ZLWS240PAF Series 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 elec- trical shock, damage to the unit or a fire hazard. WARNING and CAUTION Do not modify. @ 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. Stick the WARNING label for users on the system equipment and describe the notice in the instruction manual. @ Never operate the unit under over current or shorted conditions for 30 seconds or more and out of Input Voltage Range in specification which could result in damage or insulation failure or smoking or burning. Confirm connections to input/output terminals are correct as indicated in the instruction manual. This power supply is PC board type unit. Please hoid the board edge while mounting, and do not touch the component side. Please lift the power supply with a spacer when mounting the power supply on any surface. @ Do not drop or apply shock to power supply unit. This power supply is capable of providing hazardous energy output (240VA), the end equipment manuafacturer must provide protection to service personal against inadvertent contact with output terminals. These terminals must not be user accessible. @ 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, it must be considered hazardous and must not be made user accessible @ Do not use the product in the environment with strong electromagnetic field, corrosive gas and conductive substance. Note: CE MARKING CE Marking, when applied to a product covered by this handbook indicates compliance with the low voltage directive (2006/95/EC)in that it is complies with EN60950-1. DWG NO. : CA724-04-01C APPD CHK DWG tA | BG | Caz 25 ftanfo8 24 Tan/rzg py me Tan- 081. Terminal Explanation 1-1. ZWS240PAF @ - @=O +R eg tr , CN2 vest [ay | CNS? [| Fe+@ @F718 lsc | ae sto @Pya0 N 6) ; o- ~ i 40+ @DtHee_ it | p04 4. cn tr aif 8 on \ 1 CNS 4 \ OD / oO oO Oo @ 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 1 of CN1) Must be connected to electrically safety ground of apparatus or equipment by electrically conductive spacers. The mounting surface of the spacer should be within MAX 8mm. CN2: ON/OFF control terminal (primary circuit) See NOTE A @ +: +Output terminal @ -:- Output terminal V.ADJ: Output voltage adjust trimmer (VR51) The output voltage rises when a trimmer is turned clockwise. (N52: ON/OFF control terminal (secondary circuit) (For power supply output on and off control with an external signal.) See NOTE A *Input & Output connector (MOLEX) (also for option model /L,/A) Connector Housing Terminal Pin Input (CN1) 5414-30B 5195-06 5194PBT Output (CN51) | 5273-08A 5195-06 5194PBT *Output Current of each connector pin must be less than SA. *Hand Crimping Tooling : 11-26-0058 (MOLEX) *Connector for Remote ON/OFF control: CN2, CN52 (J.8.T) *CN2 is normally shorted by JM-2W-96 (J.S.T ) Connector Housing Terminal Pin - - XH - OOIT - PO. B2B - XH XHP -2 B OOIT - P0.6 AM or SXH - 001T - P0.6 *Hand Crimping Tool: YC-110R (J.S.T) or YRS-110 (J.S.T) NOTE A: For COVER & CHASSIS type (MODEL: ZWS240PAF/A), remote ON/OFF control cannot be used.1-2. ZWS240PAF/J @--p-O S CNI @5 Fe Q-Prge fk @Q-- io t oO +R) aa |~ [safe CN2 L: AC Input terminal (pin | of CN1) Live line (fuse in line) @ N: AC input terminal (pin 3 of CN1) Neutral line @ FG: Input terminal FG (pin 5 of CN1) Safety earth (Frame Ground) Connect to safety ground of apparatus or equipment. @ FG: Frame Ground (Connected to pin 5 of CN1) Must be connected to electrically safety ground of apparatus or equipment by electrically conductive spacers. The mounting surface of the spacer should be within MAX 8mm. @ CN2: ON/OFF control terminal (primary circuit) See NOTE A + +Output terminal @ -:- Output terminal V.ADJ: Output voltage adjust trimmer (VR51) The output voltage rises when a trimmer is turned clockwise. @ CNS2: ON/OFF control terminal (secondary circuit) (For power supply output on and off control with an external signal.) See NOTE A *Input & Output connector (J.S.T ) (also for option model /JL,/JA) Connector Housing Input (CN1) B3P-5-VH VHR-SN SVH-21T-P1.1 Output (CN51) B8P-VH VHR-8N SVH-21T-P1.1 *Output Current of each