TDK-Lambda ZWD150PAF Series User manual

PA573-04-01F
TDK-Lambda
ZWD150PAF 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 electrical
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 specification which could result in damage. There is no possibility of fire or burning.
· Confirm that connections to input/output terminals are correct as indicated in the instruction manual.
· This power supply is PC board type unit. Please hold 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 sur-
face.
· This power supply is capable of providing hazardous energy output(240VA), the end equipment manu-
facturer must provide protection to service personal against inadvertent contact with output terminals.
This terminal must not be user accessible.
· Under single fault conditions in secondary circuits, the output(s) of this product may go non-SELV be-
tween parts of the secondary circuits and earth. It is therefore necessary to earth the output(s) to maintain
SELV between output(s) and earth. Alternatively, the output(s) may be considered hazardous and must not
be made user accessible in the end equipment.
· Do not drop or apply shock to power supply unit.
ZWD150PAF Series
Instruction Manual

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TDK-Lambda
ZWD150PAF Series
INSTRUCTION MANUAL
1. Terminal Explanation
1-1. ZWD150PAF
 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.
 PE: Protective Earth (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 f8mm.
 V1: CH1 +ve Output terminal
 G1: CH1 –ve Output terminal
 V2: CH2 +ve Output terminal
 G2: CH2 –ve Output terminal
 V.ADJ: 5V Output Voltage adjust trimmer (VR1)
The 5V Output voltage rises when the trimmer is
turned clockwise.
 V.ADJ : 24V Output Voltage adjust trimmer (VR2)
The 24V Output voltage rises when the trimmer is
turned clockwise.
-R : CN3 ON/OFF control -R terminal
+R : CN3 ON/OFF control +R terminal
*Input & Output connector (MOLEX)
(also for option model /L,/A)
Recommended
Connector Housing Terminal Pin
Input
(CN1)
5414-30B
or 5273-06A(1.4.6)
5195-06
or 2139-06
or 3069
-
06
5194PBTL
Output
(CN2) 5273-08A
5195-08
or 2139-08
or 3069
-
08
5194PBTL
*Output Current of each connector pin must be less than
5A.(7A at peak load)
*Hand Crimping Tooling : 11-26-0058 (MOLEX)
*Connector for Remote ON/OFF control: CN3 (JST)
*CN3 is normally shorted by JM-2W-96 ( JST )
*Hand Crimping Tool: YC-110R (JST) or YRS-110 (JST)
Recommended
Connector
Housing
Terminal Pin
B2B - XH - A XHP – 2 BXH - 001T - P0.6
or SXH - 001T - P0.6

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TDK-Lambda
ZWD150PAF Series
INSTRUCTION MANUAL
1-2. ZWD150PAF/J
 L: AC Input terminal (pin 1 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.
 PE: Protective Earth (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 f8mm.
 V1: CH1 +ve Output terminal
 G1: CH1 –ve Output terminal
 V2: CH2 +ve Output terminal
 G2: CH2 –ve Output terminal
 V.ADJ: 5V Output Voltage adjust trimmer (VR1)
The 5V Output voltage rises when the trimmer is
turned clockwise.
 V.ADJ : 24V Output Voltage adjust trimmer (VR2)
The 24V Output voltage rises when the trimmer is
turned clockwise.
-R : CN3 ON/OFF control -R terminal
+R : CN3 ON/OFF control +R terminal
*Input & Output connector ( JST )
(also for option model /JL,/JA)
Recommended
Connector Housing Terminal Pin
Input
(CN1)
B3P5
-
VH
VHR
-
5N
SVH
-
21T
-
P1.1
Ou
t
put
(CN
2
)
B8P
-
VH
VHR
-
8N
SVH
-
21T
-
P1.1
*Output Current of each connector pin must be less than 5A.
(7A at peak load)
*Hand Crimping Tool : YC-160R ( JST )
*Connector for Remote ON/OFF control: CN3 (JST)
Recommended
Connector
Housing
Terminal Pin
B2B - XH - A XHP - 2 BXH - 001T - P0.6
or SXH – 001T - P0.6
*CN3 is normally shorted by JM-2W-96 ( JST )
*Hand Crimping Tool: YC-110R (JST) or YRS-110 (JST)

