HWS300-600 Series Instr Manual Datasheet by TDK-Lambda Americas Inc

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Instruction Manual
A231-04-01H
- 1 -
TDK-Lambda
HWS300
600 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.
DANGER
Never use this product in locations where flammable gas or ignitable substances are present.
INSTALLATION WARNING
• When installing, ensure that work is done in accordance with the instruction manual. When installation is improper,
there is risk of electric shock and fire.
• Installation shall be done by Service personnel with necessary and appropriate technical training and experience.
There is a risk of electric shock and fire.
• Do not cover the product with cloth or paper etc. Do not place anything flammable around. This might cause damage,
electric shock or fire.
WARNING ON USE
• Do not touch this product or its internal components while circuit in operation, or shortly after shutdown. You may
receive a burn.
• While this product is operating, keep your hands and face away from it as you may be injured by an unexpected
situation.
• There are cases where high voltage charge remains inside the product. Therefore, do not touch even if they are not in
operation as you might get injured due to high voltage and high temperature. You might also get electric shock or
burn.
• Do not make unauthorized changes to this product nor remove the cover as you might get an electric shock or might
damage the product. We will not be held responsible after the product has been modified, changed or dis-assembled.
• Do not use this product under unusual condition such as emission of smoke or abnormal smell and sound etc. Please
stop using it immediately and shut off the product.
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 and store these products in environments where condensation occurs due to moisture and humidity.
It might lead fire and electric shock.
• Do not drop or apply shock to this product. It might cause failure. Do not operate these products mechanical stress is
applied.
CAUTION ON MOUNTING
• 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.
• Input line, please use the wires as short and thick as possible.
• Do not use this product in special environment with strong electromagnetic field, corrosive gas or conductive
substances and direct sunlight, or places where product is exposed to water or rain.
• Mount this product properly in accordance with the instruction manual, mounting direction and shall be properly be
ventilated.
• Please shut down the input when connecting input and output of the product.
• When installing in environment where conductive foreign, dust and liquid may be present,
please consider penetration of above foreign material in the power supply by installing filter, to prevent trouble or
malfunction.
HWS300
600 Series
Instruction Manual
- 2 -
TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
CAUTION ON USE
• Before using this product, be sure to read the catalog and instruction manual. There is risk of electric shock or damage
to the product or fire due to improper use.
• Input voltage, Output current, Output power, ambient temperature and ambient humidity should be kept within
specifications, otherwise the product will be damaged, or cause electric shock or fire.
• If the built-in fuse is blown, do not use the product even after replacing the fuse, as there is risk of abnormality inside.
Be sure to request repair to our company.
• For products without built-in protection circuit (element, fuse, etc.), insert fuse at the input to prevent smoke, fire during
abnormal operation.
As for products with built-in protection circuit, depending on usage conditions, built-in protection circuit might not work.
It is recommended to provide separate proper protection circuit.
• For externally mounted fuse do not use other fuses aside from our specified and recommended fuse.
• This product was made for general purpose electronic equipment use and is not designed for applications requiring
high safety (such as extremely high reliability and safety requirements. Even though high reliability and safety are not
required, this product should not be used directly for applications that have serious risk for life and physical safety.
Take sufficient consideration in fail-safe design (such as providing protective circuit or protective device inside the
system, providing redundant circuit to ensure no instability when single device failure occurs).
• When used in environments with strong electromagnetic field, there is possibility of product damage due to malfunction.
• When used in environment with corrosive gas (hydrogen sulfide, sulfur dioxide, etc.) , there is possibility that they might
penetrate the product and lead to failure.
• When used in environments where there is conductive foreign matter or dust, there is possibility of product failure or
malfunction.
• Provide countermeasure for prevention of lightning surge voltage as there is risk of damage due to abnormal voltage.
• Connect together the frame ground terminal of the product and the ground terminal of the equipment for safety and noise
reduction. If these ground is not connected together, there is risk of electric shock.
• Parts with lifetime specifications (built-in fan electrolytic capacitor) are required to be replaced periodically. Set the
overhaul period depending on the environment of usage and perform maintenance.
Also, note that there are cases when EOL products cannot be overhauled.
• Take care not to apply external abnormal voltage to the output. Especially, applying reverse voltage or overvoltage more
than the rated voltage to the output might cause failure, electric shock or fire.
