ZWS-BAF Series Instruction Manual BEFORE USING THE POWER SUPPLY UNIT Be sure to read this instruction manual thoroughly before using this product. Pay attention to all cautions and warnings before using this product. Incorrect usage could lead to an electrical shock, damage to the unit or a fire hazard. A\ DANGER Never use this product in locations where flammable gas or ignitable substances are present. There are risks of igniting these substances and exploding by an arcing. Z\ WARNING e Do not touch this product or its internal components while circuit is live, or shortly after shutdown. There may be high voltage or high temperature present and you may receive an electric shock or burn. While this product is operating, keep your hands and face away from it as you may be injured by an unexpected situation. Do not make unauthorized changes to this product, otherwise you may receive an electric shock and void your warranty. Do not drop or insert anything into this product. It might cause a failure, fire and electric shock. Do not use this product under unusual condition such as emission of smoke or abnormal smell and sound ete. It might lead to fire and electric shock. In such cases, please contact us. Do not attempt repair by yourself, as it is dangerous for the user. Do not operate these products in the presence of condensation. It might lead fire and electric shock. AX CAUTION This power supply is designed and manufactured for use within an end product such that it is accessible to SERVICE ENGINEERS only. Confirm connections to input/output terminals are correct as indicated in the instruction manual before switching on. Input voltage, Output current, Output power, ambient temperature and ambient humidity should be kept within specifications, otherwise the product will be damaged. Do not operate and store this product in an environment where condensation might occur. In such case, waterproof treatment is necessary. e Do not use this product in environment with a strong electromagnetic field, corrosive gas or conductive substances. e For applications, which require very high reliability (Nuclear related equipment, medical equipment, traffic control equipment, etc.), it is necessary to provide a fail-safe mechanism in the end equipment. Do not inject abnormal voltages into the output of this product. The injection of reverse voltage or over voltage exceeding nominal output voltage into the output terminal or signal terminal might cause damage to internal components. e Never operate the product under over current or short-circuit conditions for more than 30 seconds, or outside its specified Input Voltage Range. Insulation failure, smoking, burning or other damage may occur. e This product contains a printed circuit board utilizing surface mounted devices. PCB stress such as bending, twisting etc. could cause damage. Therefore, please handle with care. @ When handling this product, hold the board edge and take care not to touch the component side. When installing this product in apparatus or equipment, mount it on spacers. e The outputs of this product may, under fault conditions, exceed SELV voltage limits. Therefore the outputs must be earthed in the end equipment to maintain SELV. If the outputs are not earthed, they must be considered hazardous and must not be made user accessible. @ This product has used Power Thermistor to protect the circuit from Inrush Current. Frequent repetition of input might cause damage to internal components because of generating surge current. Breaking of internal fuse is considered internal failure. In such cases, please contact us. The information in this document is subject to change without prior notice. Please refer to the latest version of the data sheet, etc., for the most up-to date specifications of the product. No part of this document may be copied or reproduced in any form without prior written consent of TDK-Lambda. Note: CE MARKING CE Marking when applied to