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TDK-Lambda
ZWD150PAF Series
INSTRUCTION MANUAL
1-3. ZWD150PAF/T
 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 (Protective Earth)
Connect to safety ground of apparatus
or equipment.
 PE: Protective Earth
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 f8mm.
 V1: CH1 +ve Output terminal
 G1: CH1 –ve Output terminal
 V2: CH2 +ve Output terminal
 G2: CH2 –ve Output terminal
 V.ADJ: 5V Output Voltage adjust trimmer (VR1)
The 5V Output voltage rises when the trimmer is
turned clockwise.
 V.ADJ : 24V Output Voltage adjust trimmer (VR2)
The 24V Output voltage rises when the trimmer is
turned clockwise.
-R : CN3 ON/OFF control -R terminal
+R : CN3 ON/OFF control +R terminal
* Input & Output connector ( EMUDEN )
(also for option model /TL,/TA)
*Connector for Remote ON/OFF control: CN3 (JST)
Recommended
Connector
Housing
Terminal Pin
B2B – XH - A XHP – 2 BXH - 001T - P0.6
or SXH - 001T - P0.6
*CN3 is normally shorted by JM-2W-96 ( JST )
*Hand Crimping Tool: YC-110R (JST) or YRS-110 (JST)
Connector
Input
(CN1)
T6957
-
A
Ou
t
put
(CN
2
)
T6958
-
A

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TDK-Lambda
ZWD150PAF Series
INSTRUCTION MANUAL
2. Terminal Connecting Method
Pay attention to the input wiring. If it is connected to the
wrong terminal, the power supply will be damaged.
· Input must be turned off when making connections.
· Connect FG terminal of input connector and mountable
PE to ground terminal of the equipment.
· Output current of each connector pin must be less than
5A. ( Except /T model 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 recommended input/output connector housing,
terminal pin & crimping tool.
Connector housing and terminal pin is not included
with this product.
· When connecting or removing connector, do not apply
stress to PCB.
ZWD150PAF

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TDK-Lambda
ZWD150PAF Series
INSTRUCTION MANUAL
ZWD150PAF/J
ZWD150PAF/T

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TDK-Lambda
ZWD150PAF Series
INSTRUCTION MANUAL
3. Explanation of Function and Precautions
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 damage unit. 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 (VR1 & VR2) which is nearby to output con-
nector is for output voltage adjustment. Please refer to the
specifications for the output adjustment range. When the
trimmer is turned clockwise, the output voltage will increase.
Note that over voltage protection (OVP) function may trigger if
the output voltage is increased excessively.
3-3. Inrush Current
This series used Power Thermistor to protect the circuit from
Inrush Current. Please carefully select input switch and fuse in
cases of high temperature and brown-out.
3-4. Over Voltage Protection ( OVP )
OVP circuit will shutdown output correspondingly. OVP for
V1, both V1 & V2 will shutdown, OVP for V2, only V2
shutdown. Manual reset or input voltage recycling is needed
for output recovery.
3-5. Over Current Protection ( OCP )
OCP type is constant current limiting with automatic recovery.
OCP function operates when the output current exceeds OCP
specifications. The output will automatically recover when the
overload condition is removed. Do not operate overload or
dead short conditions for more than 30 seconds, which could
result in damage. There is no possibility of fire or burning.
3-6. Over Temperature Protection ( OTP )
OTP circuit is built into the power supply to prevent user from
fire hazard when ambient temperature is over the specification.
3-7. Output Ripple & Noise
The standard specification for maximum ripple and noise value
is measured according to measurement circuit specified below.
When load lines are longer, ripple and noise may become larger.
In this case, electrolytic capacitor, film capacitor, etc. might be
necessary across the load terminal. The output ripple and noise
cannot be measured accurately if the oscilloscope probe ground
lead is too long.
3-8. Series Operation
Series operation is not possible.
Output
Terminal
Output
Terminal
Power
Supply
Load
3-9. Parallel Operation
Paralled operation is not possible.
Load
Output
Terminal
Output
Terminal
Power
Supply

