Ametek Sorensen DC Series Operation Manual Download Page 1

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M362295-01 Rev D

www.programmablepower.com

DCS-E 3kW Series

DC Power Supplies

Operation Manual

This manual covers models:

DCS8-350E

DCS55-55E

DCS12-250E

DCS60-50E

DCS20-150E

DCS80-37E

DCS40-75E

DCS150-20E

Summary of Contents for Sorensen DC Series

Page 1: ...62295 01 Rev D www programmablepower com DCS E 3kW Series DC Power Supplies Operation Manual This manual covers models DCS8 350E DCS55 55E DCS12 250E DCS60 50E DCS20 150E DCS80 37E DCS40 75E DCS150 20...

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Page 5: ...s only Notice of Copyright DCS E 3kW Series DC Power Supplies Operation Manual 2006 2008 AMETEK Programmable Power Inc All rights reserved Exclusion for Documentation UNLESS SPECIFICALLY AGREED TO IN...

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Page 7: ...nnel and equipment safety Always ensure that facility AC input power is de energized prior to connecting or disconnecting any cable In normal operation the operator does not have access to hazardous v...

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Page 9: ...the instructions of AMETEK is opened modified or disassembled in any way without AMETEK s consent or is used in combination with items articles or materials not authorized by AMETEK The Buyer may not...

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Page 11: ...led schematics and circuit descriptions available on our website www programmablepower com will enable greater flexibility in troubleshooting and in configuring new applications Section 1 Introducing...

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Page 13: ...ECTION 2 INSTALLATION 2 1 2 1 Introduction 2 1 2 2 Safety 2 1 2 2 1 High Energy High Voltage Warning 2 1 2 2 2 AC Source Grounding 2 2 2 2 3 Operating and Servicing Precautions 2 2 2 2 4 Parts and Mod...

Page 14: ...ctions 2 11 2 7 3 Connecting Single Loads 2 12 2 7 4 Connecting Multiple Loads 2 12 SECTION 3 BASIC OPERATION 3 1 3 1 Introduction 3 1 3 2 Standard Operation 3 1 3 2 1 Operating Modes and Automatic Cr...

Page 15: ...act Closure 4 19 4 6 Remote Monitoring of Readback Signals and Status Indicators 4 21 4 6 1 Readback Signals 4 21 4 6 2 Status Indicators 4 21 4 7 Using Multiple Supplies 4 22 4 7 1 Configuring Multip...

Page 16: ...Output Filter Inductor and Capacitor and Down Programmer Circuit A4 PCB A7 PCB A8 PCB and Power Stage Assembly 5 6 5 3 5 Auxiliary Supply OVP Control Programming Monitor Circuit A2 PCB 5 7 5 3 6 Front...

Page 17: ...6 Strain Relief Assembly 2 7 Figure 2 7 Connector J3 Default Configuration 2 8 Figure 2 8 Maximum Load Wire Length 2 11 Figure 2 9 Single Load with Local Sensing Default 2 12 Figure 2 10 Single Load...

Page 18: ...14 Using Shutdown with a TTL Compatible Positive Logic 4 17 Figure 4 15 Using Shutdown with a TTL Compatible Negative Logic 4 17 Figure 4 16 Using Shutdown with an AC or DC Input Positive Logic 4 18...

Page 19: ...90 250 Vac Three Phase 47 63 Hz or 200 250 Vac Single Phase 47 63 Hz Output power limited to 2500W for single phase input Simultaneous digital display of both DC output voltage and current Ten turn po...

Page 20: ...37 mA 150 mV 20 mA Meter Accuracy Voltage Current 0 09V 4 5A 0 13V 3 5A 0 2V 0 1 6A 0 5V 0 85A 0 65V 0 65A 0 7V 0 6A 0 9V 0 47A 1 6V 0 30A OVP Adjustment Range 0 4 8 8V 0 6 13 2V 1 22V 2 44V 2 75 60...

Page 21: ...ge 55 to 85 C Humidity Range 0 80 Non condensing Time Delay from power on until output stable 5 seconds maximum Switching Frequency Nominal 30 kHz 60 kHz output ripple Voltage Mode Transient Response...

Page 22: ...Introduction Sorensen DCS E Series 3kW Supplies 1 4 M362295 01 Rev D Figure 1 1 DCS E Series 3kW Supply Front Panel Controls and Indicators...

Page 23: ...Sorensen DCS E Series 3kW Supplies Introduction M362295 01 Rev D 1 5 Figure 1 2 DCS E Series 3kW Supply Rear Panel Connectors and Terminals including optional internal GPIB Interface...

Page 24: ...Introduction Sorensen DCS E Series 3kW Supplies 1 6 M362295 01 Rev D This page intentionally left blank...

