can take sufficient margin to a fuse permission I2t curve.
A required margin is subject to the influence by temperature conditions, and the influence of the number of times
of incoming current which occurs in an expected life. We recommend you to ask a fuse maker a proper margin.
In order to share an input line and an input electrolytic capacitor with another converter, when selecting a fuse withthe high fusing current characteristic, and a high-capacity electrolytic capacitor, there is a case which a fuse does
not blow out at the time of abnormalities.
Please perform a safety check enough in such a case.

Noise filter （C101,C103,C104,C105,C203,L101)
1.5.1 C101:X capacitor (Across-the-line capacitor)
・ Select the rated voltage matched to the input voltage specifications.
・ Use a safety standard approved product of each country.
1.5.2 C103,C104,C105,C203： Y capacitor (Line bypass capacitor)・
Use a safety standard approved product of each country.
・Be careful of the leakage current specified by each safety standard.
・With a Class II power supply, when connecting directly between the primary and secondary, use a reinforced
insulation product(Y1 class approved).
・C203 does not require a safety standard approved product, but since the withstand test voltage applied
between the primary and secondary is divided and applied according to the overall capacitance of C104 andC105 and the capacitance of C203, pay careful attention to the rated voltage.
・
1.5.3 L101：Common mode choke coil・ Be careful to confirm the rated temperature specified by the wire type and the bobbin insulation used in thecommon choke coil

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EPM Series
1.6

Application Notes

X capacitor discharge resistance (R101）

The voltage immediately before cutoff is charged in the X capacitor even when the input line is in cutoff status.
With a device at which parts of the same voltage as the X capacitor may be touched, a discharge resistor isnecessary according to the capacity of the X capacitor.
Example) IEC60950: When the X capacitor capacitance 0.1µF is exceeded; the time constant shall be 1 or less.
X capacitor capacitance：0.22uF

1≧R101・0.22×10-６
R≦4.5MΩIn addition, calculate the X capacitor voltage after t seconds from input line cutoff from the following expression
and check that there is no problem.
Vt： X capacitor voltage t seconds from input cutoff
Vt=Vo（１－e-t/CR)
Vo： Effective input voltage X√2
C： X capacitor capacitance
R： Discharge resistor value
e： Base of natural logarithm （≒2.71828）

1.7

Rectifying diode(D101)

Always perform full-wave rectification using a bridge diode or general rectifying diodes (use 4 diodes).
When selecting parts, pay attention to the rated voltage, rated current, and temperature rise.
Check that the in-rush current does not exceed the peak surge current and I2t specification of the rectifying
diode.
(Discharge the capacitors in the circuit fully and consider the conditions at which the circuit impedance is lowest
when there is a thermistor or other element whose resistance value changes with temperature.)

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EPM Series
1.8

Application Notes

Surge current prevention（TH101)

When input power is applied, an in-rush current which charges the input smoothing electrolytic capacitor flows.
An in-rush current that is too large will cause the power supply voltage to become unstable and may affect thedevices which share the power supply. The fuse and rectifying diodes used may also be damaged.
When using a power thermistor to suppress the surge current, select it by paying attention to the following:①Be sure that the temperature is within the operating temperature range of the thermistor.
②Since the characteristic is such that a rated current drop accompanies a temperature rise, check the highest
temperature of the thermistor and that the load current (power supply input current) is the rated current orless at the highest temperature.
③With a power thermistor, the relationship between the maximum value of the usable input voltage (rms) and thecapacitance of the input smoothing electrolytic capacitor are set. Check that the relationship between the input
voltage (rms) and input smoothing electrolytic capacitor is not a problem with the thermistor used.
④Since a power thermistor has a large thermal time constant and its resistance value remains low after the input
is tripped, when the input is repeatedly turned on and off, the surge current cannot be controlled. When using
under this condition, check that the effect, etc. on the fuse, bridge diode, and input power supply are no
problem.
The surge current calculation expression is:
As the calculation result is only a reference, conduct a thorough check using actual equipment.
・AC input ：Inrush Current（peak value） ： Vin (rms) ⋅ 2 ( R TH101 + R L )I2t ： Vin ( rms) 2 ⋅ C102 (R TH101 + R L )・DC input
Inrush Current（peak value） ： Vin (dc) ( R TH101 + R L )I2t ： Vin (dc) 2 ⋅ C102 2(R TH101 + R L )RL：Line impedance (Ω)
RTH101：Thermistor resistance (Ω) at 25℃
C102：electrolytic capacitor（F）

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EPM Series
1.9

Application Notes

Input smoothing electrolytic capacitor（C102)

The input smoothing electrolytic capacitor has a large effect on the characteristics and life of the product.
Select the capacitor by paying attention to the following:①Install the capacitor very close to the module (M101) and use a wide pattern to connect M101.