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TDK-Lambda
ZWD150PAF Series
INSTRUCTION MANUAL
3-10. Peak Output Current
For ZWD150PAF series, the peak output current should satisfy
the conditions below:
1)Should not exceed the rated peak current in the specification.
(eg. 10A/12A respectively for 100VAC/200VAC)
2)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
Io = Maximum allowable average output current of specifica-
tions (Io should be average load after derating at various
mounting and ambient temperature)
3)For peak output current (Ip ≤ 10A) at 100VAC & 200VAC,
the duty cycle of the peak output current is ≤ 35% and oper-
ating time of the peak output current is less than 10 seconds.
For peak output current (Ip ≤ 12A) at 200VAC only, the duty
cycle of the peak output current is ≤ 20% and operating time
of the peak output current is less than 5 seconds. Maximum
ambient has to be reduced by 10°C if 35% duty operation is
required.
Vin (VAC) Ip (max) Duty(max) t
(sec)
85 ~ 132
10A
35%
10sec
170 ~ 265 10A 35% 10sec
170 ~ 265 12A 20% 5sec
4)Formula:
ZWD150PAF: Io(ave) = Ip x D + Im x (1-D) ≤ Io spec.
(refer to derating curve)
Example : For ZWD150PAF-0524 at Ta =60°C,Mounting A,
Max Io(ave) =3A (after 50% Derating)
Io(ave) = Ip x D + Im x (1-D) ≤ Io spec.
(A)100VAC : In case of Im =0, Ip =10A,
D<30%
(B)200VAC : In case of Im =2A, Ip =12A,
D<10%
3-11. Remote ON/OFF Control
Remote ON/OFF control (CN3) function is available. Using
this function allows the user to turn the 24V output on and off
without having to turn the AC input on and off.
It is controlled by short or open between +R & -R of CN3. CN3
is provided in the secondary circuit for ON/OFF control by
means of a switch or other device.
[CN3] The control mode is shown below.
+R &
-
R
T
erminal
condition
Output condition of V2
Short < 0.5V
ON
Open
> 4.5V
OFF
3-12. Isolation Test
Isolation resistance between output and PE (Chassis) shall be
more than 100MW 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 – PE ( Chassis )
500VDC 100MW or more
AC(L)
AC(N)
+
V1
G1
FG
+
V
2
G2
Isolation
Tester
+R
-R
(ave)
PE

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TDK-Lambda
ZWD150PAF Series
INSTRUCTION MANUAL
3-13. Withstand Voltage
This series is designed to withstand 3.0kVAC between input
and output, 2.0kVAC between input and PE (Chassis) and
500VAC between output and the PE (Chassis) each for 1 mi-
nute. When performing this test, set current limit of the with-
stand voltage test equipment to 20mA ( Output - PE (Chassis) :
100mA ). The applied voltage must be gradually increased
from zero to the test value and then gradually decreased for
shut down. When timer is used, the power supply may be
damaged by high impulse voltage during timer switch on and
off. Connect input and output as follows.
Input ~ Output (dotted line )
3kVAC 1min. ( 20mA )
Input ~ PE (Chassis) (solid line )
2kVAC 1min. ( 20mA )
AC(L)
AC(N)
+V1
G1
FG
+
V
2
G2
Withstand
Voltage
Tester
+
R
-
R
Output ~ PE (Chassis)
500VAC 1min. ( 100mA )
AC(L)
AC(N)
+V2
G2
FG
+V1
G1
Withstand
Voltage
Tester
+R
- R
3-14. External connection of circuit with protective
seperation
All the outputs is protected using protection of SELV. ( As per
required in the EN50178, clause 5.2.8)
3-15. Max Current during abnormal
The Max output current of CH1 under any abnormal situation
is 9.39 A (DC)
The Max output current of CH2 under any abnormal stituation
is 16.52 A (DC)
3-16. Climatic condition
This product is certified to the Climatic condition, Type B of
the EN50178.
PE
PE

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TDK-Lambda
ZWD150PAF Series
INSTRUCTION MANUAL
4. Mounting Directions
4-1. Output Derating according to the Mounting Direc-
tions
Recommended standard mounting method is (A). Method (B),
(C), (D), (E) are also possible. Mounting (F), (G), (H), (I) are
prohibited. Refer to the derating curve. In the following de-
rating curve, average load(%) is percent of maximum output
load (both Maximum Output Current and Maximum Output
Power in specifications). Do not exceed the load deratings.
PCB type
( A )
With chassis and with chassis&cover type mounting
method
( A )
Standard Mounting
( B )
( C )
( D )
( E )
( F )
Prohibit
( G )
Prohibit
Input
Input
Output
Component
Input
Output
Input
( B )
( C )
Standard Mounting
( D )
Component
Input
Input
Input
Output
Output
Input
( H )
Prohibit
( I )
Prohibit
( E )
( F )
Prohibit

