Operation Manual HWB Series Switch Mode Power Supply PAN40001-001EA00-OM SANKEN ELECTRIC CO., LTD. http://www.sanken-ele.co.jp/en/ December 2012 Table of Contents Safety Precautions Appearance and Meaning of Safety Warnings Hazard and Caution Safety Warnings 3 4 4 Introduction to HWB Series 6 Product Models 7 Model Number Description 10 Input and Output Terminals, Connectors, and Pin Assignments 10 Functional Description Parallel operation Series operation Remote On/ Off 11 11 11 12 Installation Mounting Derating 13 13 14 Characteristic Performance 15 Specifications and Standards 16 This paper is prepared as of Dec. 2012 and subject to change without notice. PAN40001-001EA00-OM SANKEN ELECTRIC CO., LTD. 2 December 2012 Safety Precautions Be sure to observe the precautions explained below. 1. Be sure to read this complete document and the detailed specifications of the individual products in the product series before using the product. 2. The products should be handled only by persons who have competent electrical knowledge. 3. The products are DC stabilized power supplies with special structures created for mounting inside of protective electrical device enclosures. Use only when properly mounted in protected device enclosures. 4. Although Sanken strives to improve the quality and the reliability of the products, please implement safety designs that comply or exceed all industry standards and all of the regulatory requirements of the jurisdictions where the products will be used. Safety designs for use of the products are the responsibility of the customer or user. The customer or user has the responsibility not to endanger human life or health, or to damage property due to malfunction and/or failures of the products when using them. 5. When considering use of the products for the following equipment and applications, for which there is enhanced risk that the products could endanger human life or affect property maintenance or public functions, be sure to secure suf- PAN40001-001EA00-OM ! ficient fail-safe functionality of the customer or user devices by means of system redundancies and other methods: • Medical equipment, etc. that could directly endanger human life • Electric trains and other conveyances such as elevators, etc. that could result in personal injury • Vehicles and vessels, etc. that could be affected by vibration or shock • Traffic systems, etc. that could exert an important influence on society and the public • Any other applications and equipment similar to those mentioned above. 6. Be sure to observe the items below: • Do not disassemble, repair, or modify these products. • Do not touch inside of the products because of high voltage. • Use the products within the specified input voltage, frequency, output voltage, and output current ranges. • Be sure to observe designated ambient environment conditions, such as ambient temperature and relative humidity. • Each product model has a designated method for installation and mounting. Observe installation and mounting instructions. SANKEN ELECTRIC CO., LTD. 3 December 2012 Appearance and Meaning of Safety Warnings In this document, the levels of safety warnings are divided into two categories, Hazard and Caution. ! Disregarding a Hazard display and incorrectly using the product could result in death and/or serious injury. Hazard ! Prohibited action ! Disregarding a Caution display and incorrectly using the product could result in personal injury and/or physical damage. Strong warning Electric shock hazard Caution Be sure to observe the safety precautions indicated on the product and in documentation by symbols and text. The general meaning of symbols is as follows: Fire hazard Hazard and Caution Safety Warnings General Cautionary Notices ! Hazard • Shock hazard • Never take off the cover. • There is a high voltage circuit inside and touching it mistakenly could result in death and/or serious injury. • Fire hazard • If any abnormal odor or abnormal noise, or smoking or ignition arises in the product, immediately turn off the product and cut the power input to the product by opening an external circuit breaker or other means. • Please contact the vendor from which the product was purchased and/or Sanken. • In case of fire, use a fire extinguisher of a