a product covered by this handbook indicates compliance with the low voltage directive (2006/95/EC) as modified by the CE Marking Directive (2006/95/EC) in that it complies with EN60950. DWG No.: A249-04-01-A APPD CHK DWG ep her FA L Cir 4a A Bok 1 Fin Fp | Ch Sant. Ff Vi Se1. Model name identification method ZWS 50 BAF5/0 Option (*1) (*1) Blank: Standard type. Rated Output Voltage /L: With chassis model. /A:: With chassis and cover model. Output Power type /R.: With remote ON/OFF control model. (Option model /R: ZWS100BAF, ZWS150BAF only) Series Name 2. Terminal Explanation ZWSS50BAF ZWS75BAF ro COMPONENT On ro COMPONENT On @ ee tL SIDE asi SIDE ons @fe s/n Oe s|n as put ONG a INPUT i 2*r | @ @) +8 1 JL m7 Li ek -@) @ at} output _ [> oD oT outpuT = |5 OE Ni Ly ; . K+ [Se + | |e Ht S LO VR51 [ | S 5 SO VR51 [| Ox S ZWS100BAF ZWS150BAF @FO COMPONENT SIDE OFO COMPONENT SIDE O= ah @ aL te - 3 oF @}#2 3|N oureut Ones | | Tr INPUT Ly ai oO oi}L_l @Q1-pt 5 4 ro es L CNt c @ N OUTPUT 7sr 3 nm VR51 | INPUT + oX one a onsi] |} Tel @20 fie so CNS2 R51 6 oS -o Roel [_ O<-+ @_ L: AC Input terminal Live line (Fuse in line.) @ N: AC Input terminal Neutral line @ +: terminal (Protective earth) @ Mounting hole (hole diameter: 3.5mm) 0888 These holes are connected to Protective Earth of CN1. Must be connected to electrically conductive spacer. The mounting surface of the spacer should be within Max 6 8mm. Mounting hole (hole diameter: 3.5mm) These holes are not connected to Protective Earth of CN1. +:+ Output Terminal ~:~ Output Terminal V.ADJ : Output voltage adjust trimmer. The output voltage rises when a trimmer is turned clockwise. ON/OFF Control Terminal (Option model /R: ZWSLOOBAF,ZWS150BAF only) NOTE : For Cover & Chassis type (MODEL : ZWS-BAF/A), remote ON/OFF control cannot be used.3. Terminal Connection Method Pay attention to the input wiring. If it is connected to wrong terminal, the power supply will be damaged. Input must be off when making connections. Connect+-terminal of input connector and mounting hole to protective earth of the equipment. Output current of each terminal pin must be less than 5A. The output load line and input line shall be separated to improve noise sensitivity. Do not apply stress to PCB, when connecting or removing connector. Use input/output connector (housing) specified by the table below. @ Use recommended crimping tool. Connector is not included with this product. (Refer to the following) ZWSS0BAF ZWS75BAF LO or LO O as COMPONENT tos COMPONENT t iL SIDE = tf aL. SIDE L == = = CNS1 = o3 |N 13 1N ~T T INPUT oe Toy INPUT 7 ; . =a} JL moh eo fF spat Ld OUTPUT LOAD CNT OUTPUT 3. LOAD CNT Ly, : . +L 4 ot HH [ 6 Do oO VBI [ O O VR51 [| O ZWS100BAF ZWS150BAF re COMPONENT SIDE ong} OF 1 ro GOMPONENT SIDE 4 1075 L 5 t 2 0 ee _ 3a _, a3)N OUTPUT 6 LOAD ones INPUT Lip [83 _| eo1)L_] 60 Pa _ = +a l 15 a CT ao a3 IN OUTPUT LOAD VR51 [|] hl + me INPUT ON52 ati ; +e[ta Ont ONST | Jao O sek O 50 CN52 VR5I 6 oJ O far | oo Input/Output Connector Model Connector Housing Terminal Pin Maker (cnt) Common B3P5-VH(LE\SN) VHR-SN ZWSSOBAF B4P-VH(LF\SN) VER-AN Output ZWS75BAF B6P-VH(LF\SN) VHR-6N SVH-21T-P1,1 IST (CNS51) ZWS100BAF B8P-VH(LF\SN) VHR-8N BVH-21T-PL1 ne ZWS150BAF B6P-VH(LF)(SN) VHR-ON (N53) ZWSISOBAF | BY7P-VH(LEXSN) VHR-7N Hand Crimping Tool: YC-160R (J.S.T.) Remote ON/OFF Control (Option model /R : ZWS100BAF, ZWS150BAF only) Model Connector Housing Terminal Pin Maker BXH-001T-P0.6 CN52 B2B-XH-AM XHP-2 or J.S.T. SXH-001T-P0.6 Hand Crimping Tool: YC-110R (J.S.T.) or YRS-110.S.T,)4. Explanation of Function and Precautions 4-1. Input Voltage Range Input voltage range is single phase 85-265VAC(47-63Hz) or 120-370VDC. Input voltage, which is out of specification, might lead unit damage. For cases where conformance to various safeties required, described as 100-240VAC (50/60Hz). 