- 10 -
TDK-Lambda
ZWD150PAF Series
INSTRUCTION MANUAL
Output Derating
· Convection cooling
PCB type and with chassis type
Convection
Average Load (%)
Mounting
Ta
A,B C,D,E
-
10
~
40
°
C
100 100
50
°
C
100 50
60
°
C
50 0
70
°
C
0 -
With chassis and cover type
Convection
Average Load (%)
Mounting
Ta
A,B C,D,E
-
10
~
30
°
C
100 100
40
°
C
100 50
50
°
C
50 0
60
°
C
0 -
· Forced air cooling
PCB type and with chassis type
Forced air
Average Load (%)
Mounting
Ta
A,B,C,D,E
-
10
~
6
0
°
C
100
70
°
C
50
With chassis and cover type
Forced air
Average Load (%)
Mounting
Ta
A,B,C,D,E
-
10
~
5
0
°
C
100
6
0
°
C
50
*Recommended minimum air velocity : 0.7m/s
( Measured at component side of PCB, air must flow
through component side).
0
20
40
60
80
100
-10 0 10 20 30 40 50 60
Ta (°C)
LOAD (%)
0
2 0
4 0
6 0
8 0
1 0 0
-1 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0
T a (°C )
LOAD (%)
0
20
40
60
80
100
-10 0 10 20 30 40 50 60
Ta (°C)
LOAD (%)
0
20
40
60
80
100
-10 0 10 20 30 40 50 60 70
Ta (°C)
LOAD (%)
Mounting (A),(B)
Mounting (C),(D),(E)
Mounting (A),(B),(C),(D),(E)
Mounting (A),(B),(C),(D),(E)
Mounting (A),(B)
Mounting (C),(D),(E)

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TDK-Lambda
ZWD150PAF Series
INSTRUCTION MANUAL
4-2. Mounting Method
PCB type
Please use the mounting holes (5 holes of f3.5) and insert the
spacer (MAXf8.0)of height over 8mm to lift the unit. Also use
all 5 mounting holes for the unit installation. The vibration test
is taken when the unit is raised by 8mm spacers.
Please leave 4.5mm space from the unit surfaces and leave
4.5mm space from the sides of PCB. For the solder surface,
8mm space is necessary. If the space is not enough, the
specification for insulation and withstand voltage will not be
satisfied.
PE should be connected to the earth terminal of the apparatus.
If not, the EMI noise and output noise will increase.
Hatching area is maximum permissible area of metal
part for mounting.
For chassis option /L, chassis & cover option /A
Recommended mounting by following holes A or B, to meet
19.6m/s2 vibration specification. Mounting direction (F) & (G)
is prohibited as shown in section 4-1.
A: Embossed tapped and countersunk holes by 4-M4 screws
B: F4.5 holes and R2.25 slot hole by 3-M4 screws
Mounting (F), (G), (H), (I) is prohibited.
For mounting method (J), (K), (L), below, the vibration speci-
fication is 4.9m/s2, 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).
PE

- 12 -
TDK-Lambda
ZWD150PAF Series
INSTRUCTION MANUAL
C: 1-F4.5 holes and R2.25 slot hole by 2-M4 screws
D: Embossed tapped and countersunk holes by 2-M4 screws.
5. Wiring Method
 The output load line and input line shall be separated and
twisted to improve noise sensitivity.
 Use all lines as thick and short as possible to have lower
impedance.
 Noise can be eliminated by attaching a capacitor to the
load terminals.
 For safety and EMI considerations, connect FG terminal
of input connector and mountable PE to ground terminal
of equipment.
 Recommened screw torque is 0.49N.m ( 5kg.cm )
 Select the wire materials to adapt to the MOLEX and
J.S.T connector as follows.
INPUT : AWG#22 ~ #18 (Æ 0.65mm ~Æ1.05mm)
OUTPUT : AWG#22 ~ #18 (Æ 0.65mm ~Æ1.05mm)
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 is turned on. Use high breaking and 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 ac-
tual load condition.
ZWD150PAF : T5AH
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 correct.
· Check that the wire material is not too thin.
· Check if the output voltage control ( V.ADJ ) is properly
adjusted.
· If you use the Remote ON/OFF control function, make
sure the Remote ON/OFF control connector is not opened.
· Check that the output current and output wattage is not
over specification.
· Audible noise may be heard during Dynamic-Load oper-
ation.
· Audible noise may be heard when input voltage waveform
is not sinusoidal wave.
8. Repair
In case of damage of this product, please return to our service
center or factory.
9. CE MARKING/UKCA MARKING
CE MARKING
CE Marking, when applied to a product or packing
material for a product covered by this handbook, in-
dicates compliance with the Low Voltage Directive
and RoHS Directive.
UKCA MARKING
UKCA Marking, when applied to a product or pack-
ing material for a product covered by this handbook,
indicates compliance with the Electrical Equipment
(Safety) Regulations and Restriction of the Use of
Certain Hazardous Substances in Electrical & Elec-
tronic Equipment Regulations.
Input Output
Input
Input
Output
( J )
( K )
( L )