NOTE
• Take note that traces of sheet metal processing be left in our power supplies.
• When disposing product, follow disposal laws of each municipality.
• Published EMI (CE, RE) or immunity is the result when measured in our standard measurement conditions and might not
satisfy specification when mounted and wired inside end-user equipment.
Use the product after sufficiently evaluating at actual end-user equipment.
• When exporting our products, apply for necessary permissions as required by rules and regulations of Foreign Exchange
and Foreign Trade Control Act.
• Catalogue, contents of the instruction manual may be changed without a prior notice. Refer to latest catalogue or
instruction manual.
• Reproduction or reprinting the instruction manual or its portion is forbidden without our permission.
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TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
LONG-TERM STORAGE METHOD AND PERIOD
• Please keep the product in carton box.
• Please do not apply excessive vibration, shock or mechanical stress applied directly to the product.
• Please keep away from direct sunlight.
• For long-term storage temperature and humidity, the following conditions shall be used as a guideline :
Temperature range : 5℃30℃
Humidity range : 40%60%RH
Please keep away from the places where temperature and humidity can change drastically.
It can cause condensation on the product or deterioration.
• For long-term storage period, we recommend to use within 2 years after receiving the product.
There is tendency that the leakage current of an aluminium electrolytic capacitor may increase when stored without using
for a long time.
This phenomenon can be improved by applying voltage to the aluminium electrolytic capacitor to reduce the increased
leakage current through the self-recovery effect of the electrolyte.
For reference, before using products that have been stored for a very long time, please warm-up first for 30 minutes or
more without taking load.
< Criterion of warm up voltage condition >
(1)Implementation period : 1 year or above after the delivery
(2)Electrical continuity condition
Input voltage : Rating
Load : 0A
Ambient temperature : Normal temperature
Time : 30 minutes or more
4,,
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TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
1. Model name identification method
HWS 300 – 5 /
Option (*1) (*1)
/ “No assigned” : Standard type
Rated Output Voltage /PV : Output voltage can be controlled
by external voltage.
Output Power type (Only 12 – 48V output model)
Series name
2. Terminal Explanation
Please pay extra attention to the wiring. Incorrect connection will damage the power supply.
2-1. Front Panel Explanation
HWS300 HWS600
V.ADJ : Output voltage adjustment trimmer.
(The output voltage rises when a trimmer is turned clockwise.)
ON : Output (Power On) indication LED
(The indicator turns on when the power supply output is in normal operating condition.)
CN1, CN2 : Remote sensing, ON/OFF control signal, Current balance signal, Power fail signal,
Output voltage external control signal. (Refer to 2-2.)
: Earth ( ) terminal, M4 screw.
AC input terminal L : Live Line (Fuse in line), M4 screw.
AC input terminal N : Neutral line, M4 screw.
+ : + Output terminal
(HWS300: M4 screw x 2 / HWS600: M5 screw x 2)
- : - Output terminal
(HWS300: M4 screw x 2 / HWS600: M5 screw x 2)
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TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
2-2. CN1, CN2 Connector pin Configuration and Function
CN1 and CN2 are same pin configuration and function.
They are connected to each other in this power supply unit.
When the pin of CN1 side is shorted, the same function pins of CN2 side are also shorted.
Please note that the function cannot be separately set with CN1 and CN2.
Pin No.
Configuration
Function
1 Vm +Output monitor terminal. Connected to +Output terminal in this Power supply unit.
( +Vm terminal cannot supply load current. )
2 S
Remote sensing terminal for +output.
(For remote sensing function, which compensates for line drop between power supply terminals
and load terminals. Connect to +Vm terminal when remote sensing function unnecessary. )
3 Vm -Output monitor terminal. Connected to -Output terminal in this Power supply unit.
( -Vm terminal cannot supply load current. )
4 S
Remote sensing terminal for -output.
(For remote sensing function, which compensates for line drop between power supply terminals
and load terminals. Connect to -Vm terminal when remote sensing function unnecessary. )
5 PC Current balance terminal.
( For output current balancing in parallel operation. )
6 COM GND for PC and PV signals.
7 PV
( Optional )
Output voltage external control terminal.
( For power supply output voltage control with an external voltage.
Standard Model don’t have this function and indicate NC mark at panel.
