BEHLMAN BL5000 Series User'S Manual And Technical Reference Manual Download Page 1

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USER'S GUIDE AND

TECHNICAL REFERENCE

AC SOURCE

BEHLMAN MODEL BL5000 SERIES

PART NUMBER:______________

MODEL ____________________

FOR SERVICE ASSISTANCE

CONTACT BEHLMAN

CUSTOMER SERVICE DEPARTMENT

PHONE TOLL FREE 1-800-874-6727

OR WRITE

BEHLMAN

CUSTOMER SERVICE DEPARTMENT

80 CABOT COURT

HAUPPAUGE, NY 11788

PHONE: (631) 453-0410

FAX : (631) 951-4341

FOR SALES INFORMATION:

PHONE: (631) 435-0410

USA : (800) 874-6727

FAX : (631) 951-4341

DATE:06/11

REV. C

Summary of Contents for BL5000 Series

Page 1: ..._____________ FOR SERVICE ASSISTANCE CONTACT BEHLMAN CUSTOMER SERVICE DEPARTMENT PHONE TOLL FREE 1 800 874 6727 OR WRITE BEHLMAN CUSTOMER SERVICE DEPARTMENT 80 CABOT COURT HAUPPAUGE NY 11788 PHONE 631 453 0410 FAX 631 951 4341 FOR SALES INFORMATION PHONE 631 435 0410 USA 800 874 6727 FAX 631 951 4341 DATE 06 11 REV C ...

Page 2: ...he customer being liable for all shipping handling and repair costs When packing for reshipment use the original shock absorbent material and shipping container to preclude damage to the equipment Insure that the return authorization numbers RMA is available on the container for identification SHIPPING INSTRUCTIONS RACK MOUNTED UNITS 1 Box es must be double wall with minimum 350 lbs bursting test ...

Page 3: ...orization RMA number This number must be attached to the equipment sent back for warranty repair Equipment must be shipped back to Behlman prepaid No collect shipments will be accepted Behlman shall be excused from supplying warranty service if the unit s case has been open or if the unit has been subject to unauthorized repair All service outside the scope of this warranty shall be paid for by th...

Page 4: ...n the presence of flammable gases or fumes Operation of any electrical instrument in such an environment constitutes a definite safety hazard KEEP AWAY FROM LIVE CIRCUITS Operating personnel must not remove equipment covers Component replacement and internal adjustments must be made by qualified maintenance personnel Do not replace components with power applied Under certain conditions dangerous v...

Page 5: ...ents single phase power 2 5 Supplemental input protection 2 6 T5 and T5D options 2 7 Installation Considerations 3 OPERATION 3 1 Controls and Indicators 3 2 To Operate The Equipment 3 3 Shutdown Procedure 3 4 Line Drop Compensation 3 5 Remote Programming 3 6 External Sync 3 7 Operational Considerations 4 MAINTENANCE AND ADJUSTMENTS 4 1 Maintenance 4 2 Adjustments 5 THEORY OF OPERATION 5 1 General ...

Page 6: ...942 000 Power Chassis Assembly 3 phase 106 977 1XX Power Chassis schematic 3 phase 106 956 006 Power Chassis schematic 1 phase 106 956 009 Outline Control Chassis 106 909 508 Outline Drawing Input Chassis 3 phase 106 977 500 Outline Drawing Input Chassis single phase 106 909 514 NOTE some drawings are common to other model series APPENDIX A IGBT Driver A 1 B IEEE 488 Remote Interface Operation B 1...

Page 7: ...al transformer chassis for higher voltages The table and list below summarizes these options Any of the models can include all or any combination of the available options if desired TABLE 1 BEHLMAN 5000 SERIES MODELS MODEL INPUT VOLTAGE ac OUTPUT VOLTAGE ac BL5000C 1 120V 208V 3N 0 135 3N BL5000C 2 220V 380V 3N 0 135V 3N BL5000C 3 277V 480V 3N 0 135V 3N BL5000C 4 200V 3N 0 135V 3N BL5000C 5 346V 6...

Page 8: ...act the decision to include this information in this manual is reserved solely by Behlman All special unit manuals will include an addendum that explains the modification and refers to any special operating considerations warranted by the modification Any exceptions to standard unit specifications will also be addressed by the addendum When ordering replacement or additional manuals make sure to c...

Page 9: ...3 THIS PAGE BLANK FOR ADDENDUMS ...

Page 10: ...00 of rated output into any power factor load Distortion 1 5 maximum THD measured at full load 100 Vac 50 Hz Load Regulation 0 7 from no load to full load 250msec typical Line Regulation 0 1 for 10 of line change Efficiency 85 90 with 3 phase input Metering Voltmeter Accuracy 1 of range 1 digit 1 volt resolution Ammeter accuracy 1 of range 1 digit 0 1 amp resolution Frequency Meter 1 of range 1 di...