A triangle wave high frequency current
flows. Make the wiring wide and short.

Input voltage(VDC)
入力電圧（VDC)②Select an electrolytic capacitor such that the ripple voltage is 25Vp-p or less.
In addition, make sure that the peak voltage of the ripple voltage does not exceed the input voltage range.
Take the variation in capacitance and the capacitance reduction due to aging into consideration when selecting thecapacitance.

Ripplevoltage
25Vp-p or

Input voltage range
110VDC to 450VDC

Time (t)The capacitance required to reduce the ripple voltage to 25Vp-p or less can be estimated from the following
expression. As the calculation result is only a reference, conduct a thorough check using actual equipment.

C102 ≥ 4 ⋅ K ⋅ Io(max) (5 ⋅ f ⋅ (50 2 ⋅ Vin (rms) − 625))
Vin(rms)：Effective input voltage(Vrms)
ｆ：Commercial power frequency（Hz）
Io(max)：Maximum output current in use(A)K：Coefficient (varies depending on model. Refer to the following.)
・EPM0310SJ ： 4.71
・EPM0510SJ ： 7.14
・EPM1205SJ ： 16.0
・EPM1210SJ ： 15.0
・EPM1505SJ ： 18.8
・EPM1510SJ ： 18.8
・EPM2405SJ ： 30.0

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EPM Series

Application Notes③Calculate the guaranteed life of the electrolytic capacitor and check that there is no problem.
Since the life calculation expression is different depending on the capacitor manufacturer and type, requesting life
calculation by the manufacturer of the capacitor used is recommended.
Generally, life can be calculated by using the temperature and ripple current of the electrolytic capacitor.
1)Electrolytic capacitor temperature
The temperature at which the temperature on the body of the electrolytic capacitor is maximum is measured
and is made a life calculation parameter.
2) Ripple current
For AC input, a charging current (IL) and discharging current (IH) flow in the input smoothing electrolytic
capacitor. These currents are measured individually and frequency correction is performed on IH and it ismade a life calculation parameter as 120Hz ripple current.
Discharging current (high frequency)

Charging current (low frequency)

Effective value: IH (rms)

Effective value: IL (rms)

AC input

The ripple current (I120) frequency corrected to 120Hz is calculated from the following expression:

I120 (rms) = I L (rms) 2 + (I H (rms) ⋅ fc) 2
fc: Frequency correction coefficient (Refer to the electrolytic capacitor catalog.)
For stable DC input, the ripple current by high frequency charging/discharging current is assumed for input
electrolytic capacitor.

Input current: IDC (ms)DC input

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EPM Series

Application Notes

The ripple current of an electrolytic capacitor is a triangle wave high frequencycurrent with the input current(DC current) made the average value. Ripple current is calculated as follows:
Discharging current (Idis)

Charging current (Ich)

Iripple = Idis 2 + Ich 2
1.10

Output smoothing electrolytic capacitor（C201)

The output smoothing electrolytic capacitor has a large effect on the characteristics and life of the product.
Select the electrolytic capacitor by paying attention to the following:①Install the capacitor very close to the module (M101) and use a wide pattern to connect M101.

Triangle wave high frequency current flows.
Make the wiring wide and short.

②Use an electrolytic capacitor with good frequency characteristics and low impedance.
Output ripple and noise and rise time may be affected depending on the ESR and ESL and wiring impedance ofthe capacitor.
③If the capacitance is too large, the overcurrent protection function may operate and the rise may be faulty at
startup. A recommended value is shown in the following table.
Please ask us, when the capacity more than the following table is required.
Model

Recommendation capacitanceCR modeCC modeEPM0310SJ

5600uFmax

3300uFmax

EPM0510SJ
EPM1205SK

4700uFmax
750uFmax

3000uFmax
470uFmax

EPM1205SJ

1500uFmax

1000uFmax

EPM1210SJ/SK
EPM1505SJ/SK

2400uFmax
1000uFmax

1300uFmax
680uFmax

EPM1510SJ/SK

2700uFmax

1800uFmax

EPM2405SJ/SK

680uFmax

470uFmax④Since abnormal oscillation may occur by large phase delay if a capacitor with a very small ESR such as atantalum capacitor or multilayer ceramic capacitor is used, use an electrolytic capacitor.
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EPM Series

Application Notes⑤

When the overvoltage protection operated, check that the rated voltage of the electrolytic capacitor was notexceeded.
The following rated voltage is recommended:
・3.3V output ： Rated voltage 10Vor more
・5V output： Rated voltage 10Vor more
・12V output ： Rated voltage 25Vor more
・15V output ： Rated voltage 25Vor more
・24V output ： Rated voltage 35Vor more⑥