Page 25: ...ation Remote Programming operation monitoring and programmable functions are described in Section 4 Advanced Operation 2 2 SAFETY Please review the following points for both personal and equipment saf...

Page 26: ...e voltages or frequencies in excess of those specified may cause leakage currents in excess of 5 0 mA peak from the AC line to the chassis ground 2 2 3 Operating and Servicing Precautions Exceeding th...

Page 27: ...or component damage Reinstall cover If damage is found to have occurred save all packing materials and notify the carrier immediately Refer to the terms of the warranty Direct repair problems to the m...

Page 28: ...ollowing part numbers Chassis Mounted Parts Housing Tyco 641685 1 Contact Pins Tyco 350821 1 Mating Connector Parts Connector Housing Tyco 643267 1 Contact Pins Tyco 350821 1 2 5 1 AC Input Power Conn...

Page 29: ...821 1 ADDITIONAL PARTS REQUIRED 8 to 12 AWG wiring three 3 wires for single phase inputs or four 4 wires for three phase inputs The neutral CONNECTOR wire of three phase four 4 wire systems is not req...

Page 30: ...train relief is assembled from supplied pieces and attaches to the AC input connector to provide support for the AC input cord PARTS SUPPLIED Two 2 pieces strain relief Part number MI 6432 661 Tyco 64...

Page 31: ...d strain relief tab A into AC input connector slot C See Figure 2 6 4 Install screws in holes provided on outside of strain relief pieces Thread through to screw standoff inside opposite piece Tighten...

Page 32: ...5 seconds before powering on again 2 Turn the voltage and current controls fully counter clockwise 3 Connect the unit to an AC outlet 4 Turn the front panel AC power switch ON After a short power on d...

Page 33: ...be illuminated 2 6 4 Front Panel Function Checks 1 Press OVP CHECK switch and check that the voltmeter displays approximately the model rated output voltage plus 10 2 Turn OVP SET potentiometer counte...

Page 34: ...the load is shorted The table below shows the maximum current rating based on 450 amps per square centimeter for various gauges of wire rated for 105 C operation Operation at the maximum current ratin...

Page 35: ...aking the Connections Load connections to the power supply are made at the positive and negative output terminals or bus bars at the rear of the power supply Refer to the rear panel diagram in Figure...

Page 36: ...nsing 2 7 4 Connecting Multiple Loads Proper connection of distributed loads is an important aspect of power supply applications Two common methods of connection are the parallel power distribution me...

Page 37: ...or a distinct set of terminals especially established for distribution use Connecting the sense leads to these terminals will compensate for losses and minimize the effect of one load upon another Fig...

Page 38: ...Installation Sorensen DCS E Series 3kW Supplies 2 14 M362295 01 Rev D This page intentionally left blank...

Page 39: ...ating modes Constant Voltage Mode and Constant Current Mode and two control modes Local Programming Mode default setting and Remote Programming Mode Both operating modes are available regardless of wh...

Page 40: ...nce is low enough that the load current IL is greater than the current limit setting ISET or IL ISET In constant current mode the power supply maintains the output current at the selected value ISET w...

Page 41: ...nitoring See Section 4 2 Configuring for Remote Programming Sensing and Monitoring Figure 3 2 Local Mode Default Configuration SETTING OUTPUT VOLTAGE AND CURRENT LIMIT After installing the power suppl...

Page 42: ...nergy before altering J3 connector pin connections 2 Remove the local sense jumpers connecting J3 pins 13 to 25 positive sense and pins 12 to 24 negative sense or return sense 3 Connect the positive s...

Page 43: ...rensen DCS E Series 3kW Supplies Basic Operation M362295 01 Rev D 3 5 Figure 3 3 Connecting Remote Sense Lines CAUTION Do not use remote sensing with multiple supplies connected in series or in parall...

Page 44: ...Basic Operation Sorensen DCS E Series 3kW Supplies 3 6 M362295 01 Rev D This page intentionally left blank...

Page 45: ...mal shutdown OVP status remote local programming mode and voltage current mode operation Section 4 6 Calibrated Readback Signals for output voltage and output current with selectable 0 5V or 0 10V sca...

Page 46: ...e programming When set to REM Remote Programming control of BOTH output voltage AND current limit is passed to external voltage and or current sources which are connected to the J3 connector Resetting...

Page 47: ...Sorensen DCS E Series 3kW Supplies Advanced Operation M362295 01 Rev D 4 3 Figure 4 1 Connector J3 Pin Descriptions for Remote Programming Remote Monitoring and Sense Connections...

Page 48: ...ale factor over voltage protection OVP programming mode and scale voltage and current monitor range and shutdown circuit logic 4 2 2 Locating Jumpers Switch and Connector Switch SW1 and jumpers JMP1 a...