8 NC No connect
9 CNT Remote ON/OFF control terminal.
( Power supply ON/OFF control with an external signal. )
10 TOG GND for CNT and PF signals. ( Same as Pin No.12 )
11 PF
Power fail signal (PF signal) output terminal.
( As the output voltage drops, or FAN stops and AC input voltage down, “Power Fail” terminal
will output “High”.
12 TOG GND for CNT and PF signals. ( Same as Pin No.10 )
CN1, CN2 Connector & Housing & Terminal Pin
PART DESCRIPTION PART NAME MANUFACT
PIN HEADER S12B-PHDSS JST
SOCKET HOUSING PHDR-12VS JST
TERMINAL PINS SPHD-002T-P0.5(AWG28~24)
SPHD-001T-P0.5(AWG26~22)
JST
HAND CRIMPING TOOL YRS-620(SPHD-002T-P0.5)
YC-610R(SPHD-001T-P0.5)
JST
CN1
1
3
5
7
9
11
4
2
6
8
10
12
CN2
1
3
5
7
9
11
4
2
6
8
10
12
4,, 7—7 v:
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TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
3. Terminal Connection Method
Please pay extra attention to the wiring. Incorrect connection will damage the power supply.
· When connecting input and output wiring, and CN1, CN2, input AC-Line should be off.
· Input wiring and output wring shall be separated to improve noise sensibility.
· The protective earth (PE) must be connected to the terminal or chassis.
· Remote sensing lines shall be twisted or used shielded wired.
· Remote ON/OFF control lines shall be twisted or used shielded wires. Separate from load line.
· Output current of each terminal screw shall be less than 40A for HWS300. And shall be less than 60A for HWS600.
HWS300 Panel Side (Common HWS600)
Basic connection (Local sensing)
Connect “+S” terminal to “+Vm” terminal and
“-S” terminal to “-Vm” terminal. Connect
“CNT” terminal to “TOG” terminal with the
attached connector.
ON/OFF control required
“TOG” terminal is ground for “CNT” terminal.
Remote sensing required
Connect “+S” terminal to “+” terminal of load and “-S”
terminal to “-” output terminal of load with wires.
PF signal output required
Open collector method shown below shall be used.
“TOG” terminal is ground for “PF” terminal.
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TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
4. Functions and Precautions
4-1. Input Voltage Range
Input voltage range is single phase 85 ~ 265VAC (47 ~ 63Hz) or 120 ~ 330VDC. Input voltage, which is out of
specification, may cause unit damage. Rated input voltage for safety standard application is 100AC-240VAC(50/60Hz).
4-2. Output Voltage Range
Output voltage is set to the rated value at shipment. V.ADJ trimmer on the front panel side is may be used to adjust the
output voltage within the range specified.
Output voltage range is within ±20% of rated output voltage (48V Output Model : -20% ~ +10%).
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 output voltage will be shut down.
4-3. Over Voltage Protection (OVP)
The OVP function (Inverter shutdown method, manual reset type) is provided. OVP function operates within 125-145%
of the rated output voltage value (48V type: 115-135%), and the output will be shut down when OVP function triggers.
To reset OVP, remove the input of power supply for a few minutes, and then re-input. Or, use CNT reset ( remote
ON/OFF : OFF to ON). OVP value is fixed and not to be adjusted externally.
Never apply more than rated output voltage to output terminal, which may leads damage. In the case of inductive load,
use decoupling diode at output line.
4-4. Over Current Protection (OCP)
The OCP function is provided. OCP characteristic is constant current limiting, (less than 5V output model: with Hiccup
operation) automatic recovery. OCP function operates when the output current exceeds 105%(24V output model: 119%)
of maximum DC output current specification. The output will be automatically recovered when the overload condition is
canceled. Never operate the unit under over current or shorted conditions for more than 30 seconds, which may leads
damage. OCP setting is fixed and not to be adjusted externally.
4-5. Over Temperature Protection (OTP)
The OTP function (manual reset type) is provided. When ambient or internal temperature rises abnormally, OTP
function operates and output will be shut down. After shut down, remove the input and cool it down to reset OTP.
Then re-input.
