ZWS-AF Series ZWSSOAF /75AF /LOOAF/ 1LSOAF Instruction Manual BEFORE USING THE POWER SUPPLY UNIT Pay attention to all warnings and cautions before using the unit. Incorrect usage could lead to an electrical shock, damage to the unit or a fire hazard. WARNING and CAUTION @ Do not touch the internal components, they may have high voltage or high temperature. You may get electrical shock or burned. @ When the unit is operating, keep your hands and face away from it, you may get injured by an accident. @ This power supply is primarily designed and manufactured to be used and enclosed in other equipment. @ Do not operate overload or dead short condition for more than 30 seconds which could result in damage or insulation failure. There is no possibility for fire or burning. @ Confirm connections to input/output terminals are correct as indicated in the instruction manual. @ This power supply is PC board type unit. PCB stress such as bending, twisting could cause damage. Therefore, please handle with care. @ When handling, hold the board edge and take care not to touch component side. When mounting power supply unit on apparatus or equipment, lift the power supply with spacer. @ Do not drop or apply shock to power supply unit. @ This power supply has a possibility that hazardous voltage may occur in output terminal depending on failure mode. The outputs of these products must be earthed in the end use equipment to maintain SELV. If the outputs are not earthed, they must be considered hazardous and must not be made user accessible. Note: CE MARKING CE Marking, when applied to a product covered by this handbook indicates compliance with the low voltage directive (73/23/EEC) as modified by the CE Marking Directive (93/68/EEC) in that it complies with EN60950. DWG NO. : A193-04-02C APPD CHK DWG Tulle. | Lb donde | UHal , Fep.0? | h Feb, OF | 1. Feb. oF1.Terminal Explanation m@ ZWSS50AF . apo [og] ne G mer * at (PF =, 8 a @ : a aw yO ( oO ag O OY ce m@ ZWS75AF m@ ZWS100AF m@ ZWSISOAF . ix: 86 a @ L: AC input terminal (pin 6 of CN1) Live line(fuse in line) @) N: AC input terminal (pin 4 of CN1) Neutral line () FG: Input terminal FG (pin 1 of CN1) Safety earth (Frame Ground) Connect to safety ground of apparatus or equipment. @ FG: Frame Ground (Connected to pin | of CNI) Must be connected to electrically safety ground of apparatus or equipment by clectrically conductive spacers. The mounting surface of the spacer should be within MAX 8mm. a &) CN2: ON/OFF control terminal (primary circuit) See NOTE A @ +: + Output terminal @ : Output terminal V.ADJ: Output voltage adjust trimmer. The output voltage rises when a trimmer is turned clockwise. CN52 : ON/OFF control terminal (secondary circuit) (For power supply output on and off control with an external signal.) See NOTE A NOTE A: For COVER & CHASSIS type (MODEL: ZWS-AF/JA), remote ON/OFF contral cannot be used. 12. 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 connection. @ Connect FG terminal to ground terminal of the equipment. @ Vutput current of cach termina! pin must be less than 5A. @ The output load line and input linc shall be separated and twisted to improve noise sensitivity. @ Remote ON/OFF control line shall be twisted or use shielded wire. @ When connecting or removing connector, do not apply stress to PCB. @ Use the input/output connector specified in outline drawing. Also, use recommended crimping tool. Connector is not included with this product. m@ ZWSSOAF Po] ree mw 8 baw ne "yrs a ne [oe | COMPONENT SIDE abe tHe |n TO Teo &) Sea , eet suit 3 = tt ( O ) +|2sh 5 Oo \ Oo / oe NU w ZWS7S5AF on (a on [8] twe2 [oo] O iam ff ]FS oe: loa COMPONENT SIDE Sirs a Ses [f')! wen f. Nt to ) OG oO we m ZWSI00AF a a Lae fe. our) [ef Ly TPG on