Page 11: ...T terminal strip of the power chassis See additional info for single phase inputs b OUTPUT POWER Output power lines load are connected to the NA NB NC and Neutral provided on the AC OUTPUT terminal strip of the control chassis For T option units the load is connected to the AC OUTPUT optional transformer chassis c Interconnection between chassis Connect HI GND and LOW of power chassis to HI GND an...

Page 12: ...upply This chart can also serve as a guide for sizing the input service to the unit Note refer to the single phase input information for C8 9 10 models The following lists should be used to select the proper line fuse size for the model numbers shown The selections are based on nominal line voltages and maximum output power All fuses carry a 600 Vac rating DO NOT substitute any other fuse type MOD...

Page 13: ...10 350 VA If operating at 240 Vac 216 V 10 low line input then the input current requirement is 12 450 216V 57 6 amperes The actual input current will be somewhat lower depending on the line impedance in series with the power supply Also if the load being powered is reactive the actual input current could be considerably lower Testing under actual conditions may yield results allowing the use of a...

Page 14: ...8 Figure 2 2 Single phase inputs ...

Page 15: ...h chassis to house the external transformers and range relay for T5D units Units supplied with T5 options may vary slightly depending on actual customers requirements Units with a or 0 to 300 Vac output are considered standard Units supplied with other voltages will be assigned a 4 digit engineering number T5 units require some special operating considerations Refer to section 3 of this manual for...

Page 16: ...distance of four inches is required between the rear panel and any obstruction to prevent back pressure from reducing air flow This device is intended for use in a relatively clean environment For this reason air filters are not provided on the intakes If air filtering is desired it may be added at the expense of reduced air flow This may result in some required de rating of the output power avail...

Page 17: ...to desired frequency 6 Set OUTPUT switch to ON to energize load NOTE It is permissible to energize a load gradually by setting the OUTPUT switch ON and rotating the VOLTS control from zero or a low voltage position up to the voltage desired 3 3 SHUTDOWN PROCEDURE 1 Set OUTPUT switch to OFF 2 Set VOLTS control fully counter clockwise 3 Set line circuit breaker to OFF 3 4 ADJUSTMENT OF LINE DROP COM...

Page 18: ...ition and removal of output power Output power is automatically restored on termination of over temperature condition 7 Digital readout meters VOLTS Provides output voltage RMS display AMPS Provides output current RMS display FREQ Provides output frequency display 7a Meter Select Switch 3 position rotary that selects which output phase is displayed on readouts 8 VOLTS control Used to establish des...

Page 19: ...13 Figure 3 1 BL5000 AC Source Control Chassis Front and Rear Panel Views ...

Page 20: ...utput voltage from 1 100 Input impedance greater than 50K ohms 300msec response 5 Frequency control hi 0 10V applied controls output frequency from 45 500 Hz Input impedance greater than 20K ohms 6 Output relay control Application of short to pins 6 7 will activate the output relay 7 Output relay control Application of short to pins 6 7 will activate the output relay 8 Range relay control Applicat...

Page 21: ...usually do not present any problem for the power source Inductive and capacitive loads may present a special problem based on their construction and the way in which they are energized Motors and tungsten filament lamps also present some special start up concerns The following is intended to give the end user some insight into applying the AC source to these types of loads DRIVING REACTIVE LOADS C...

Page 22: ...as Crest Factor High values of crest factor cause distortion of the AC voltage waveform The amount of distortion incurred is dependant on many factors and is beyond the scope of this manual It should be noted that this type of load may cause the output waveform to exhibit flat topping This should not be associated with a defect of the power source Most real world electric distribution systems exhi...

Page 23: ...maller devices will trigger at lower currents 5 Point in the AC waveform where the short occurs highest current at max peak A second current limit circuit responds to the long term a few hundred milliseconds current When the preset current limit trip point is reached the output voltage will decrease to maintain a constant current and sinusoidal output This condition will exist until the overload i...

Page 24: ...FILTERS VACUUMING OPERATING OUTSIDE THE ALLOWABLE ENVIRONMENT AND PHYSICALLY DAMAGING THE UNIT The decision on whether a units warranty is voided will be exclusively reserved for Behlman 4 2 ADJUSTMENTS NOTE All the potentiometers used in the procedures that follow are located on the control chassis Always use a non metallic screwdriver when adjusting potentiometers 4 2 1 TEST EQUIPMENT REQUIRED T...

Page 25: ...switch to ON 5 Adjust VOLTS control until volts meter indicates 10 Vrms minimum 6 Adjust 45 Hz potentiometer R15 until frequency counter indicates 45 Hz 4 2 4 HIGH END FREQUENCY TRIM 500 Hz R16 on motherboard 1 Turn FREQ control fully cw 2 Adjust 500 Hz potentiometer R16 until frequency counter indicates 500 Hz 4 2 5 FREQUENCY METER ADJUST Hz METER R19 on Motherboard 1 Turn FREQ control fully ccw ...