4-6. Low Output Detection Circuit (PF)
Low output voltage detection circuit is provided. Power Fail (PF) signal will turn “High” level to indicate the abnormal
status when the output voltage becomes within 65 ~ 80% of rated value caused by either the drop or brownout of the
input voltage or OCP, OVP and OTP function operation. When the built-in FAN motor of this power supply unit stops,
PF signal will turn to “H”. The PF signal is isolated from input and output by a photo-coupler. It uses the open collector
method shown in below.
PF
TOG
VCE max=30V
IC max=20mA
he made of control erminu]
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TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
4-7. Remote Sensing (+S, -S terminal)
This function compensates voltage drop of wiring from output terminals to load terminals. Connect “+S” terminal to “+”
terminal of load and “-S” terminal to “-” terminal of load with sensing wires. The total line voltage drop (+ side line and
- side line) shall be less than 0.3V. In case that sensing lines are too long, it is necessary to put an electrolytic capacitor in
following 3 placed;
1) across the load terminal,
2) between “+S” terminal and “+” terminal,
3) between “S” terminal and “”terminal.
When the function of remote sensing is not in used, connect +S terminal to +Vm terminal, and –S terminal to –Vm
terminal by the attachment connector.
If remote sensing terminals are opened, the stability and the accuracy of the output deteriorated. Therefore, terminal
+S, -S must be connected.
4-8. Remote ON/OFF Control
Remote ON/OFF control is provided.
Using this function, output on/off is allowed to control without input voltage on/off. The output is turned to ON when
TOG and CNT terminals are shorted, and the output is turned to OFF when these terminals are opened. When the
function is not used, connect TOG and CNT terminals. The standards for this function are as follows. “TOG” terminal is
return for “CNT” terminal.
(1) TTL compatible. The maximum input voltage to CNT terminal is 12V, and the maximum allowable reverse voltage
is -1V. The sink current for CNT terminal is 3.5mA.
(2) A switch and relay or a transistor can be used as ON/OFF switch.
(3) Remote ON/OFF control circuit is isolated from the input and output by a photo-coupler and can be controlled
regardless of the output potential (+ or -). Connect TOG terminal to ground of control signal.
The mode of control
CNT Level for TOG Terminal
Output Built-in Fan
Short or L (0V - 0.8V) ON Rotate
Open or H (2.4V - 12V) OFF Stop
+
+
+
-
-S
+S
Load
Power
Supply
+
+
-
CNT
TOG
3.5mA
Relay, Transistor,
TTL, etc.
Sink Current
50 47 j 3 3 3 m m ,,m ,m $5,», flee»,
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TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
4-9. Output Ripple & Noise
The standard specification for maximum ripple value is measured specified measurement circuit (JEITA-RC9131A).
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 measure accurately if the probe ground lead of
oscilloscope is too long.
4-10. Series Operation
For series operation, both method (A) and (B) are possible.
There might be a step in the output rise waveform during series operation.
Method (A) Method (B)
+
-
Power
Supply
Coaxial Cable
1.5m 50Ω
Load
R:50Ω
C:4700pF
C
ROscillo-
scorp
100MHz
+Vm
-Vm
Load
Power Supply
-S
+S
+Vm
-Vm
-S
+S
+Vm
-Vm
Load
Power Supply
-S
+S
+Vm
-Vm
-S
+S
Load
+Vm 3‘ 9-— ,:v.“ 3 PC can lg] (+3 er ] é) Eb
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TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
4-11. Parallel Operation
Current balancing function is provided. Both operations mode (A) and (B) are possible.
(A) To Increase the Output Current
Connecting PC to PC terminal and COM to COM terminal, the current balancing function activates and output current
of each power supply is equivalently supplied to load. Wires to PC terminals, COM terminals shall be as short as
possible and same length and twisted.
There is a possibility that output could be unstable caused by external noise. For this case, disconnect COM terminal and
connect -S terminal from parallel power supply to a single point on the load. Please refer connection Method (A)-2.