4-2. Output Voltage Range Output voltage is set the rated value at shipment. V.ADJ trimmer (VR51) can adjust the output voltage within the range. Output voltage range is within == 10% (only 48V : +10%, -20%) of nominal output voltage. To turn the trimmer clockwise, the output voltage will be increased. Take note when the output voltage is increased excessively, over voltage protection (OVP) function may trigger and voltage will be shut down. Furthermore, when increasing the output voltage reduce the output current so as not to exceed the maximum output power. 4-3. Inrush Current This series equipped Power thermistor to limit the inrush Current. This series are Power thermistor method so that higher current will flow at higher ambient temperature or re-input condition. Please select input switch and fuse carefully with the high temperature and re-input the power condition. The Inrush Current value is under cold start at 25C in the specification. 4-4. Over Voltage Protection (OVP) The OVP function (Inverter shut down method, manual reset type) is provided. OVP function operates within 3.3V: 115% - 150%, 5V: 115%- 140%, 12V-48V: 115%-135% of nominal output voltage. When OVP triggers, the output will be shut down. To reset OVP, remove the input of power supply for a few minutes, and then re-input. In addition, the setting value of OVP is fixed and not adjustable. Pay attention not to apply higher voltage externally to the output terminal to avoid unit failure. In case of inductive load, put protective diode in series to the output power line. 4-5. Over Current Protection (OCP) ZWSSOBAF, ZWS75BAF: Fold back limit and Hiccup mode with automatic recovery. ZWSI100BAF, ZWS150BAF: 3.3V, 5V Constant current limit and Hiccup mode near shorted conditions with automatic recovery. ZWSIOOBAF, ZWSIS0BAF: 12V - 48V Constant current limit with automatic recovery. OCP function operates when the output current exceeds 105% of maximum DC output current of specification. The outputs will be automatically recovered when the overload condition is canceled. Never operate the unit under over current or shorted conditions for more than 30seconds, which may leads damage or insulation failure. OCP setting is fixed and not to be adjusted externally. 4-6. Output Ripple & Noise The standard specification for maximum ripple value is measured according to measurement circuit specified by JEITA-RC9131B. When load lines are longer, ripple will becomes larger. In this case, electrolytic capacitor, film capacitor, etc. might be necessary to use across the load terminal. The output ripple cannot be measure accurately if the probe ground lead of oscilloscope is too long. 150mm |; coe FD . ower Supply Cl C2 a Coaxial Cable 15m 500 C1:0.luF Film Cap. C2:100uF Electric Cap. C3 :4700uF Ceramic Cap. R1 :50Q Oscilloscope Bandwidth : 100MHz4-7. Series Operation For series operation, either method (A) or (B) is possible. ZWSSOBAF, ZWS75BAF (A) Power Supply my a Q Output Terminal ia XS Lg) ' i I i I i Load i I I | i ran iC ars Output (| Terminal a ! or ) Power Supply QD Output Tenninal OQ wr Load O a WT Output Terminal gD ar YS @ Load (*1) In case of (A), please connect bypass diodes to prevent reverse voltage. Please select a bypass diode with maximum forward current rating more than output load current. And maximum reveres voltage must withstand each power supply output voltage. ZWSI00BAF, ZWS150BAF (A) Power Supply Output Terminal 9 @ Load Ca @ Output Terminal QO o O 4-8. Parallel Operation For parallel operation, method (B) is possible. (A) To increase the output current is not possible. Power Supply Output Terminal Load f D2 be Output Terminal _ 4-9, Isolation Test (B) Power Supply DOD Ty AT XD Output Load Terminal a Oo Oo a gD tp) Output Load Terminal CQ QD Oo 7) (B) To use as Back-up Power Supply 1. Adjust the output voltage of each power supply to be the same. 2. Set power supply output voltage higher by the forward voltage drop (Vf) of diode. Use within the specification for output voltage and output power. Power Supply Output B _ Terminal HY > ee Load oH Output