Page 26: ...meter select switch to phase B 5 Adjust R58 on the B phase control board so that the front panel ammeter matches the external ammeter 6 Repeat the above step with the load on phase C Again adjust R58 on the phase C board so that the front panel ammeter matches the measured load current on phase C 7 Adjust the VOLTS control fully CCW and set the OUTPUT switch to Off 4 2 9 20 KHz TRIANGLE WAVE TRIM ...

Page 27: ...rovide the required filtering The output of the power chassis is a bipolar DC voltage of 250 Vdc centered around the circuit common Additional circuitry is incorporated to provide in rush current limiting and overload protection 5 2 2 In rush surge limiting is provided by placing large power resistors in series with two of the input phase voltages and the power chassis transformer primary During p...

Page 28: ...urther filtering produces a clean sine wave at the frequency of the VCO Phase displacement is determined by the PROM data 5 4 4 The mother board also produces a triangle wave signal that is common to the PWM modulators contained on the phase control cards discussed later 5 4 5 All inter connection between circuits and controls are provided via the Motherboard Four 22 pin card edge connectors are p...

Page 29: ...is adjustable via the front panel 5 6 METERING 5 6 1 Metering is provided by DC signals taken from the phase control cards These signals are derived from the voltage and current monitoring circuits These signals are attenuated and applied to the front panel DVM s The frequency display derives it s data from the VCO signal 5 7 MISCELLANEOUS 5 7 1 Internal heat sink temperature is monitored via a se...

Page 30: ...programmable memory logic device U18 provides all the required communication functions RS232 communications are handled directly by U17 while IEEE 488 protocol is handled by buss controller U19 U19 is an industry standard TMS 9914 Data stored in the U18 EEPROM determines which communication proto call is selected EEPROM data also determines scale factor and other set up parameters which are determ...

Page 31: ...processor and scaled to provide the proper current and voltage data to the controlling computer The output frequency of the power supply is measured by monitoring its internal clock signal via U4 This input is labeled Hz FDBK Control of the output on off relay and range relay is provided via the interface board via dry contacts from K1 and K2 These small PCB mounted relays are controlled by U18 Al...

Page 32: ...an over current of 10 µsec duration when short circuited An extremely fast protection circuit is used here for this reason LOW SPEED OVER CURRENT CUTOFF A low speed cutoff circuit slowly turns off the IGBT driver in response to an over current sensing This feature protects the IGBT against damage from high voltage spikes generated during normal drive speed cutoffs PIN DESCRIPTION 1 Connected to sm...

Page 33: ...ger C 0 Not a controller 1 2 IEEE 488 BUS COMMANDS 1 Single Line Commands IFC Clears GPIB interface 2 Multi Line Command DCL Resets AC Power Supply to the quiescent state if a catastrophic failure is not present The only way to clear a catastrophic failure is to read the Power Supply s response by using the Status command 1 3 GPIB COMMUNICATION The embedded TMA receives ASCII encoded command strin...

Page 34: ... 3 are sent then generate error message SET FREQ value Optional Sets frequency of output voltage to given value in Hz The following values are permitted 45 value 5 0 0 Default is 6 0 Hz only if SET FREQ SRN FREQ or SRX FREQ are not received Otherwise the values shall be used in the order stated SRX VOLT value Optional Sets maximum limit for SET VOLT command If SET VOLT value is greater than SRX VO...

Page 35: ...p command ignored Legal values are 45 value 5 0 0 If a value for SRN FREQ is not specified SRN FREQ defaults to 45 SET VLT 0 Set LO voltage range SET VLT1 Set HI voltage range Delay is necessary after issuing setup command due to output voltage slew rate of 100v per 250 ms On dual range Power Supplies this command selects the LO or HI voltage range Dual Ranges are 0 135 volts and 0 135 0 27 0 volt...

Page 36: ...cr lf Closes output relay contacts Connects AC Power Supply outputs to output terminal block The setup command specifies the voltage and frequency The setup command must be entered before the CLS CH 0 command OPN CH 0 cr lf Opens output relay contacts Disconnects output of AC Power Supply from output connector AC Power Supply retains voltage and frequency assigned by setup command RST ACS CH 0 Res...

Page 37: ...onse messages and conditions exclude confidence and internal self sp cr lf Device error messages F 07ACS 0 DEV BIT TEST FAILURE description consisting of up to 6 0 characters cr lf TMA error messages All begin with F 07ACS 0 MOD This message is followed by one explanatory message from the following text ILLEGAL NOUN AC Power Supply does not recognize illegal noun ILLEGAL NOUN MODIFIER AC Power Sup...