Page 49: ...d near the front panel six 6 near the rear panel Use a 1 Philips screwdriver 3 Loosen but do not remove the six 6 Philips screws located three 3 to a side in the slots along each side of the power sup...

Page 50: ...s or making connections to external devices such as voltage sources current sources or resistances Read Section 2 2 Safety and follow the procedures in this section whenever the rear panel connector J...

Page 51: ...pported for the DCS E Series 3kW supply Refer to Section 4 3 1 for a procedure and a connection diagram for programming output voltage and current limit using the REM LOC switch Subsequent sections pr...

Page 52: ...ut voltage and current limit with external voltage and or current sources For programming output voltage and current limit using the REM LOC switch 1 Connect the programming source between pins 9 volt...

Page 53: ...0 of the model rating The output current limit may be programmed using another source or set locally by adjusting the front panel current limit control Figure 4 4 Programming Output Voltage with a 0 5...

Page 54: ...Resetting Jumpers and Switch PROGRAMMING OUTPUT VOLTAGE WITH A 0 1 MA SOURCE 1 Remove the jumper between pins 20 and 21 of connector J3 2 Connect the external programming source between pin 9 voltage...

Page 55: ...put positive and 21 1 mA current source for voltage control to the counter clockwise end of the 5k potentiometer and connect the tap and clockwise end of the potentiometer to pin 12 return Adjusting t...

Page 56: ...Output Current Limit with a 0 5 Vdc Source PROGRAMMING OUTPUT CURRENT LIMIT WITH A 0 10 VDC SOURCE 1 Set jumper JMP2 to its A B location 2 Remove the jumpers connecting pins 10 to 11 and 22 to 23 on c...

Page 57: ...voltage from 0 to 100 of the model rating Adjusting the front panel voltage control sets the output voltage Figure 4 10 Programming Output Current Limit with a 0 1 mA Source PROGRAMMING OUTPUT CURRENT...

Page 58: ...t any time by pressing the OVP CHECK switch the OVP set point is the value displayed on the digital voltmeter To set the trip level from the front panel 1 Adjust the power supply output to zero volts...

Page 59: ...ween pin 3 positive and pin 12 return on the J3 connector on the rear panel See Figure 4 12 and Figure 4 13 The use of shielded twisted pair wiring is recommended Ground the shield to J3 connector pin...

Page 60: ...voltage and current fall to zero and the S D Shutdown LED on the front panel is illuminated Pushing the switch once more resets it to its OUT position and normal power supply operation is resumed 4 5...

Page 61: ...15 3 Set internal switch SW1 8 to select the desired circuit logic as defined in the table below Switch SW1 8 Setting TTL Signal Level Output Condition OPEN Positive logic HIGH OFF LOW ON CLOSED Nega...

Page 62: ...e AC or DC source to pin 1 positive and pin 2 return on the J3 connector on the rear panel See Figure 4 16 and Figure 4 17 3 Set internal switch SW1 8 to select the desired circuit logic as shown in t...

Page 63: ...e external relay to pin 15 15 Vdc Auxiliary Output on connector J3 Connect the other side of the relay to pin 14 TTL Shutdown Input Also connect pin 2 Shutdown Return to pin 6 Auxiliary Supply Ground...

Page 64: ...v D Figure 4 19 Using Shutdown with Contact Closure of a Normally OPEN Relay Negative Logic Figure 4 20 Using Shutdown with Contact Closure of a Normally CLOSED Relay Positive Logic Figure 4 21 Using...

Page 65: ...ignal Range Signal Return Switch Setting Output Voltage Pin 19 Pin 12 SW1 4 CLOSED 0 5 Vdc OPEN 0 10 Vdc Output Current Pin 7 Pin 12 SW1 3 CLOSED 0 5 Vdc OPEN 0 10 Vdc The readback signal represents 0...

Page 66: ...output terminal of the next supply See Figure 4 22 The total voltage available is the sum of the maximum voltages of each supply add voltmeter readings The maximum allowable current for a series stri...

Page 67: ...y Note When operating multiple supplies in parallel the operating mode of each supply will depend on the load current being drawn For example with two DCS 60 50E power supplies operating in parallel w...

Page 68: ...the negative output terminal of one supply to the positive output terminal of the second supply The positive output terminal of the first supply then provides a positive voltage relative to the common...

Page 69: ...tive Negative Supply Local sense lines shown are default J3 connections 4 8 OUTPUT VOLTAGE BIASING The power supply output may be biased up to a maximum of 400 Vdc with respect to the chassis WARNING...

Page 70: ...Advanced Operation Sorensen DCS E Series 3kW Supplies 4 26 M362295 01 Rev D This page intentionally left blank...