connector pin must be less than 5A. *Hand Crimping Tool : YC-160R (J.S.T ) Terminal Pin *Connector for Remote ON/OFF control: CN2, CN52 (J.S.T) Terminal Pin BXH - 001T - P0.6 or SXH - OOIT - P0.6 *CN2 is normally shorted by JM-2W-96 (J.S.T ) *Hand Crimping Tool: YC-110R (.S.T) or YRS-110 (.S.T) Connector Housing B2B- XH- AM XHP -2 NOTE A: For COVER & CHASSIS type (MODEL: ZWS240PAF/JA), remote ON/OFF control cannot be used.1-3. ZWS240PAE/T | @+o @ gaye | cusp cnt CN2 VR51 -@ Fe CNSt -e esi oO @ L: AC Input terminal L (M4 screw) Live line (fuse in line) @ N: AC input terminal N (M4 screw) Neutral line @ FG: Input terminal FG (M4 screw) Safety earth (Frame Ground) Connect to safety ground of apparatus or equipment. @ FG: Frame Ground Must be connected to electrically safety ground of apparatus or equipment by electrically conductive spacers. The mounting surface of the spacer should be within MAX 8mm. CN2: ON/OFF control terminal (primary circuit) See NOTE A +:+Output terminal (M4 screw) @ -:- Output terminal (M4 screw) V.ADJ: Output voltage adjust trimmer (VR51) The output voltage rises when a trimmer is turned clockwise. * Input & Output connector (EMUDEN ) (also for option model /TL,/TA) Connector Input (CN1) T6957-A Output (CN51) T7094-A. *Connector for Remote ON/OFF control: CN2, CN52 (J.S.T) Connector Housing Terminal Pin B2B - XH- AM XHP - 2 BXH - OOIT - 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) CNS52: 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: ZWS240PAF/TA), remote ON/OFF control cannot be used.1-4. ZWS240PAF/S @ be) +R 23 ]-R | oO cnt + ves" | t+ @ Tal) Ae ost @ [| N Cc ~@ D | ye -~ Oo L: AC Input terminal L (M4 screw) Live line (fuse in line) @ N: AC input terminal N (M4 screw) Neutral line @ FG: Input terminal FG (M4 screw) Safety earth (Frame Ground) Connect to safety ground of apparatus or equipment. FG: Frame Ground Must be connected to electrically safety ground of apparatus or equipment by electrically conductive spacers. The mounting surface of the spacer should be within MAX 8mm. CN2: ON/OFF control terminal (primary circuit) See NOTE A +: +Output terminal (M4 screw) - : - Output terminal (M4 screw) V.ADJ: Output voltage adjust trimmer (VR51) 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 8e8 @ *Input & Output connector ( EMUDEN ) (also for option model /SL,/SA) Connector Input (CN1) T6969-A Output (CN51) T7093-A *Connector for Remote ON/OFF control: CN2, CN52 (L.S.T) Connector Housing Terminal Pin B2B - XH - AM XHP - 2 BXH - 001T - P0.6 or SXH - OO1T - 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) NOTE A: For COVER & CHASSIS type (MODEL: ZWS240PAF/SA), remote ON/OFF control cannot be used.2. Terminal Connecting 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 FG terminal of input connector and mount- able FG to ground terminal of the equipment. Output current of each connector pin must be less than 5A. ( Except /T, /S models which M4 screw is used. ) The output load line and input line shall be separated and twisted to improve noise sensitivity. @ Remote ON/OFF control lines shall be twisted or use shielded wire. Use the input/output connector housing, terminal pin as specified in outline drawing. Also, use recom- mended crimping tool. Connector housing and terminal pin is not included with this product. When connecting or removing connector, do not apply stress to PCB. ZWS240PAF ports -~O +Rlag|-R oO { re nz = | EARTH tlie COMPONENT SIDE eet 4 3N f 6 BeSvAG eit pur ourar [CNT 3 2 Lebo N51 o ZWS240PAE/J pate {) +A 93 ]-R oO i eNz VR51 I cal | cnt : EaRia Sire COMPONENT_ SIDE 2 ~ 8 f ~| BeevAG ae ouTPuT : | +16 7 8 CNSi Oo oO LOAD LOADavol avor Ogee) - Fn ee 0 iw 0 [2] > e & LZ 8 2 o oO Oo uu a a a i nv 6 kK t | a 5 2 Zz z oO oO oa S = oO 8 oO ry 5 @ Se e PF _ z ae KE /o8 JOO 0 o on 0 _ Be + Ps x T ay < S| z | 8g S & 2 > { ws \ =< >2 wt a | a Ba aa Ye A = |% z= S Ss & [38 N N bee me Lp ee3. Explanation of Functions and Precautions of oscilloscope is too long. 3-1. Input Voltage Range Input voltage range is single phase 85 ~ 265VAC (47 ~ 63Hz ) or 120 ~ 370VDC. Input voltage which is out