mT Im 4 ee __ eT 0 6 _I! cM atl UTP LT en {__ | - 4 ! | a \ Oo i CNSmw ZWSI50AF * Connector for Remote ON/OFF Control : CN2, CN52(J.S.T) Connector Housing Terminal Pin B2B-XH-AM XHP-2 BXH-001T-P0.6 or SXH-001T-P0.6 CN2 is normally shorted by JM-2W-96 (J.S.T) Hand Crimping Tool : YC-110R (J.S.T) or YRS-110 (J.S.T) * Input & Output Connector (MOLEX) ZWSSOAF ZWST5AF Connector. Housing Terminal Pin | Connector . Housing Terminal Pin Input: CN1 5414-30B 5195-06 5194PBTL 5414-30B 5195-06 5194PBTL Output: CN51 {| 5273-04A 5195-04 5194PBTL 5273-06A 5195-06 5194PBTL ZWS100AF ZWSI50AF Connector. Housing | Terminal Pin | Connector | Housing Terminal Pin Input: CN1 5414-30B 5195-06 = 5194PBTL 5414-30B 5195-06 = 5194PBTL Output: CN51 5273-06A 5195-06 5194PBTL CN53 2273-0BA | 3195-08 >194PBTL 5273-07A 5195-07 5194PBTL CNS3 is used only for ZWS150AF Hand Crimping Tool : JHTR5904 (MOLEX) * ZWS-AF/J Input & Output Connector (J.S.T) ZWSSOAF/I ZWST5AF/] Connector Housing Terminal Pin | Connector | Housing Terminal Pin Input: CN1 B3P-5-VH VHR-5N SVH-21T-P1.1| B3P-5-VH | VHR-5N SVH-21T-P1.1 Output: CN51 B4P-VH | VHR-4N_ SVH-21T-P1.1}| B6P-VH | VHR-6N SVH-21T-P1.1 ZWSIOOAF/I ZWS150AF/J Connector Housing Terminal Pin | Connector | Housing Terminal Pin Input: CN51 | B3P-5-VH | VHR-5N SVH-21T-P1.1 | B3P-5-VH | VHR-5N SVH-21T-P1.1 Output: CN51 B6P-VH | VHR-6N SVH-21T-P1.1 B8P-VH | VHR-8N SVH-21T-P1.1 CN53 B7P-VH | VHR-7N | SVH-21T-P1.1 CNS3 is used only for ZWS150AF Hand Crimping Tool : YC-160R (J.S.T) Pin-order of J.S.T connectors are opposite to pin-order of MOLEX. Please refer to outline drawing.3. Explanation of Functions and Precautions 3-1. Input Voltage Range Input voltage range is single phase 85 ~ 265VAC ( 47 ~ 63Hz ) or 120 ~ 370 VDC. Input voltage which is out of specification may cause unit dam- age. For cases where conformance to various safety specs(UL,CSA,EN) are required, input voltage range will be 100~240VAC(50/60Hz). 3-2. Output Voltage Range V.ADJ trimmer(VR5 1) that is nearly output con- nector can adjust the output voltage within the range. Output voltage range is within +10% of nominal output voltage. To turn the trimmer clockwise, the output voltage will be increased. Note over voltage protection ( OVP ) function may trigger if the output voltage is increased ex- cessively. 3-3, Inrush Current This series has used Power Thermistor to protect the circuit from Inrush Current. Please carefully select input switch and fuse in cases of the high temperature and re-input the power. 3-4. Over Voltage Protection (OVP ) The OVP function ( Inverter shut down method, manual reset type ) is provided. OVP function operates within 115-135% (5V type: 115-140%) of nominal output voltage. When OVP triggers, the output will be shut down. The input shall be removed for a few minutes, and then re-input for INPUT recovery of the output. OVP setting shall be fixed and not to be adjusted externally. 3-5. Over Current Protection (OCP ) Constant current limiting, automatic recovery. OCP function operates when the output current exceeds 125( 5V type : 105%) of maximum output current of specification. The output will be automatically recovered when the overload condition is canceled. Do not operate overload or dead short conditions for more than 30 seconds, which could result in damage or msulation failure. 3-6, Output Ripple & Noise The standard specification for maximum nipple value is measured according to measurement cir- cuit specified by EIAJ-RC9131. When load lines are longer, mpple 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. / , AEE gR . 1) [ . Yr fcr |oscitoscope iBandwid:h 1 QOMHz R: 502 C*. 