powder/ABC type approved for use on electrical fires. Note: Never use water. PAN40001-001EA00-OM SANKEN ELECTRIC CO., LTD. 4 December 2012 Other Precautions ! Caution Each power supply model has a designated input/output range. Be sure to use the products within designated input/output range. ! Be sure that the total power consumption connecting with the load does not exceed the rated output capacity per each power supply. If a power supply is used under an overload condition, it could cause fire. Be sure to use thick wire for input/output wiring, and that it is appropriate for the input/output power. If thin wires are used, it could cause fire. Be sure not to use and/or store the products in temperature, humidity, and dew condensation conditions beyond the ambient environmental conditions specified in the catalog and/or operation manual, otherwise failure of the products could result. ! When the power supply is operated in dusty conditions, please apply dust proofing measures. The dust could interfere heat dissipation and cause failure and/or fire. ! When the power supply is installed, be sure to use designated screws (paying particular attention to screw length and diameter), otherwise electric shock and/or fire could result. The products are not intended for use in equipment that requires high reliability for sustaining human life. Be sure not to use the products for any particular application such as in nuclear reactor and/or power control systems, aerospace applications, special Medical equipment, and so forth. ! When installing the products, be sure to connect each input terminal and output terminal without fail, otherwise malfunction and damage to the products, personal injury, and fire could result. Be sure not to apply any external voltage to output terminals of the products, otherwise damage to the internal devices of the products could result. Be sure not to use and/or store the products in an environment with corrosive gases such as hydrogen sulfide, sulfur dioxide, and so forth, otherwise damage to the products could result. When operating the products in an environment with interference from radio waves, electric fields, or magnetic fields, the products may malfunction, which could lead to failures. Be sure not to use the products under such conditions. ! Although Sanken strives to improve the quality and the reliability of the products, the customer and user are responsible to be sure to apply safe design of their equipment before using the products. PAN40001-001EA00-OM SANKEN ELECTRIC CO., LTD. 5 December 2012 Introduction to HWB Series General Description The HWB series employs proprietary Soft-switched Multiresonant Zero-cross (SMZ) type resonant-mode circuits to achieve large noise reduction in the converter unit. Moreover, this is a switching power supply which has realized ultra-low noise (ripple voltage, conducted emission, and noise electric field strength) like a dropper power supply, employing a proprietary resonant mode hybrid IC and transformer. Applications include: • Medical equipment • Measuring equipment, semiconductor manufacturing equipment, testing equipment, and control equipment • Equipment that has a dropper power supply installed Features and options • Low ripple voltage 5 mV(p-p) or less (measured with a 100 MHz oscilloscope. Spike element excluded) • Low conducted emission Approximately 20 dB margin for VCCI Class B, FCC Class B, and CISPR Class B • Low noise electric field strength Complies with VCCI Class B, FCC Class B, CISPR Class B Single output models (cover optional) HWB015x 15 W HWB030x 30 W Cover PAN40001-001EA00-OM • World-wide input range 85 to 264 VAC continuous input or 85 to132 VAC, 170 to 264 VAC automatic switching (HWB060S) • Compact, lightweight, low price Volume and weight are approximately a quarter of a dropper type, and price is approximately a half • CE marking compatible Acquired CE mark for Low Voltage Differential • Safety standards ▫ Acquired UL60950-1, CSA60950-1, TUV(EN60950-1) ▫ Acquired TUV(EN60601-1), UL60601-1 ▫ M option type supports medical equipment • Parallel operation Made possible by adjusting overcurrent protection (HWB060S) • Options ▫ C: Cover (Output derating required) ▫ M: Supports medical equipment, with low leakage current 50 μA or less (standard: 0.25 mA or less) ▫ R: Output remote on/off control using external voltage control • Free warranty on parts for 3 years HWB060x 60 W Dual Output SANKEN ELECTRIC CO., LTD. 6 December 2012 Product Models LED operation display Output voltage adjuster Clear plastic protector 110 Optional cover 92 +V –V NC or RC ~L ~N (6X)M4 X 8 9 Side View (10.8) 129 (2X)M4 Mounting Screw Holes 34 35 (with cover) 4.5 Mounting Hole 4 15 W Single Output Models: HWB015S-05 (5 V), HWB015S-15 (15 V) Weight: 350 g typical LED operation display Output voltage adjuster 14 110±0.3 4.5 12.5±0.3 27.5±0.3 Label Clear plastic protector 110 Optional cover 92 +V 0V –V NC or RC ~L ~N (7X)M4 X 8 9 (10.8) 129 Models: HWB015D-15 (15 V) Weight: 350 g typical PAN40001-001EA00-OM (2X)M4 Mounting Screw Holes 34 35 (with cover) 4.5 Mounting Hole 15 W Dual Outputs Side View 4 14 110±0.3 SANKEN ELECTRIC CO., LTD. 4.5 12.5±0.3 27.5±0.3 Label 7 December 2012 LED operation display Output voltage adjuster Clear plastic protector 136 Optional cover 92 +V –V NC or RC ~L ~N (6X)M4 X 8 9 Side View (10.8) 155 (2X)M4 Mounting Screw Holes 34 35 (with cover) 4.5 Mounting Hole 30 W Single Output 4 Models: HWB030S-05 (5 V), HWB030S-12 (12 V), HWB030S-15 (15 V) Weight: 380 g typical LED operation display Output voltage adjuster 14 136±0.3 4.5 12.5±0.3 27.5±0.3 Label Clear plastic protector 136 Optional cover 92 +V 0V –V NC or RC ~L ~N (7X)M4 X 8 9 (10.8) 155 Models: HWB030D-15 (15 V) Weight: 410 g typical PAN40001-001EA00-OM (2X)M4 Mounting Screw Holes 34 35 (with cover) 4.5 Mounting Hole 30 W Dual Outputs Side View 4 14 136±0.3 SANKEN ELECTRIC CO., LTD. 4.5 12.5±0.3 27.5±0.3 Label 8 December 2012 LED operation display Output voltage adjuster Optional cover Clear plastic protector 170 92 +V –V NC or RC ~L ~N (6X)M4 X 8 10 Side View (9.8) 190 (2X)M4 Mounting Screw Holes 60 W Single Output Models: HWB060S-05 (5 V), HWB060S-12 (12 V), HWB060S-15 (15 V), HWB060S-24 (24 V) Weight: 550 g typical PAN40001-001EA00-OM 38 39 (with cover) 4.5 Mounting Hole 4 14 170±0.3 SANKEN ELECTRIC CO., LTD. 4.5 12.5±0.3 27.5±0.3 Label 9 December 2012 Model Number Description Appear only if options selected HWB [NNN] [A] –[NN] [–AA] [–A] Option 2, C: Cover Option 1 M: (Medical) low leakage R: Remote on/off RM: Remote on/off and low leakage Nominal total rated output voltage Output channels D: Dual S: Single Nominal total rated output wattage Series identifier, for example, “HWB” for HWB series Options Selected R: Remote On/Off M: Medical equipment support (low leakage current) C: Cover on product – – – –C – – ● –R ● – – Suffixes (None) –R–C ● – ● –M – ● – –M–C – ● ● –RM ● ● – –RM–C ● ● ● Input and Output Terminals, Connectors, and Pin Assignments Terminal TB1 Pin Number PAN40001-001EA00-OM Name Function N AC input (neutral) 2 L AC input (live) 3 FG FG input RC (R option only) Remote On/Off input NC No connection –V Output (GND) Single Output Dual Output 1 1 2 3 4 4 5 5 – 6 0V Common 6 7 +V Output SANKEN ELECTRIC CO., LTD. 10 December 2012 Functional Description Parallel operation Parallel operation can be performed only with the HWB060S models. Please contact Sanken if you intend to perform parallel operation. Sanken provides this function as a special feature. During parallel operation, each unit must be operated within 90% of rated current. Connect Schottky barrier diodes to the units as shown in the diagram to balance the output currents of all units during parallel operation. Select diodes having withstand voltage more than the output voltage and having current capacity that is more than output current (Sanken FMJ-2303, 30V 30A recommended). TB1 HWB060S Load +V + –V GND TB1 +V HWB060S –V Note: When designing the application, be sure to provide for dissipation of the self-generated heat from the diodes. Adjust and check the output voltage of each power supply to ensure that the same voltage is reached. Use load wires with the same thickness and length to balance output power of each power supply. Series operation The HWB series can be connected in series, as shown in the diagrams. For configurations where diodes are required, select Schottky barrier diodes which are rated to handle the expected output current flow when the output voltage rises to the breakdown level. Current should not flow