of specification may cause unit damage. For cases where conformance to various safety specs(UL,CSA,EN) are required, input voltage range will be 100 ~ 240VAC ( 50/60Hz ). Oscilloscope Bandwidth : [(OOMHz 150mm R:50Q C1 : 4700pF Film Capacitor C2: 100uF Electrolytic Capacitor C3: 0.1uF Film Capacitor 3-2. Output Voltage Range V.ADJ trimmer(VRS51) that is nearby to output connector is for output voltage adjustment within the range of specifications. To turn the trimmer clockwise, the output voltage will be in- creased. Note over voltage protection (OVP) function may trigger if the output voltage is increased excessively. 3-8. Series Operation For series operation, either method (A) or (B) is possible. Method (A ) 3-3. Inrush Current P ower This series has used Power Thermistor to protect the circuit Supply from Inrush Current. Please carefully select input switch and . : : Output ay fuse in cases of the high temperature and re-input the power. : Terminal a 3-4. Over Voltage Protection (OVP ) Load The OVP function ( Inverter shut down method, manual reset OT wy, type ) is provided. OVP function operates within the range of Output OVP specifications. When OVP triggers, the output will be shut Terminal e Le down, The input shall be removed for a few minutes, and then re-input for recovery of the output. OVP setting is fixed and not to be adjusted externally. 3-5. Over Current Protection (OCP ) Method (B ) Constant current limiting, automatic recovery. OCP function Power operates when the output current exceeds OCP specifications. Supply The output will be automatically recovered when the overload condition is cancelled. Do not operate overload or dead short Output O CF) conditions for more than 30 seconds, which could result in Terminal Load damage or insulation failure. = 3-6. Over Temperature Protection (OTP ) t GS OTP circuit is built into the power supply to prevent power Output ~ Load supply from damage when ambient temperature over the Terminal specification. 3-7. Output Ripple & Noise 3-9, Parallel Operation The standard specification for maximum ripple value is (A) To increase the output current is not possible. measured according to measurement circuit specified by JEITA-RC9131. When load lines are longer, ripple becomes larger. In this case, electrolytic capacitor, film capacitor, etc. might be necessary to use across the load terminal. The output ripple cannot be measured accurately if the probe ground lead -7-(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, Power Supply Output * eo Terminal om Load Output t Terminal ee & 3-10. Peak Output Current For ZWS240PAF series, the peak output current should satisfy the conditions below: 1)Should not exceed the rated peak current in the specifica- tions.(eg. 20A for ZWS240PAF-24) 2)Duty cycle of the peak output current should be < 35 %, and operating time of peak output current is less than 10 sec- onds. If the power supply is operated under convection cooling, and ambient exceeds 45C, the following oper- ating period for peak current is recommended. Ambient Temperature (C) -10 ~ +45C +45C onwards Peak current operating time within 10 seconds within 5 seconds 3)The relation between peak output current with average out- put current is defined as below: Ip = Peak output current Im = Minimum output current D = Duty cycle, t/T T = Peak output current operating time T = Period lo = Maximum allowable average output current of specifica- tions (Io should be average load after derating at various mounting and ambient temperature) Formula: ZWS240PAF: 1.5 x Io > Ip D + ln x (1-D) Example I : For ZWS240PAF-24 at Ta =60 C,Mounting A, Max Io =6A (after 60% Derating) 1.5xIo > Ip x D+ Im? x (1-D) (A): In case of Im =0, Ip =20A, D<13.5% (B): In case of Im =4A, Ip =20A, D<9.9% Example II : Following table illustrate some peak load operation examples for ZWS240PAF-24. Please note that the actual Io in peak load operation is low . Max allowable Examples of peak load average load after . Actual . . derating, calculated by derating by various above formula To Mounting and Ta : Average Load(%) To(A) Ip (A)max Dmax Im(A) Io(A) 100% 10 20 35.0% 3.92 9.55 90% 9 20 30.4% 0 6.08 80% 8 20 24.0% 0 4.80 70% 7 20 18.4% 0 3.68 60% 6 20 13.5% 0 2.70 50% 5 20 9A% 0 1.88 40% 4 20 6.0% 0 1.20 30% 3 20 3.4% 0 0.68 20% 2 20 1.5% 0 0.30 10% 1 20 0.4% 0 0.08 4)Peak output current operation (Maximum 10 seconds, Duty < 0.35) is possible after establish of output volt- age. Please avoid peak current operation during start up.3-11. 