Page 71: ...g of active and passive components such as op amps transistors resistors capacitors diodes transformers and inductors 5 2 BASIC FUNCTIONAL BLOCKS The DCS E 3kW Series supply is a single isolated outpu...

Page 72: ...PCB into a variable duty cycle 30 kHz waveform which is applied to the primary winding of the power transformer Feedback signals from the A2 PCB voltage and current control circuits and a current sens...

Page 73: ...ming circuit and provide a control signal for the A3 PCB PWM circuit Thermal sensors monitor the temperature of the input rectifier heatsink the main switching transistor heatsink and the output recti...

Page 74: ...y Schematics for links to the Elgar website to access illustrations of the following assemblies 1 AC Input and RFI Filter Circuit A5 PCB 2 Input Rectifier and Inrush Limiting Circuit A6 PCB 3 PWM Sync...

Page 75: ...Resistor R2 provides a discharge path for the bulk capacitor C2 on power down Capacitors C1 C3 and C4 provide noise filtering The initial power up inrush current to capacitor C2 is limited by resistor...

Page 76: ...utput controls the charging rate of the PWM timing capacitor thereby synchronizing the two signals The PLL also serves to shut down the PWM whenever the sync signal from the A2 PCB is absent by applyi...

Page 77: ...gative than the reference at pin 5 approximately 0 125 Vdc the output of U1 B goes positive and FET Q1 is turned on by U1 A through resistor R4 Resistor R1 acts as a current shunt for the down program...

Page 78: ...On initial power up the output of U14 B is held low by a 5V reference signal on pin 6 As the raw supply voltage increases the voltage on pin 5 increases until at a raw supply voltage of approximately...

Page 79: ...nt control circuits decreases and causes the output of the PWM error amplifier to decrease which reduces the output pulse width from the PWM and reduces the voltage and current output to the selected...

Page 80: ...mit is necessary the J3 connector must be used to select the programming source In the voltage control circuit analog switches U4 C and U4 B select which of the three programming sources is enabled ac...

Page 81: ...ector Diodes CR26 and CR27 clamp any out of range or reverse polarity inputs Trimpot R93 is used to null any offset voltage from U10 Trimpot R60 is used to calibrate the signal For programming with re...

Page 82: ...h OPEN or 0 10V with the switch CLOSED REMOTE SHUTDOWN CIRCUIT AND THE FRONT PANEL STANDBY SWITCH The remote shutdown circuit and the front panel standby switch are used to disable the output of the s...

Page 83: ...l switch SW1 4 is OPEN removing resistor R53 from the scaling resistors Operation of the current readback circuit is the same as the voltage readback circuit The circuit is made up of op amp U2 switch...

Page 84: ...tput for the seven segment displays The A D conversions are done and the displays updated approximately three times per second In the voltage display circuit the 5V reference from the A2 PCB is divide...

Page 85: ...EMOTE LOCAL SWITCH SW1 This press ON press OFF switch activates both the voltage and current remote programming selector circuits on the A2 PCB via P1 connector pin 19 See Section 5 3 5 for a descript...

Page 86: ...Theory of Operation Sorensen DCS E Series 3kW Supplies 5 16 M362295 01 Rev D This page intentionally left blank...

Page 87: ...servicing power supplies High energy levels can be stored at the output voltage terminals on all power supplies in normal operation In addition potentially lethal voltages exist in the power circuit...

Page 88: ...hese steps Shut the power supply off immediately Disconnect it from the AC power source Check all load programming and monitoring connections and circuits Check the AC input for correct voltage and fr...

Page 89: ...to the power supply output See Note 1 Apply 1 of program voltage e g 0 1 for 0 10Vdc or 0 05 for 0 5Vdc programming source Adjust R95 until the DVM indicates 1 of the rated output current e g 0 5A for...

Page 90: ...embly Most assemblies consist of parts common to all DCS E Series 3kW model assemblies as well as parts that are model specific or differential Each of the parts and assemblies listed whether complete...

Page 91: ...1 1 1068531 150 1068531 1 Driver Bridge PWM A3 5360351 03 5360111 01 5360351 02 5360111 01 5360351 02 5360111 01 5360351 02 5360111 01 5360351 02 5360111 01 5362297 01 5360351 02 5360111 01 5360351 02...

Page 92: ...Maintenance Sorensen DCS E Series 3kW Supplies 6 6 M362295 01 Rev D This page intentionally left blank...

Page 93: ...MBR30045CT 25 59A 100V One 1 MUR7015 10 24A 300V One 1 MUR3040PT 5 9A 500V One 1 MUR1560 5A 600V One 1 MUR758 Connect the diode in series with either supply output to prevent the battery from discharg...

Page 94: ...us Forward Current ratings should be a minimum of 1 5 times the Power Supply maximum output current Heatsink may be required There also may be a need for higher voltage rated parts dependent on load c...

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