PO Terminal a Isolation resistance between Output - + (Protective Earth) is more than 100M Q at 500VDC-. For safety operation, voltage setting of DC isolation tester must be done before the test. Ensure that the unit is fully discharged after the test. Output - 4 (Protective Earth) : 50OVDC More than 100M Q ZWSSOBAF, ZWS75BAF Isolation Tester ZWSI00BAF, ZWSI150BAF Isolation Tester +R(CN52) R(CNS2) 1This series is designed to withstand 3.0kVAC between input and output, 2.0kVAC between input and 1 (Protective Earth) and S00VAC between output and 1 (Protective Earth) each for 1 minute. When testing withstand voltage, set current limit of the withstand voltage test equipment to 10mA (output - 1 (Protective Earth): 20mA). The applied voltage must be gradually increased from zero to the testing value and then gradually decreased for shut down. When timer is used, the power supply may be damaged by high impulse voltage at timer switch on and off. Connect input and output as follows. Input - Output(Dashed line) : 3.0KVAC Imin(10mA) Input - 4 (rotective Earth)(Solid line) : 2.0kVAC 1min(10mA) Output - L (Protective Earth) : SOOVAC Imin(20mA) ZWSSOBAF, ZWS75BAF Withstand Voltage Tester Withstand Voltage @) Tester +R(CNS52) O tL -R(CNS2) 4-11. Remote ON/OFF Control (Option model /R : ZWS100BAF, ZWS150BAF only) Remote ON/OFF control (CN52) function is available as option. ( /R). Using this function allows the user to turn the output on and off without having to turn the AC input on and off. However, for Cover & Chassis type (MODEL: ZWS-BAF/A) cannot be used. It is controlled by the voltage applied to +R and R. This circuit is in the Secondary (output) side of the power supply unit. Do not connect in the Primary (input) side. And this circuit is isolated from the Secondary (output). +R & -R terminal condition Output Condition SW ON (Higher than 4.5V) ON SW OFF (Lower than 0.8V) OFF External voltage level: E External resistance : R. -R T R: External resistance 4.5 = 2.5VDC No required E : External voltage level 12.5 -24.5VDC 1.5kQ -5-5. Mounting Directions 5-1. Output Derating according to the Mounting Directions. Recommended standard mounting method is (A). Method (B)-(F) are also possible. Refer to the output derating below. Load(%) such as below derating curve indicates output power. (A) Standard (B) Mounting CN1 5-2. Output Derating FIN Make sure that the specified temperature range is maintained. ECONVECTION COOLING ZWSS50BA 120 100 Load (%) n Oo -10 0 10 20 30 40 Ta (C) 50 60 70 80 120 100 Load (%) 10 20 30 40 Ta (C) ZWSI100BAF, ZWS150BAF 120 - 100 80 an oa Load(%) _ o Ta (C) * Mounting (A),(),(C) Mounting (D) @ Mounting (E) k Mounting (F) Ta Ta (%) (C) Mounting (A),(B),(C) | Mounting (D) | Mounting (E) Mounting (F) -10-+35 100 +40 100 100 100 91 +45 100 100 90 83 +50 100 88 80 74 +60 75 64 60 37 +70 50 40 40 40 * Mounting (A),(B) ~-@- Mounting (C) l Mounting (D),(E) ~&-~ Mounting ) Ta Load (%) (C) _| Mounting (A),(B) | Mounting (C) | Mounting (D),(E) | Mounting ) -10 - +30 100 +40 100 100 100 82 +45 100 100 88 74 +50 100 88 77 65 +60 75 64 53 48 +70 50 40 30 30 Mounting (A),(B) # Mounting (C),(E) ~tk Mounting (D) Mounting (F) Ta Load (%) (C) __| Mounting (A),(B) | Mounting (C),(E) | Mounting(D) | Mounting (F) -10 - +30 100 +40 100 100 80 85 +50 100 80 60 70 +60 15 60 40 55 +70 50 40 20 40FORCED AIR COOLING ZWSSOBAF, ZWS75BAF, ZWS100BAF and ZWS150BAF @ Mounting (A) - F) 120 : . Ta Load (%) Electrolytic capacitor allowable Max temparature oO, . (0) Mounting (A) - () Allowable Max temparature +10 - +60 100 Model +70 70 C6 cs1 C52 70C 70C ZWSSOBAF | 80C | (for 24V,48V) | (for 3V-15V) o 75C 75C popes ZWSTSBAF | 80C | (for 24V,48V) | (for 3V-15V) 0 : i : : : : : 4 ZWS100BAF s0c 75C -10 0 10 20 30 40 50 60 70 = 80 Ta (Pc a@C) ZWSIS0BAF | 80C 75C The entire component must be cooled. The maximum temperature of the electrolytic capacitor C6, C51 and C52 must keep lower than Electrolytic capacitor allowable Max temperature