4790pF Film Capecitur C2: TW QuF Electric Capacitor C3. O.1uF Film Capacitor3-7. Series Operation For scrics operation, either method ( A } or (B) is possible Method ( A ) Power Supply Output Terminal @ Load OY Output Terminal D Method ( B ) Pows Supply @ Output T. i Co} erminal oO @ Load om Output Terminal Q Load 3-8. Parallel Operation (A) To increase the output current is not possible. am Os wn | A i ax OT = Hh 4 oO e (B) To use as Back-up Power Supply 1. Set power supply output voltage higher by the forward voltage drop(VF) of diode. 2. Adjust the output voltage of each power supply to be the same. 3. Use within the specifications for output voltage and output power. _83~_ be - we be f 3-9. Peak Output Current For ZWS-AF series, relation with average output current and peak output current must satisfy for- mulas below. Also operating time at peak output 18 less than 10sec. When using pulse load, audible noise can be heard from power supply unit. Ip | -tonasponneen fen GA Ip aA 0A (Ip - a) xT a fav2Im= +aip: Peak output current { A ) fav: Average output current { Maxitnum output current of Specification (A)) Im : Average output current ( A} t: Pulse width of peak output current { sec ) ( Operating time at peak output } T : Period ( see ) 3-10, Remote ON/OFF Control Remote ON/OFF control(CN2,CN52) function is available. Using this function allows the user to turn the output on and off without having to turn the AC input on and off. Remote ON/OFF control can be used by fol- lowing 2 modes. However, for Cover & Chassis type (MODEL: ZWS-AF/JA), can not be used. *Using CN2 It is controlled by short or open between +R & -R of CN2, CN2 is provided in the primary circuit for ON/OFF control by means of a switch or other de- vice. When using this connector. which is consid- ered to be electrically connected to the mains input voltage, all the requirements of EN60950 must be met with respect to the connector, wiring and switch ete. Tn particular: 1) Basic insulation must be provided between the ON/OFF control circuit and earth. 2) Reinforced insulation must be provided be- tween the ON/OFF control circuit and any sec- ondary circuit or accessible part. 3) Wiring must be routed such that damage to the insulation of the wire or additional slecving cannot occur. 4) The switch must mect requirocments for rein- forced insulation from the ON/OFF control cir- cuit to actuator/accessible parts. [CN2] The control mode is shown below. +R & -R terminal condition ; Output Condition SHORT ON OPEN OFF *Using CNS2 At first, remove short piece of CN2. 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 conncect in the Primary ( input ) side. And this circuit is isolated from the output by a photo-coupler. [CN352] The control mode 1s shown below, +R & -R terminal condition Output Condition SW ON (Higher than 4.5) ON SW OFF (Lower than 0.8V) OFF External voltage level: E External resistance : R 4.3 ~ 12, 5VDC No required 12.5 ~ 24.5VDC 15kQ3-11. Isclation Test Isolation resistance between output and FG ( chas- sis ) shall be more than 10OMQ. at 5O00VDC. For safety operation, voltage setting of DC isolation tester must be done before the test. Ensure that it is fully discharged after the test Output ~ FG ( chassis ) S500VDC 100MQ or more Isolation Tester +R(CNS2) -R(CN52) 3-12. Withstand Voltage This series is designed to withstand 3.0kKVAC between input and output, 2.0K VAC between in- put and FG ( chassis ), and 500VAC between output and FG ( chassis ), each for 1 minute. When testing withstand voltage, set current limit of withstand voltage test equipment at 20mA ( Output-FG ( chassis ): 100mA ). The applied voltage must be gradually increased from zero to 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( dotted line ) 3kVAC Imuin. (20mA ) Input ~ FG( chassis )( solid line ) 2kVAC Imin. ( 20mA ) Withstand