Page 38: ... its upper limit The OVERTEMP LED on the front panel will light CURRENT LIMIT FAULT cr lf SHORT CIRCUIT FAULT AC SUPPLY cr lf An output loading fault has occurred causing the supply to exceed 5 0 0 rated current output The supply automatically shuts down and opens its output relay The OVERLOAD LATCH LED on the front panel will light 1 6 ADDRESS SELECTION The GPIB Address for the BL Series Power Su...

Page 39: ...specified during the SET VOLT command GPIB PROGRAMMING EXAMPLE FOR THREE PHASE UNIT Examples of actual command strings transmissions and typical responses are outlined below All commands must be in upper case ASCII lower case characters are ignored All commands transmitted to the BL must terminate with a carriage return cr and a line feed lf as will all responses received from the BL IMPORTANT NOT...

Page 40: ... 115 V on high range 50Hz and read back what the actual voltage current and frequency being output is set at Transmit setup command FNC ACS CH 0 SET VOLT 115 SET FREQ 5 0 SET BLT1 cr lf Transmit status command to request status response STA cr lf Talk address the BL Source to enable response space cr lf Positive response indicating status is OK Transmit output relay close command CLS CH 0 cr lf Tr...

Page 41: ...us is OK Transmit output relay close command CLS CH 0 cr lf Transmit status command to request status response STA cr lf Talk address the BL source to enable response space cr lf Positive response indicating status is OK Transmit fetch volt command for phase 2 FTH VOLT2 cr lf Talk address the bl source to enable response 12 0 0 cr lf Transmit fetch volt command for average of 3 phases FTH VOLT cr ...

Page 42: ... that the RS232 interface is connected to a host computer The interface is configured to communicate with the following format Duplex Full Baud Rate 9600 Bits 8 Parity None Stop Bits 1 Other BAUD rates however are available by special order 1 2 EIA 232 CONNECTIONS SIGNAL AC SOURCE HOST DB 9 ANY GND 5 GND RXD 2 TXD TXD 3 RXD The RS232 interface does not currently support hardware handshaking Use of...

Page 43: ...X SRN CLS OPN RST CNF IST STA INX MODIFIERS FREQ VOLT CURR VLT0 VLT1 NOUN ACS The BL Series Power Supply can be used in point to point mode where a host Computer is connected irectly to One Power Supply NOTES 1 Leading zeroes must be entered for commands 2 Leading zeroes are blanked in response transmit EXAMPLES 1 4 AC POWER SUPPLY SYNTAX Setup Command FNC ACS CHO SET VOLT value SET FREQ value SRX...

Page 44: ...s not specified the required maximum value for SET VOLT default to 135 or 270 dependant on range selected and type of unit SRN VOLT value Optional Sets minimum value limit for SET VOLT command If SET VOLT value is less than SRN VOLT value in a command string an error message is generated and a setup command ignored The following values are permitted 0 value 135 or 270 dependent on range selected a...

Page 45: ...his command by transmitting the RMS voltage in volts measured at its output in decimal format as follows sp digit digit digit dp digit digit cr lf eos FTH CURR cr lf eos The AC Supply responds by transmitting the current in amps measured at its output in decimal format as follows sp digit digit dp digit cr lf eos FTH FREQ cr lf eos The AC Supply response by transmitting the frequency in hertz meas...

Page 46: ...wing response messages and conditions exclude confidence and internal self test RESPONSE Status OK sp cr lf eos Device error messages F07ACSO DEV BIT TEST FAILURE description consisting of up to 60 characters cr lf eos TMA error messages All begin with F07ACSO MOD This message is followed by one explanatory message from the following text ILLEGAL NOUN AC Power Supply does not recognize illegal nou...

Page 47: ...or Messages All begin with F00ACS0 DEV This message is followed by one explanatory message from the following text OVERTEMP FAULT cr lf eos The heatsink temperature has exceeded its upper limit The OVERTEMP LED on the front panel will light CURRENT LIMIT FAULT cr lf eos SHORT CIRCUIT FAULT AC SUPPLY cr lf eos An output loading fault has occured causing the supply to exceed 500 rated current output...

Page 48: ...e response indicating error condition Typically a negative response would only occur if an error existed in the entry or reception of the command string or the values entered were out of range of the AC Source Transmit output relay close command CLS CHO cr lf eos Transmit status command to request status response STA cr lf eos Talk address the AC Source to enable response space cr lf eos Positive ...

Page 49: ...f eos Positive response indicating status is OK Transmit output relay close command CLS CHO cr lf eos Transmit status command to request status response STA cr lf eos Talk address the AC Source to enable response space cr lf eos Positive response indicating status is OK Transmit fetch volt command FTH VOLT cr lf eos Talk address the AC Source to enable response 115 0 cr lf eos Transmit fetch curre...

Page 50: ...6 1 SECTION 6 PARTS LIST AND DRAWINGS ...

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