1. Adjust the output voltage of each power supply to be same value within 1% or 100mV whichever is smaller.
2. Use same length and type of wires for all load lines.
3. Use the power supply within the rated output current for all paralleled models.
4. Parallel operation is possible up to 5 units.
(B) To Use as a Backup Power Supply
1. Adjust the output voltage of each power supply to be same value.
2. Set power supply output voltage higher by the forward voltage drop of diode.
3. Use within the specifications for output voltage and output current.
Method (A) Method (A)-2
Method (B)
PC
+Vm
-Vm
PC
Load
Power Supply
-S
+S
COM
COM +Vm
-Vm
-S
+S
+Vm
-Vm
Load
Power Supply
-S
+S
+Vm
-Vm
-S
+S
Output Power(W)=(Vo+Vf) x Io
Vo+Vf
Vo+Vf
Vo
Io
PC
+Vm
-Vm
PC
Load
Power Supply
-S
+S
COM
COM
+Vm
-Vm
-S
+S
WP “F wk wk
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TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
4-12. Isolation Test
Isolation resistance between output and (chassis) shall be more than 100MΩ at 500VDC and between output and
CNTPF shall be more than 10MΩ at 100VDC. 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 ~ (chassis) : 500VDC 100MΩ or more Output ~ CNT · PF : 100VDC 10MΩ or more
4-13. Withstand Voltage
This series is designed to withstand 3.0kVAC between input and output, 2.5kVAC between input and (chassis),
500VAC between output and (chassis), and 100VAC between output and CNTPF terminal each for 1 minute. When
testing withstand voltage, set current limit of withstand voltage test equipment at 20mA.
(Output- (chassis) and Output-Control: 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) : 3.0kVAC 1min. (20mA)
Input ~ (chassis) (solid line) : 2.5kVAC 1min. (20mA)
AC(L)
AC(N)
Withstand
Voltage
Tester
+S
+
Vm
+
-
-
Vm
-S
PC
COM
PV
CNT
TOG
PF
AC(L)
AC(N)
+S
Isolation
Tester
+
Vm
+
-
-
Vm
-S
PC
COM
PV
CNT
TOG
PF
AC(L)
AC(N)
+S
Isolation
Tester
+
Vm
+
-
-
Vm
-S
PC
COM
PV
CNT
TOG
PF
w.“ 3 (+3 69 9“ Vin j 9 Loud Currem
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TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
Output ~ (chassis) : 500VAC 1min. (100mA) Output ~ CNT· PF : 100VAC 1min. (100mA)
*This product have monolithic ceramic capacitor in secondary circuit to frame ground.
Some of the withstand voltage tester may generate high voltage at the matching with monolithic ceramic
capacitor and may cause the unit damage.
So, please check the waveform of test voltage.
4-14. Output Voltage External Control (PV)
Output voltage external control function is available as option with model name followed by “/PV”. Output voltage can
be varied by applying an external voltage (1 - 6V) to “PV” terminal and “COM” terminal. Note if an external voltage is
not applied, there will be no output. Please consider the following characteristics.
Note 1. Regarding output voltage adjustment below 20%, please consult our sales.
Note 2. For 48V output model only, spaces below must be followed. Limit output voltage variation range at 20% ~ 110%.
At PV voltage variation 1V ~ 5.5V.
AC(L)
AC(N)
Withstand
Voltage
Tester
+S
+
Vm
+
-
-
Vm
-S
PC
COM
PV
CNT
TOG
PF
AC(L)
AC(N)
Withstand
Voltage
Tester
+S
+
Vm
+
-
-
Vm
-S
PC
COM
PV
CNT
TOG
PF
+Vm
-Vm
Load
Power Supply
-S
+S
COM
PV
External voltage
Connection method
Output Voltage Derating
100% 83%
Voltage
Nominal
Output
0
20%
110%
120%
90%
Load Current
Output Voltage
Output Voltage Linearity
5.5V
6V 5V
Voltage
Nominal
Output
0
20%
1V
110%
120%
PV voltage (Nominal Input Voltage)
Output Voltage
mm? (9:2.- A '0’], <——> OO 00 ] ‘—‘—‘8 OO 00
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TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
4-15. Output Peak Current
For 24V output model, please meet the following condition. Reduce peak current value according to output derating as
section 5-1.
Input Voltage range : AC180V~265V
Continuous Peak output time (τ) : Within 10 seconds
Peak output current (Ip) : Within the rated peak output current
Average DC output current (Im) : Within the rated output current
Ip : Peak output current (A)
Iav : Rated output current (A)
Im : Average output current (A)
τ : Peak current pulse width (sec)
T : Period (sec)
5. Mounting Directions
5-1. Output Derating according to the Mounting Directions.