Calculate the guaranteed life of the electrolytic capacitor and check that there is no problem.
Since the life calculation expression is different depending on the capacitor manufacturer and type, requesting
life calculation by the manufacturer of the capacitor used is recommended.
Life can be calculated by using the temperature and ripple current of the electrolytic capacitor, the same as the
input smoothing electrolytic capacitor.
1) Electrolytic capacitor temperature
The temperature at which the temperature on the body of the electrolytic capacitor is maximum is measured andis made a life calculation parameter.
2) Ripple current
A high frequency ripple current by charging/discharging current flows in the input electrolytic capacitor.
The ripple current is calculated by splitting it into the top (charging current) and bottom(discharging current) of
output current (Io).
Charging current (Ich)

Discharging current (Idis)

Iripple = Idis 2 + Ich 2⑦When planning to split the ripple current by using multiple electrolytic capacitors,be sure that ripple current
measurement does not cause an unbalance.

When current measurement leads, etc. are installed

When the capacitor whose current is not to be

Only

measured has the same impedance as the capacitor toto the capacitor to be measured, the impedance isunbalanced and accurate measurement is not possible.

Rev.3.1 May, 2013

be measured, accurate measurement is possible.

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EPM Series
1.11

Application Notes

LCπ type filter（L201,C202)

Output ripple voltage reduction is possible to a certain degree by using a low impedance electrolytic capacitor at
C201. However, the addition of a one-stage LCπ type filter is effective in lowering the output ripple voltage more.
①Since a ripple current equivalent to C201 may flow depending on the impedance of L201, check the ripple
current,temperature rise, and life of C202 also.
②Triangle wave high frequency current also flows in L201. Check that L201 is not saturated at the peakcurrent.
In addition, consider the DC resistance of L201 and check that there is no problem with temperature rise.

High frequency current also flows in L201 and C202.
Check that L201 is not saturated even at Ip.

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EPM Series
2.

Protection function

2.1

Overcurrent protection function

Application Notes

An overcurrent protection function is provided as protection when an output short circuit or overload occurs.
The operation mode is automatic reset operation.
Overload detected

出力電圧

Output voltage

過負荷検出

Automatic reset operation

自動復帰動作Intermittent operation in low power region
低電力領域で間欠動作
出力電流
Outputcurrent

・Automatic reset operation
In the output short circuit and overload states, intermittent operation is performed in the low power region.
Operation is automatically reset to normal operation when the short circuit or overload is removed.

2.2

Overvoltage protection function

An overvoltage protection function is provided to prevent damage by impression of an overvoltage onto the load.
The operation mode is latch operation.
When the overvoltage protection circuit operated, it is reset by turning off the input and then turning on the input
again.
Reset time changes with input electrolytic capacity, input voltage, etc.
Avoid impressing a voltage onto the output terminals from the outside by wrap around from overvoltage operation
check and the load side at receiving inspection because it may cause damage.
Overvoltage operation check is a method that checks operation by changing the resistance value of Vref.
For more information, please contact us.

2.3

Overheating protection function

An overheating protection function is provided to prevent damage, smoke generation, etc. if the moduletemperature becomes abnormally high for some reason.
The operation mode is latch operation.
When the overheating protection function operated, it is reset by cutting off the input and then turning on the
input again.
Please insure the cause of the over-heat condition is removed prior to resetting the system.

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EPM Series
3.

Application Notes

Startup time adjustment

The startup time at which the output voltage rises to 90% of the specified output voltage after input power is first
applied is set as follows:
Input voltage (VDCin)

Output voltage

Startup time (ts)The startup time can be adjusted by connecting an external resistor and capacitoras follows:
Connect capacitor C to Vcc (pin 11) and -DCIN (pin 10) of M101.
Use a capacitor C with a rated voltage of 35V or more.
When using an electrolytic capacitor, check the temperature rise and life.

⑫ +DC IN
⑪ Vcc
C102
C

⑩ -DC IN

M101

Startuptime (S)
起動時間[ms]

1000
800
600
400
200
0
0

50

100

150

Added
capacitor C (µF)
付加コンデンサC[uF]

4.

Pattern design precautions

4.1

Main current line
Since the input current, output current, and high frequency current flow in the bold line parts of the connection
diagram (figure below), make the pattern wide and short.

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EPM Series

Application Notes

4.2 Input and output capacitors
Install the input smoothing capacitor (C102) and output capacitor (C201) close to M101. When there is a PFC
output capacitor and a separate inverter smoothing capacitor, these capacitors can be shared. However, when
the distance is long, the input smoothing capacitor only for M101 must be installed near M101. In addition, when
the pattern from the output terminals and load of M101 is narrow and long, make the pattern wide thick and shortbecause it had an effect on output accuracy.