through the diodes during normal operation at steady state. HWB HWB TB1 TB1 +V –V Load Load +V + –V GND + HWB HWB TB1 GND TB1 Load +V +V + –V –V GND Connection example where diodes are necessary PAN40001-001EA00-OM Connection example where diodes are not necessary SANKEN ELECTRIC CO., LTD. 11 December 2012 Remote On/ Off Circuit Requirements HWB (with remote on/off option) For remote control of output on/off switching, HWB units with the R option must be used. An external power supply (5 to 24 V) also is required. An external switch is used to control the input from the external power supply. In the example diagrams, use of an optoisolator and a transistor are shown. The output is enabled by applying voltage (4.5 to 30 VDC) to the RC terminal. The range of inflow current from the external power supply is from 1.5 to 5 mA (typ). The voltage differential between the RC and –V terminals must be 30 V or less. TB1 RC –V On/Off Switching using an optoisolator HWB (with remote on/off option) TB1 Configuration Examples External Power Supply RC • For remote control of an individual HWB single output unit, connect the RC terminal to the positive terminal of the external power supply and the –V terminal to the negative terminal of the external power supply and to the GND terminal of the load. • For an individual HWB dual output unit, connect the RC terminal to the positive terminal of the external power supply and the 0V terminal to the common of the load. HWB (single output, with remote on/off option) TB1 –V On/Off Switching using a transistor ! CAUTION: If a voltage, current, or configuration that is not specified is applied, it could cause malfunction and/or damage to the power supply. Load +V RC External Power Supply + External Power Supply HWB (single output, with remote on/off option) –V TB1 GND Load +V Connection example for one HWB single output unit RC + External Power Supply –V HWB (dual output, with remote on/off option) TB1 Load +V RC HWB (single output, with remote on/off option) TB1 + +V External Power Supply 0V COM RC –V – –V Connection example for one HWB dual output unit PAN40001-001EA00-OM GND 30 V (max) – Connection example for two HWB single output units SANKEN ELECTRIC CO., LTD. 12 December 2012 Installation Mounting Adequate free air space is mandatory to allow convective airflow to cool the unit. If the cooling effect is insufficient, output could stop. • Ensure there is free airspace clearance both at the back and top of the unit. The unit must be mounted vertically to allow for convection current flow. See illustration below. • Mounting flanges are provided at the front and rear of the unit. Insert a screw at the rear of the rack shelf and slide the unit slot around the screw. Then fasten a screw through the screw hole in the flange at the front of the unit. Then tighten the rear screw to the slot. • If the product is used in a dusty environment, an air filter may be required and the filter may affect ventilation efficiency. In such situations, derating could be required. Please consult with Sanken for the details. Airflow for cooling Recommended free airspace Airflow for cooling Vertical Side (Surface must be vertical) Rack Shelf Bottom Side (Must be placed horizontally on top of rack shelf) Fastening screw hole ! Slide-in slot CAUTION: Do not insert screws into unit case; insert through mounting flanges only PAN40001-001EA00-OM SANKEN ELECTRIC CO., LTD. 13 December 2012 Derating Derating is applied to each power unit independently. To prevent the load factor from being truncated due to the derating, make sure the power unit is used within specification, considering both derating of total rated power of the unit and adjacent sources of heat or interference with cooling air flow. The derating characteristic of the products at various ambient temperatures is shown in the chart below. Derating characteristic versus ambient temperature HWB060S-05 Other Model Output Current (% of Maximum) 100 PAN40001-001EA00-OM 60 W unit without cover, and all other models 100 60 W unit with cover installed 80 70 0 0 –10 0 10 20 30 40 Ambient Temperature (°C) SANKEN ELECTRIC CO., LTD. 50 60 14 December 2012 Characteristic Performance Noise characteristics (HWB060S-15) Output Ripple Noise At Input = 100 V, output = 15 V, 