Recommended standard mounting method is (A). Method (B) is also possible.
Refer to the derating below.
HWS300
(A) (B) (C) Inhibit (D) Inhibit
HWS600
(A) (B) (C) Inhibit (D) Inhibit
(Ip-a) x τ
T
Im = + a < Iav
Duty = x100 (%)
τ
T
0A
Im
Ip
τ
T
Standard
Mounting
Standard
Mounting
Duty up to 35(%)
aA
- 14 -
TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
70
50 40 20 0
-10
Ambient Temperature ()
40
80
60
0
20
100
Load (%)
5-2. Output Derating
5-3. Mounting Method
(1) Forced air cooling type power supply.
This power supply has ventilating holes on the front
and back side panels. Keep these two areas freely as
much as possible.
(2) The maximum allowable penetration is 6mm.
Incomplete thread of mounting screw should not be
penetrated.
(3) Recommended torque for mounting screw :
M4 screw : 1.27 N · m( 13.0kgf · cm )
6. Wiring Method
(1) The output load line and input line shall be separated to improve noise sensitivity.
(2) The sensing lines shall be twisted and separated from the output lines for remote sensing.
(3) Use all lines as thick and short as possible to make lower impedance.
(4) Attaching a capacitor to the load terminals can eliminate noise.
(5) For safety and EMI considerations, connect terminal to the mounting set ground terminal.
(6) Recommended torque for the terminal ;
HWS600 Output terminal (M5 screw) : 2.50 N · m (25.5kgf · cm )
HWS300 Input, Output terminal & HWS600 Input terminal (M4 screw) : 1.27 N · m (13.0kgf · cm )
[ The PHD connector manufacture method ]
This product is using SPHD-001T-P0.5 or SPHD-002T-0.5 connector made from JAPAN SOLDERLESS TERMINAL
MFG CO LTD.
Regarding to manufacture of a connector, it becomes the regulation as following.
a). Appricable Wire and Crimping tool
Wire size is AWG#26 ~ AWG#22 and insulation outer dia is φ1.0 ~ φ1.5 mm.
Appreciable wire per barrel size is UL1007 (standard wire ) and its equivalent standard wire can be used.
Regarding the AWG#22, use UL1061 or its equivalent standard wire,because wire insulation outer diameter
of UL1061 is samll.
Crimping tool is as below.
Crimping tool Crimping applicator Dies
AP-K2 or AP-KS MKS-LS-10 or MKS-L-10 SPHD-001-05/SPHD-002-05
Ta()
Load (%)
Mounting(A) Mounting(B)
-10 ~ +50
100
+70 50
More than 50mm M ore than 50mm
Fan
Front Side
Air flow
Top
Back Side
Mounting A,B
fl M ere conductor pmlmdmg Vengm is \ong Lfiéfl era barre‘ bites wire nsmauon er conduncr protruding lengm \s shun Wire msmallun ‘5 nm crimved suffimenfly Wue condumuy comes an
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TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
b). Crimping Operation
The reference value of wire strip is 2.3mm. As wire strip length differs depending on type of wire and crimping method,
decide the best wire strip length considering processing condition. When wire is stripped, do not damage or cut off
wire conductores.
Table of crimp height
SPHD-001T-P0.5
Wire Insulation O.D (mm)
Crimp height (mm)
Type Size Conductor part Insulation part
UL1007
AWG #26
1.3 0.60 ~ 0.70 1.7
UL1007
AWG #24
1.5 0.65 ~ 0.75 1.8
UL1061
AWG #22
1.4 0.70 ~ 0.80 1.8
SPHD-002T-P0.5
Wire Insulation O.D (mm)
Crimp height (mm)
Type Size Conductor part Insulation part
UL1007
AWG #28
1.2 0.55 ~ 0.60 1.6
UL1007
AWG #26
1.3 0.60 ~ 0.65 1.7
UL1007
AWG #24
1.5 0.62 ~ 0.67 1.8
Note 1. Crimp height at wire barrel should be set to pre-determined dimensions.
Note 2. Adjust crimp height at wire insulation barrel to the extent that wire insulation is slightly pressed,
and set it so that crimping is not excessivery.
Note 3. Crimping condition at wire insulation barrel is as below Fig.1.