Voltage Tester Oulput ~ FG( chassis ) SO0VAC Imin. ( 100mA ) Withstand Voltage Tester & +R(CN52) -R(CNS52)4, Mounting Directions 4-1. Output Derating according to the Mount- ing Directions Recommended standard mounting method is (A). Method (B), (C ), (D), (E), and (F) are also possible. Refer to the derating below. In the following derating curve, the average output current ig considered to be 100%. (A) (B) (C) STANDARD CN1 pe 1 \ jpcomponent pl (D) (E) (F) CNI Output Derating (Convection cooling) ZWSS50AF (%) 100 80 60 40 20 Average Load { % ) Q Mounting (A) I | _ Mounting (B),(C),(D) Mi (E).(F) -10 0 20 40 50 60 Ambient Temperature (7C} ZWSSOAF Output Derating LOAD (%) Mounting! A B Cc D E F Ta -10~+40C | 100 | 100 |. 100 | 100 | 100 | 100 +45C 100 | 100 | 100 | 100} 88 | 88 +50C 100 | 83 $3 | 83 ) 75 | 75 455C 85 66 66 66 62 62 +60 70 50 50:4 30-] 50 30 ZWS7TSAF (96 ) 100 80 Mounting (A) - 60 Mounting (B),(C) 3 Mountiag (D).(E),(F) 3 40 2 20 = 0 -10 0 20 40 50 60 Ambient Temperature (%) ZWS7S5AF Output Derating LOAD (%) Mounting] A B Cc D E F Ta -10-+30C | 100 | 100] 100 | 100 | 100 100 +40C 100 | 100] 100 | 80 | 890 80 +50C 100 | 66 | 66 | 606 | 60 | 60 +55 $5 | 50 | 50 |) 50 | 50 50 +60C jf -f-if-if]-dtf-ZWS100AF (%) 100 80 Mounting ( 60 Mounting (B)C) | Mounting ( 40 20 Average Load ( % ) 0 -10 0 20 40 50 60 Ambient Temperature (C) ZWS100AF Output Derating LOAD (%) Mounting! A B C D E F Ta -10~+30C}] 100 | 100] .100 | 100 | 100 | 100 +40C 100 | 100 | 100 | 75 75 | 75 SOC 100] 68 + 68 | 30 | 50] 50 +53C 80 | 50 | 30 - - - +600 | 60] - To - - - - ZWSIS50AF (% } 100 _~ gO Mounting (A) =z Mounting (B},(C) = Tx < 40 & 20 ft 0 -10 #0 20 40 50 60 Ambient Temperature = (%) ZWSIS50AF Output Derating LOAD (%) Mounting} A B Cc D E F Ta -10-+25C |} 100] 100] FOO | 100 | Lo0 100: +35C 100} 100 | 100 | 84 | &4 84 +40C 100} 88 | 88 | 76 | 76 | 76. +50C 75 | 60 | 60 | 60 | 60 60 +60C 50] - - - - ir coolin For foreed air cooling, airflow of 0.7m/s above is needed for component side. As a reference for forced cooling, let air flow so that E-cap.C6 temperature becomes lower than 85C. oO FF cnt Cg L oN, 2 Ne/ v ZWSSOAF,75AF,100AF (%) 100 ~ 80 ~ 60 3 3 40 5 20 > < 0 -10 #0 60 70 Ambient Temperature (7 } ZWSSOAF,75AF,100AF Output Derating LOAD (%) Mounting ABCD EF Ta -10~+60C fers 100 +65C 85 +70 ae 70 ZWS150AF (%) 100 80 = 60 2 a 2 20 * < 0 -10 = 90 30 60 Ambient Temperature (C)ZWSI150AF Output Derating LOAD (%) Mounting A, B, C, D. E, F Ta -10~4+50C 100 455C 85 . +60C 70 4-2. Output Derating according to the Mount- ing Directions (With Cover & Chassis type : MODEL ZWS-AF/JA ) This series has Cover & Chassis model as op- tion. Recommended standard mounting method is (A). Method (B),(C). (D), (E) are also possible (Method F. is impossible). Refer to the derating below. In the following derating curve, the average output current is considered to be 100% (A) (B) {C) STANDARD CNI say Np jcomponent 4 | | -4 LL (D) (E) (F) CN1 Ko 10 ZWSS50AFIJA (%) 100 Mounting (A) 80 Mounting (R),(C),(D) 60 _ Mounting (E) 40 20 Average Load ( ) 0 -10 60 20 40 50 Ambient Temperature (C) ZWSSOAF/JA Output Derating LOAD (%) Mounting] A B Cc D E F Ta -10~+30C | 100 | 100 | 100 | 100 | 100; - +35C 100 | 100 | 100 | 100 | 88 - +40C 100 | 83:7 83 | 83 | 75 - +45C 85 | 66 | 66 | 66 | 62 - +50C 70 | 50 | 50 | 50 | 50 - ZWS7TS5AF/JA (%) 100 80 Mounting (A) 60 M c 40 Mountng (D),(E) - Average Load ( % ) 20 0 -10 0 20 40 80 Ambient Temperature (C) ZWSTSAF/JA Output Derating LOAD (%)) Mounting] A B Cc D E F Ta -10~+20C | 100 | 1006 | 100 | 100] 100 | - 430C 100 j 100 | 100 | 80 | 80 - +49C | 100 | 66.] 