2.6 A, Room Temperature Ch 1: Noise (2 mV/div), time = 10 ms/div Output Ripple Noise At Input = 240 V, output = 15 V, 2.6 A, Room Temperature Ch 1: Noise (2 mV/div), time = 10 ms/div Conducted Emissions At Input = 100 V, output = 15 V, 2.6 A, Room Temperature Conducted Emissions At Input = 240 V, output = 15 V, 2.6 A, Room Temperature Noise Electric Field Strength At Input = 100 V, output = 15 V, 2.6 A, Room Temperature Noise Electric Field Strength At Input = 240 V, output = 15 V, 2.6 A, Room Temperature PAN40001-001EA00-OM SANKEN ELECTRIC CO., LTD. 15 December 2012 Specifications and Standards Input Conditions Model 15 W Dual Output 15 W Single Output Output Power HWB 015S-05 HWB 015S-15 Allowable Input Voltage Range Input Current [1] HWB 015D-15 HWB 030S-05 0.4 A (typ) 0.5 A (typ) 0.5 A (typ) 0.7 A (typ) 0.8 A (typ) 70% 75% 75% 75% 77% Rated Frequency Output Conditions [3] HWB 030D-15 HWB 060S-05 HWB 060S-12 HWB 060S-15 HWB 060S-24 100 to 120 VAC / 200 to 240 VAC 85 to 132 VAC / 170 to 264 VAC Automatic switching 0.9 A (typ) 0.9 A (typ) 1.2 A/0.7 A (typ) 1.5 A/0.9 A (typ) 1.8 A/1.0 A (typ) 2.0 A/1.0 A (typ) 80% 75% 80% 85% 85% 5V 12 V 15 V 24 V 3.5 A 80% 30 A (100 VAC) / 60 A (240 VAC) (max) at cold start 5V 15 V ±15 V 3.0 A 1.3 A 0.65 A Output Voltage Variation 5V 12 V 15 V ±15 V Rated output voltage +10%, –5% (dual output model; interlocked ± voltage variation) Rated Output Current 6.0 A 3.0 A Allowable Output 2.6 A 1.3 A 10.0 A 5.2 A 5.2 A 39 W 50 W 62 W 78 W 0% to 100% Current Range [7] Maximum Output Power 15 W 19.5 W 19.5 W 30 W 36 W 39 W 84 W Ripple [4,7,8] 5 mVP-P 10 mVP-P Ripple Noise [4,7] 10 mVP-P 20 mVP-P Constant Voltage Accuracy[5,6,13] ±3% ±5% Leakage Current Output Holding Time ±3% ±5% ±3% 0.25 mA (max); option M 50 μA (max) Startup Time 1 second (typ) 20 ms (min) at rated output power (15 W) Overcurrent Protection Overvoltage Protection[9] Remote Sensing Remote On/Off Control[12] Operations Display 20 ms (min) at rated output power (15 W) LED lights (green) Operating Humidity Range 30% to 90% (no condensation) Storage Humidity Range 30% to 90% (no condensation) Natural air cooling 10 to 55 Hz Sweep Time 3 minutes Acceleration 19.6 m / s2 (2 G) Excitation Time Shock Resistance Installation Conditions 20 ms (min) [11] Optional support (off at RC terminal open, on when applying external voltage of 4.5 V to 30 V between RC terminal and –V terminal) –25° to 85°C Excitation Direction 20 ms (min) Not provided Storage Temperature Range Vibration Frequency 20 ms (min) Detection above 115% of rated current (output cutoff) –10° to 60°C Cooling Requirements 20 ms (min) Detection above approximately 105% of rated current (drooping automatic recovery) Operating Temperature Range[7] Vibration Resistance Others[1] HWB 030S-15 50 / 60 Hz (47 to 440 Hz) Efficiency (typ) [1] Rated Output Voltage Additional Functions HWB 030S-12 60 W Single Output 100 to 240 VAC, 85 to 264 VAC continuous input Inrush Current [2] Environmental Conditions 30 W Dual Output 30 W Single Output x, y, z 3 directions, each for 1 hour 98 m / s2 (10 G) conducted on an oak board with a flat surface and a thickness of 10 mm or more; lift one side of installation surface of the unit to 50 mm and drop it on the board; drop 3 times on each side Derating is required depending on mounting method Continued on the next page… PAN40001-001EA00-OM SANKEN ELECTRIC CO., LTD. 16 December 2012 Continued from the previous page… 15 W Single Output Output Power Insulation Withstand Voltage Insulation Resistance Insulation[10] Model HWB 015S-05 HWB 015S-15 15 W Dual Output HWB 015D-15 30 W Single Output HWB 030S-05 HWB 030S-12 HWB 030S-15 30 W Dual Output HWB 030D-15 60 W Single Output HWB 060S-05 HWB 060S-12 HWB 060S-15 Batch Input Batch Output (R) 3000 VAC for 1 minute or 3600 VAC for 1 second (leakage current 15 mA or less), option M 4000 VAC for 1 minute Batch Input - FG 1500 VAC for 1 minute or 1800 VAC for 1 second (leakage current 15 mA or less) Batch Output (R)-FG HWB 060S-24 500 VAC for 1 minute or 600 VAC for 1 second (leakage current 15 mA or less) Batch Input Batch Output (R) 100 MΩ (measured with 500 VDC) Batch Input - FG 100 MΩ (measured with 500 VDC) Batch Output (R) 100 MΩ (measured with 500 VDC) Applicable Standards UL60950, CSA60950 certified Safety Standards TŰV (EN60950) certified Designed to meet Electrical Appliance and Material Control law TŰV (EN60601), UL 60601 certified with option M Designed to meet FCC Class B (120 VAC) Conducted Emissions Designed to meet CISPR pub. Class B (230 VAC) Designed to meet VCCI Class B (100 VAC) 1. Specified under rated input/output conditions at an ambient temperature of 25°C. 2. More current above noted values may flow at restart (power thermistor used). 