Note 4. For AWG#28,#26,#24, use UL1007 type. For AWG#22, use UL1061 type.
Fig.1 Fig.2: Examples of defective crimping
Check of crimping appearance visually for correct crimping as referring to above Fig.2
Check the tensile strength at crimped part when operation finishes.
Table of tensile strength at crimped part.
SPHD-001T-P0.5
Wire size Requirement N min. Actual value N
UL1007 AWG#26 20 39.2 ~ 45.1
UL1007 AWG#24 30 68.6 ~ 74.5
UL1007 AWG#22 40 92.1 ~ 96.0
SPHD-002T-P0.5
Wire size Requirement N min. Actual value N
UL1007 AWG#28 15 27.034.3
UL1007 AWG#26 20 44.148.0
UL1007 AWG#24 30 66.671.5
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- 16 -
TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
c). Inserting contact into housing
Inserting crimped contact into housing
(1) Do not apply any pulling force to crimped part, and insert contact parallel to housing
(2) Insert contact into housing without stopping to innermost
(3) Check secure locking per each insertion by pulling wire softly in order to check that contact does not come off
housing. Besides, check whether there is the backlash in the direction of insertion axis.
Defect example of slation insertion
d). Mating and Unmating Connector
(1) Inserting connector
Hold receptacle housing securely and insert into header straight against to header post until click sounds.
(2) Unmating connector
Hold all wires securely and fix receptacle housing by fingers so as to pry, and then, withdraw it on the mating axis.
e). Routing of Wire
Routing wire so as not to apply external force to connector except force to such an extent that wire slightly buckles,
considering an enough length to route and fixing of wire.
7. The life expectancy
The life of the power supply depends on the life of the built-in aluminum electrolytic capacitor being used and fan
mounted products will depend on fan life. Each life is described in reliability data.
The life of the aluminum electrolytic capacitor varies depending on the method of mounting the power supply, the load current,
and the ambient temperature. Please refer to “Electrolytic Capacitor Lifetime”.
The life of the fan depends on the fan intake or exhaust temperature. Please refer to “Fan Life Expectancy.
Please do not use the product which passed over the life expectancy. There is a risk of unexpected output shutdown and
specifications may not be satisfied.
Please contact us for maintenance or exchange the product which passed over the life expectancy.
8. 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 or time-lag type fuse, not 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.
HWS300 : 10A
HWS600 : 15A
- 17 -
TDK-Lambda
HWS300
600 Series
INSTRUCTION MANUAL
9. Fan life expectancy
The Fan-life has limitation. Therefore, periodic maintenance by exchanging the life-expired fan is required for the
power supply. The following figure shows the life of fan.
The difference between the intake temperature and the exhaust temperature of the Power supply at Io=100% :
HWS300 : 4℃
HWS600 : 8
10. Before concluding that the unit is at fault…
Before concluding that the unit is at fault, make the following checks.
(1) Check if the rated input voltage is connected.
(2) Check if the wiring of input and output is correct.
(3) Check if the I/O terminal connection is properly tighten by regulated torque.
(4) Check if the wire thickness is enough.
(5) Check if the output voltage control (V.adj) is properly adjusted. OVP might be trigged and output is shut down.
(6) If use function of the Remote ON/OFF control, check if the Remote ON/OFF control connector is not opened.
If in open condition, power supply will not output.
(7) Check if the built-in FAN is not stopped. Is FAN stopped by something irregulars or etc?
If FAN stops, the PF signal turn “High’’ level and OTP might be activated.
(8) Power supply has ventilating holes on the front and back panels. Check if there is any irregulars or dust, etc.
(9) Is the chassis of power supply hot abnormally? The output is shut down by OTP operation.
Please re-input after the unit to cool down sufficiently.
(10) Check if the output current and output wattage does not over specification.
(11) Audible noise can be heard when input voltage waveform is not sinusoidal.
(12) Audible noise can be heard during dynamic load operation.
11. Warranty Period
This product is warranted for a period of 5 years from the date of shipment.
For damages occurring at normal operation within this warranty period, repair is free of charge.
Please read the General Safety Instruction before using the products.
1
10
0 50 100
Fan exhaust temperature ()
Life expectancy (year)
HWS600
HWS300
Air Flow
Measuring point
Measurement point of fan exhaust temperature
50mm
P.S.

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