Example of a bad pattern

Example of a good patternPrimary side

Primary side

Primary side

Primary side

4.3 Pattern prohibited area
When a double sided circuit board is used, do not provide a pattern directly below M101 of the parts side of thecircuit board. If there is a pattern directly below M101 of the parts side, the insulation distance between the
primary and secondary sides will not meet the specified value and safety cannot be ensured.

Secondaryparts prohibited area
2次部品禁止領域

Rev.3.1 May, 2013

Primary side

Primary side

Primary side

Primary side

The installation prohibited area of primary parts and secondary parts is shown in the figure below.
Do not install parts inside the dotted lines.

Primary
parts prohibited area
1次部品禁止領域

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EPM Series
5.

Application Notes

Noise filter layout precautions
When a noise filter (X capacitor, choke) is located near the module, the original noise reduction effect may not
be produced and noise reduction may become difficult.
Make the distance between noise filter and module long.
Electrolytic capacitor
Electrolytic

Bridge diodeBridge diodeChoke

X capacitor

capacitor

Choke

Installing a bridge diode and electrolytic capacitor
between noise filter and module is recommended.

X capacitor

Example of bad layout

6.

Example of good layout

Recommended hole diameter, land, and pin pitch
Hole dia.φ1.2

・Parts side view
・Numbers with a circle are pin numbers
To provide strength against vibrationand dropping, provide lands at all pins
and solder.
Land dia.φ3.5

7.

Recommended soldering conditions (lead-free solder)①Flow soldering: 255±3 ℃ 5 seconds or less②Soldering iron: 350℃(MAX) 4 seconds or less

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EPM Series
8.

Application Notes

Output derating
When the ambient temperature exceeds +60℃, reduce the output power in accordance with the output derating
chart below.
When the ambient temperature is affected by the heat generated by surrounding components, then the ambient
temperature measurement point must be made in proximity to the heat generating components as shown below
When there are no heat generating parts nearby, make the temperature 20mm from the module and 20mm above
the circuit board the ambient temperature.
100

Load factor (%)

80

60

40

20

0
-20

-10

0

10

20

30

40

50

60

70

80

周囲温度（℃）
Ambient
temperature (°C)

Ambient temperature measurement point when there are heat generating parts nearby

Ambient temperature measurement point

Ambient temperature
周囲温度測定箇所
measurement point

Heat
gener

発熱
部品

Heat

ating

Module
モジュール

gener

parts

ating
parts

ModuleAmbient temperature measurement point when there is no effect of heating generating part
Ambient temperature
measurement point

Ambient temperature measurement point

ModuleExtended line ofcenter of module
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EPM Series

Application Notes

User Precautions●The content of this manual is subject to change without prior notice for the purpose of improvements, etc.
Ensure that you are in possession of the most up-to-date information when using this product.
●The operation examples and circuit examples shown in this manual are for reference purposes only, and Tamura
Corporation disclaims all responsibility for any violations of industrial property rights, intellectual property rights
and any other rights owned by Tamura Corporation or third parties that these may entail.
●The circuit examples and part constants listed in these specifications are provided as reference for theverification of characteristics. The user is to perform design, verification, and judgment under his or her own
responsibility, taking into account the various conditions.
●Tamura Corporation constantly strives to improve quality and reliability, but faults and failures are bound tooccur with some probability in power products. To ensure that failures do not cause accidents resulting in injury
or death, fire accidents, social damage, and so on, users are to thoroughly verify the safety of their designs indevices and/or systems.
●This product is intended for use in consumer electronics (electric home appliances, business equipment,
information equipment, communication terminal equipment, measuring devices, and so on.) If considering use ofthis product in equipment or devices that require high reliability (medical devices, transportation equipment,
traffic signal control equipment, fire and crime prevention equipment, aeronautics and space devices, nuclear
power control, fuel control, in-vehicle equipment, safety devices, and so on), please consult a Tamura sales
representative in advance. Do not use this product for such applications without written permission from
Tamura Corporation.
●This product is intended for use in environments where consumer electronics are commonly used.
It is not designed for use in special environments such as listed below, and if such use is considered, theuser is to perform thorough safety and reliability checks under his/her responsibility.
- Use in liquids such as water, oil, chemical solutions, or organic solvents, and use in locations where the productwill be exposed to such liquids- Use that involves exposure to direct sunlight, outdoor exposure, or dusty conditions- Use in locations where corrosive gases such as salt air, C12, H2S, NH3, SO2, or NO2, are present- Use in environments with strong static electricity or electromagnetic radiation- Use that involves placing inflammable material next to the product- Use of this product either sealed with a resin filling or coated with resin- Use of water or a water soluble detergent for flux cleaning- Use in locations where condensation is liable to occur●This product is not designed to resist radiation.
●This product is not designed to be connected in series or parallel.
Do no operate this product in a series, parallel, or N+1 redundant configuration.
●The content of this manual may not be transferred or copied without prior written permission.

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