in the above table. As reference, set wind velocity at 0.7m/s. ZWSSOBAF, ZWS75BAF CN1 on O | ie ZWS100BAF ZWS150BAF CNI CNI (INPUT) (INPUT) C) C@-3. Mounting Method Insert the spacer (Max 8) of height more than 8mm to lift the unit. And use all mounting holes for the unit installation. The vibration spec is specified under this mounting condition. : & Mounting Holes size 4 holes 3.5mm. ] Height more than 8mm spacer Allowable area by metal pieces is 9mm from each PCB comers. Refer to figure below. Te Condition to meet Isolation & Withstand Voltage standard. Ss s & + a o & + ow og S gs 7 O Component side | Vv. | PCB | More cq than 4mm | a Ler Sg | o & | ge | 2 | | | I Keep 4mm space from the surfaces and sides of PCB. Especially, 8mm space is necessary from the solder surface. If the space is not enough, the specification of isolation and withstand will not be satisfied. O Take the space in the power supply surroundings and the upper area of ee ee components to keep enough for convection cooling. g ~~ oOMi Protective Earth ( t (Protective Earth).should be connected to the earth terminal of the equipment. Also 2 mounting holes are should be connected to the Chassis by metal spacer. If not, the conducted noise, radiation noise and output noise will increase. - Earth Terminal * Chassis (Conductor) | Wii ee _ Metal spacers 6. Wiring Method (1) The output load line and input line shall be separated each other and twisted individually to improve noise. (2) Use all lines as thick and short as possible to made lower impedance. (3) Noise can be reduced by attaching a capacitor to the load terminals. (4) For safety and EMI considerations, connect between + (Protective Earth) terminal of input connector and Frame Ground terminal of equipment firmly. 7. External Fuse Rating Refer to the following fuse rating when selecting the external fuses that are to be used on input line. Surge current flows when line turns on. Have to use slow-blow or time-lag type fuse, not fast-blow fuse. Fuse rating is considered by in-rush current value at line turn-on. Do not select the fuse according to input current (RMS.) values under the actual load condition ZWSSOBAF :2.5A ZWSTSBAF :3.15A ZWSI100BAF : 3.154 ZWSIS50BAF : 5.0A 8. Before concluding that the unit is at fault (1) Check ifthe rated input voltage is connected. (2) Check ifthe wiring of input and output is correct. (3) Check if the wire thickness is enough. (4) Check if the output current and output wattage dose not over specification. (5) Check if the output voltage control (V.ADJ) is properly adjusted. OVP might be triggered and output is shut down. (6) Audible noise can be heard when input voltage waveform is not sinusoidal wave. (7) Audible noise can be heard daring Dynamic-Load operation. (8) Ensure that a large capacitor is not connected on the output side. Please use within maximum capacitance shown below. Maximum external capacitance Model 33V. | SV 2v | SV 24V 48V ZWSSOBAF : ZWS75BAF 10,000uF 5,000uF 2,000uF 500uF ZWS100BAF:ZWS150BAF 15,000uF No specification9. Warranty Period Warranty Period applies for Mounting Methode (A). However, for forced air cooling, mounting method is not specified. For damages occurring at normal operation within this warranty period, repair is free of charge. For other mounting methods, please inquire to TDK-Lambda. CONVECTION COOLING il] FORCED AIR COOLING ZWSSO0BAEF, ZWS75BAF ZWSS50BAF, ZWS75BAF ZWS150BAF ZWS100BAF ZWS100BAF, ZWS150BAF Mounting (A) Mounting (A) Mounting (A)-(F) 100 100 100 = s & 60 s z 3 zg g 40 50 50 60 Ta (C) Ta (C) Ta (C) VY 7] Warranted for a period of 5 years Warranted for a period of 3 years Following cases are not covered by warranty. (1) Improper usage like dropping products, applying shock and defects from operation exceeding specification of the units. (2) Defects resulting from natural disaster (fire, flood etc). (3) Unauthorized modifications or repair by the buyers defects not cause by our company. ~10-