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 following 2 modes. However, for Cover and Chassis type (eg. ZWS240PAF/A, /JA, /TA, /SA) cannot 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 device. When using this connector, which is considered 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 etc. In particular: 1) Basic insulation must be provided between the ON/OFF control circuit and earth. 2) Reinforced insulation must be provided between the ON/OFF control circuit and any secondary circuit or accessible part. 3) Wiring must be routed such that damage to the insulation of the wire or additional sleeving cannot occur. 4) The switch must meet requirements for reinforced insulation from the ON/OFF control circuit to actuator/accessible parts. [CN2] The control mode is shown below. +R & -R Terminal condition Output condition Short ON Open OFF *Using CN52 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 connect in the Primary ( input ) side. And this circuit is isolated from the output by a photo-coupler. [CN52] The control mode is shown below. +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 4.5 ~12.5VDC No required 12.5 ~24.5VDC 1.5kO 3-12. Isolation Test Isolation resistance between output and FG (Chassis) shall be more than 100MQ at 500VDC-. 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 ) S00VDC 100MQ or more AC(L) + q ACN) +R(CN52) Isolation Tester 4 FG -R(CN52) 3-13. Withstand Voltage This series is designed to withstand 3.0kVAC between input and output, 2.0k VAC between input and FG (Chassis) and 500VAC between output and the FG (Chassis) each for 1 minute. When testing withstand voltage, set current limit of the withstand voltage test equipment to 20mA ( Output - FG (Chassis) : 100mA ). 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 (dotted line ) 3kKVAC imin. (20m AC(N) ] With chassis, with chassis&cover type +R(CN52) (A) (B) > FG -R(CNS2) Standard Mounting 5 Withstand Voltage Component 5 Tester NA | te EEE : CPE IE bd | , 4. Mounting Directions 4-1. Output Derating according to the Mounting (C) Directions Input 2 Recommended standard mounting method is ( A ). Method (B), (C), (D ), (E) are also possible. Mounting (F), (G), (H), (1) are prohibited. Please do not use installation method ( F ), where the PCB will be on the top side and heat will be ; Output trapped inside the unit. Refer to the derating below. In the . LA following derating curve, average load(%) is percent of S| maximum output load (both Maximum Output Current and - Maximum Output Power in specifications). Do not exceed the ( F) ; load deratings. Prohibit PCB type (A) Standard Mounting deen ee ~ "I |, Component beet tnrewernny ae) -10-(G) (1) (H) Output Derating Convection cooling PCB type and with chassis type 100 > \ wo oO Average Load (%) ON oO Mounting (C),(D) ~ Mounting (A) 4 -~ Mounting (B) With chassis and cover type 100 \S yy = % SON zy Mounting (A) IN XY 3 60 t t > N N gp Mounting (B),(C) py IN S 40 7 Mounting (D),(E) N Z S 20 N 0 -10 0 10 20 30 40 50 Ambient Temperature (C) Convection Average Load (%) 7 ounting A B Cc D E -10~ 5C 100 100 | 100 100 100 15C 100 100 100 80 80 25C 100 80 80 60 60 50C 50 30 30 10 10 @ Forced air cooling PCB type and with chassis type 40 I i i 20 Mounting (E)~ sLLL LI ] -10 0 10 20 30 40 50 60 Ambient Temperature (C ) Convection Average Load (%) th ounting A B C D E -10~ 25C | 100 100 100 100 100 30C 100 100 100 100 | 87.5 35C 100 100 90 90 75 40C 100 | 93.3 80 80 62.5 45C 100 | 86.7 70 70 50 50C 86.7 80 60 60 37.5 55C 73.3 60 50 50 25 60C 60 40 40 40 12.5 100 S 80 2 + | \ Ss 3 60 Mounting 2, (A),(B),(C),(D),(E) = 40 S < 20 0 -10 0 10 20 30 40 50 60 70 Ambient Temperature (C) Forced air Average