3. Output characteristics such as ripple, ripple noise, and constant voltage accuracy are measured at the end of the output connector. 4. Ripple noise is measured with a 100 MHz oscilloscope using a 1:1 probe. 5. Output voltage can be changed within the maximum output power and rated output current. 6. The constant voltage accuracy is measured with a static input range of 85 to 264 VAC, a static load range of 0% to 100%, a time drift of 10 minutes to eight hours and an ambient temperature range of –10°C to 60°C. However, the load current at –10°C to 0°C and 50°C to 60°C is specified by the temperature derating curve. 7. Ambient temperature of 0°C to 50°C is specified by rated load conditions. The load current at –10°C to 0°C and 50°C to 60°C is specified by the temperature derating curve. 8. Frequencies of 100 Hz to 1 kHz and ripple of 100 Hz are –55 dB or less in total (ambient temperature of 25°C). 9. Reset is performed by reapplying input voltage. 10. Insulation conditions are specified at normal temperature and humidity. For medical equipment-support model (M option), insulation withstand voltage of batch input and batch output is 4000 VAC for 1 minute. 11. Specified at a rated power of 60 W for HWB060S-15. 12. Prepare a separate power supply for remote on/off control signal. 13. Cross-regulation has an accuracy of ±7% under the condition where load current of one side is less than 10%. PAN40001-001EA00-OM SANKEN ELECTRIC CO., LTD. 17 December 2012 Sanken reserves the right to make, from time to time, such departures from the detail specifications as may be required to permit improvements in the performance, reliability, or manufacturability of its products. Therefore, the user is cautioned to verify that the information in this publication is current before placing any order. When using the products described herein, the applicability and suitability of such products for the intended purpose shall be reviewed at the users' responsibility. Although Sanken undertakes to enhance the quality and reliability of its products, the occurrence of failure and defect of semiconductor products at a certain rate is inevitable. Users of Sanken products are requested to take, at their own risk, preventative measures including safety design of the equipment or systems against any possible injury, death, fires or damages to society due to device failure or malfunction. Sanken products listed in this publication are designed and intended for use as components in general-purpose electronic equipment or apparatus (home appliances, office equipment, telecommunication equipment, measuring equipment, etc.). Their use in any application requiring radiation hardness assurance (e.g., aerospace equipment) is not supported. When considering the use of Sanken products in applications where higher reliability is required (transportation equipment and its control systems or equipment, fire- or burglar-alarm systems, various safety devices, etc.), contact a company sales representative to discuss and obtain written confirmation of your specifications. The use of Sanken products without the written consent of Sanken in applications where extremely high reliability is required (aerospace equipment, nuclear power-control stations, life-support systems, etc.) is strictly prohibited. The information included herein is believed to be accurate and reliable. Application and operation examples described in this publication are given for reference only and Sanken assumes no responsibility for any infringement of industrial property rights, intellectual property rights, or any other rights of Sanken or any third party that may result from its use. The contents in this document must not be transcribed or copied without Sanken’s written consent. PAN40001-001EA00-OM SANKEN ELECTRIC CO., LTD. 18 December 2012