66 | 60 | 6o | - 145C 83 30 50 | 50 50 - soc | of - | - | - | oT -ZWSLOOAF/JA 96} 100 2 80 2 3 M uw AO i= on 0 -16 ZWSI00AF/JA Output Derating Mounting (A) 0 Ambient Temperature 60 Mounting (Bue) | | (D),(E} 20 40 30 (C) LOAD (%) Mounting] A B C D E Ta -10~+20C] 100] 100 | 100 | E00} 00 430C 100 | 100 | 100 | 80) 80 40 | 100} 67 | 67 | 60 | 60 +45C 80 50 350 | 350} 50 +50T | 60] - - - | - ZWSIS50AF/JA (%) 100 _ 80 Mounting (A) <= ~ so | Mounts @Ien0) 3 Mounting (E) 2 40 5 20 < 0 10 6 20 40 50 Ambient Temperature (C} ZWSIS0AF/JA Output Derating LOAD (%) Mounting} A B Cc D E Ta -}0-45C | 1007 100] 100 | 100 | 100 +20C 100} 100} 100 | 100 81 +20C 100} 80 } 86 80 68 +40C 65 | 60 | 60 | 60 | 36 +45C 50 | 50 | 50 | 50 | 50 11 Derati i i For usage of ZWS-AF/JA madel, method ts the same as the standard type (7WS-AP) forced cooling. Mounting method (F) is impossible ZWSS0AF/JA, TSAF/JA (98) 100 80 = 60 x 4 0 -10 0 50 60 Ambient Temperature (C ) ZWSSOAF/JA,7SAF/JA Output Derating LOAD (%) Mounting A.B,.C,.D.E Ta -10~450%C 100 HST. 85 +600 |. 70 ZWSI100AF/JA (%) 160 80 2 60 2 40 pan) a 29 5 as 0 -10 0 50 60 Ambient Temperature (C} ZWSI00AF/JA__ Output Derating LOAD (%) Mounting ABCDE Ta -10~+50C 100 455C 80 +60C 60ZWSI150AF/JSA (%) 100 80 = 60 = g 40 a = 20 5 > ct 6 -10 0 40 50 Ambient Temperature (C ) ZWSIS50AF/JA Output Derating LOAD (%) Mounting A,B,C,D,E Ta - -10~440C. 100 +45C 85 +50C 70 4-3. Mounting Method Please use the mounting hole as: ZWSSOAF~ZWSI50AF: 4holes of 63.5 And insert the spacer (MAX 8mm) of height over 8mm to lift the unit. Also use all 4 mounting holes for the unit installation. The vibration spec. is the value taken when the unit is raised by 8mm spacers. ~ TY << a 0 TAN amo SPACER And allowable area by metal pieces is 9mm from each PCB comers. Refer to figure below. Srem. 3mm one TT B ] fed. oo g LL oo Serum 9mm mm Please leave 4mm space from the surfaces and the sides of PCB, especially from the solder surface, 8mm space is necessary. If the space is not enough, the specification of insulation and withstand will not be satisfied. MIN 4mm oa a ae 2 a MIN. 4mm ae a 7 a ao < Ee 7 ER ~ oo a a MIN 4rnm a MIN 8mm a FG should be connected to the earth terminal of the apparatus. If not, the conducted noise and output noise will increase. CHASSIS (CONDUCTOR)S. Wiring Method @ The output load line and inpmt line shall he separated and twisted to improve noise sen- sitivity. @ Use all lines as thick and short as possible to make lower impedance. Noise can be eliminated by attaching a capacitor to the load terminals. @ For safety and EMI considerations, connect FG to ground terminal of equipment where power supply is mounted on. Recommended screw torque is 0.49N.m (3kg.cm). @ Sclect the wire materials to adapt the connector as follows. INPLT : 7WSS0AF~15Q0AF---AWGH#?27~#18 OUTPUT : ZWSSCAF~ISOAF---AWG#22~218 6. External Fuse Rating Reter to the following fuse rating when select- ing the external fuses that are to be used on in- put line. Surge current flows when line turns on. Therefore use slow-blow fuse or time-lug fuse. Do not use fast-blow fuse. Fuse rating is speci- fied 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. ZWSSO0AF :2.0A ZWSTSAF :3.15A ZWSILOOAF :3.15A ZWSISOAF 25.04 13 7. Before concluding that the unit is at fault... Before concluding that the unit is at fault, make the following checks. Check if the rated input voltage is connected. Check if the wiring of input and output is cor- rect. Check if the wire material is not too thin. Check if the output voltage contro! (V.ADJ) is properly adjusted. Check if the ourput current and output wattage dose not over specification. Audible noise can be heard during Dynamic- Load operation. Audible noise can be heard when input voltage waveform is not sinusoidal wave. 8. Notes 1. Overvoltage Category II 2. Radio Interference Suppression Test is not performed.