Load (%) ounting Ta A,B,C,D,E -10~ 60C 100 70C 70With chassis and cover type 100 = 80 A ; rT 3 60 Mounting oo (A),(B),(C),),) 5 40 < 20 0 -10 O 10 20 30 40 50 60 Ambient Temperature (C) Forced air Average Load (%) ounting Ta A,B,C,D,E -10~ 50C 100 60C 70 *Recommended minimum air velocity : 0.7m/s (Measured at component side of PCB, air must flow through component side). As a reference for forced Air Cooling, let air flow so that the transformer T1 core temperature is lower than 80C Test point (GORE) \ NAME PLATE Ti J c NN L PCB =e 4-2. Mounting Method PCB type Please use the mounting hole (5 holes of $3.5) and insert the spacer (MAX8.0)of height over 8mm to lift the unit. Also use all 5 mounting holes for the unit installation. The vibration spec is the value taken when the unit is raised by 8mm spacers. HEIGHT MORE THAN 8mm SPACER (4} -12- EG we MIT OE A OIL Please leave 4mm space from the surfaces and leave 4mm space from 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 voltage will not be satisfied. | NOT LESS THAN z z = | | 3 : ze bE NOT Less, ssl hor LESS THAN nnn _25 mrt 4mm | ao 4 a + | | a ve i & 1 4mm NBT LESS THAN NOT LESS snow! FG should be connected to the earth terminal of the apparatus. If not, the EMI noise and output noise will increase. WIRE FG [| tA I | AT METAL SPACERS OF CHASSIS (CONDUCTOR) Hatching area is maximum permissible area of metal part for mounting. g 9 n ey Loy o an o yo 9 9 an For chassis option /L, chassis & cover option /A Recommended mounting method is mounting (A), (B), (C), (D), (E) by bottom plate of chassis to meet 19.6m/s vibration specification as shown in section 4-1. The power supply can be mounted through holes A or B. A: Embossed tapped and countersunk holes by 4-M4 screws B: 4.5 holes and R2.25 slot hole by 3-M4 screws (For /SL and /SA models, these holes can not be used)CHASSIS COMPONENT SIDE Mounting (F), (G), (H), (1) is prohibited. For mounting method (J), (K), (L), below, the vibration specification is 4.9m/s, mounted through holes C or D. Note: Output derating for mounting (J) is same as mounting (C). Output derating for mounting (K) is same as mounting (E). Output derating for mounting (L) is same as mounting (D). @ Select the wire materials to adapt the MOLEX and J.S.T connector as follows. INPUT : AWG#22 ~ #18 OUTPUT : AWG#22 ~ #18 6. 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. Use slow-blow fuse or time-lag type fuse. Do not use fast-blow fuse. Fuse rating is specified 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. ZWS240PAF: 6.3A 7. Before concluding that the unit is at fault... (J) (K) (L) Before concluding that the unit is at fault, make the following Output Input checks. Input N = Zz Check if the rated input voltage is connected. \ y - Check if the wiring of input and output is correct. N N : . oa: : \ 5 5 Check if the wire material is not too thin. 5 Check if the output voltage control (V.ADJ ) is properly A N . Eee 4 Input Output adjusted. , BAZ Ifyou use function of the Remote ON/OFF control, check 5 if the Remote ON/OFF control connector is not opened. @ Check if the output current and output wattage do not over 2 specification. @ Audible noise can be heard during Dynamic-Load 7 q operation. ir Audible noise can be heard when input voltage waveform is not sinusoidal wave. C: 2-4,5 holes and R2.25 slot hole by 3-M4 screws (For/SL and /SA models, these holes can not be used) 8. Notes D: Embossed tapped and countersunk holes by 2-M4 screws. 5. Wiring Method 1) Over voltage Category II. 2) Radio Interference Suppression Test is not performed. @ The output load line and input line shall be separated and 9, Repair twisted to improve noise sensitivity. @ Use all lines as thick and short as possible to make lower In case of damage or repair of this product, please return to impedance. @ Noise can be eliminated by attaching a capacitor to the load terminals. our service center or factory. @ For safety and EMI considerations, connect FG terminal of input connector and mountable FG to ground terminal of equipment. @ Recommened screw torque is 0.49N.m (5kg.cm ) -13-