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Elgar Sorensen DCS 3kW Series Operation Manual Download Page 80

 

SECTION 7

 

DRAWINGS AND SCHEMATICS 

Please click on the link below to access assembly drawings, schematics, bills of materials, and 
latest updates to this manual. To view these documents, you must be connected to the Internet. 

DRAWINGS

 

 

 

Operation Manual  

7-1 

Summary of Contents for Sorensen DCS 3kW Series

Page 1: ...CA 92121 2294 1 800 73ELGAR 1 800 733 5427 Tel 858 450 0085 Fax 858 458 0267 Email sales elgar com www elgar com 2002 by Elgar Electronics Corporation This document contains information proprietary to...

Page 2: ...advertent contact with hazardous voltages is eliminated To guard against risk of electrical shock during open cover checks do not touch any portion of the electrical circuits Even when the power if of...

Page 3: ...rical Shock CAUTION Refer to Accompanying Documents Off Supply Standby Supply On Supply Protective Conductor Terminal Fuse Direct Current DC Alternating Three Phase Earth Ground Terminal Chassis Groun...

Page 4: ...presentatives shall in no circumstance be liable for any direct indirect special penal or consequential loss or damage of any nature resulting from the malfunction of the product Remedies under this w...

Page 5: ...upply lists its features and provides tables of specifications Section 2 Installation reviews safety and inspection procedures then goes through the basic set up procedures Directions for the assembli...

Page 6: ...LATION 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 Modifications 2 2...

Page 7: ...ns 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 Crosso...

Page 8: ...Remote Monitoring of Readback Signals and Status Indicators 4 20 4 6 1 Readback Signals 4 20 4 6 2 Status Indicators 4 20 4 7 Using Multiple Supplies 4 21 4 7 1 Configuring Multiple Supplies for Seri...

Page 9: ...tor 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 Panel Displays and Controls A1 P...

Page 10: ...nfiguration 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 with Remote Sensing 2 12 Figure 2 11 Multiple Loads with Local S...

Page 11: ...4 16 Figure 4 15 Using Shutdown with a TTL Compatible Negative Logic 4 16 Figure 4 16 Using Shutdown with an AC or DC Input Positive Logic 4 17 Figure 4 17 Using Shutdown with an AC or DC Input Negati...

Page 12: ...outputs from 20A to 350A Input voltage 190 250 Vac Three Phase 47 63 Hz or 200 250 Vac Single Phase 47 63 Hz Simultaneous digital display of both DC output voltage and current Ten turn potentiometer v...

Page 13: ...age Current 8 mV 350 mA 12 mV 250 mA 20 mV 150 mA 40 mV 75 mA 55 mV 55 mA 60 mV 50 mA 80 mV 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...

Page 14: ...ange 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 Time 1 mS recovery to 1...

Page 15: ...Introduction Sorensen DCS Series 3kW Supplies Figure 1 1 DCS Series 3kW Supply Front Panel Controls and Indicators 1 4 Operation Manual...

Page 16: ...Sorensen DCS Series 3kW Supplies Introduction Figure 1 2 DCS Series 3kW Supply Rear Panel Connectors and Terminals including optional internal GPIB Interface Operation Manual 1 5...

Page 17: ...Remote Programming operation monitoring and programmable functions are described in Section 4 Advanced Operation Please review the following points for both personal and equipment safety while using t...

Page 18: ...perating and Servicing Precautions Exceeding the maximum model rated input voltage may cause permanent damage to the unit Always disconnect power discharge circuits and remove external voltage sources...

Page 19: ...ests contains electrical and operational tests you can perform to ensure the unit is in proper working order after shipment The tests are to be performed once the AC input connector has been assembled...

Page 20: ...0821 1 Connector Housing AMP 643267 2 Mating Connector Parts Contact Pins AMP 350821 1 2 5 2 5 1 AC Input Power Connection Before you can use the DCS system supply you must determine your AC input pow...

Page 21: ...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 required Figure 2 1 AC Connector and Co...

Page 22: ...strain 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 Two 2...

Page 23: ...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 to clamp outer jacket...

Page 24: ...nd 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 delay the front panel digital meters will light up Both...

Page 25: ...ront 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 counter clockwise and check...

Page 26: ...le below shows the maximum current rating based on 450 amps per square centimeter for various gauges of wire rated for 105 degrees C operation Operation at the maximum current rating results in approx...

Page 27: ...oad 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 1 2 The power supply pr...

Page 28: ...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 method and the radial dis...

Page 29: ...rminals 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 Figure 2 11 and Figure 2 1...

Page 30: ...Constant Current Mode and two control modes Local Programming Mode default setting and Remote Programming Mode Both operating modes are available regardless of which control mode is used This section...

Page 31: ...L 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 while the load voltage varies with the loa...

Page 32: ...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 supply and connecting the l...

Page 33: ...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 sense lead to pin 13 an...

Page 34: ...orensen DCS Series 3kW Supplies Basic Operation Figure 3 3 Connecting Remote Sense Lines CAUTION Do not use remote sensing with multiple supplies connected in series or in parallel Operation Manual 3...

Page 35: ...s 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 scales Section 4 6 Multip...

Page 36: ...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 the switch to LOC retu...

Page 37: ...Sorensen DCS Series 3kW Supplies Advanced Operation Figure 4 1 Connector J3 Pin Descriptions for Remote Programming Remote Monitoring and Sense Connections Operation Manual 4 3...

Page 38: ...e 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 and JMP2 are located on...

Page 39: ...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 supply 4 Lift cover off a...

Page 40: ...s in this section whenever the rear panel connector J3 is to be reconfigured The steps to follow are Dissipating stored energy Making the connections Powering up Refer to the Dissipating Stored Energy...

Page 41: ...ns required for remote programming of output voltage and or current limit without using the REM LOC switch Remote Programming Options Control of Programming Scales Programming with the Output Voltage...

Page 42: ...between pins 10 current limit programming input positive and 12 return 3 Set the front panel REM LOC switch to REM Figure 4 3 Programming Output Voltage and Current Limit Using the REM LOC Switch Not...

Page 43: ...with a 0 5 Vdc Source Programming Output Voltage with a 0 10V Source 1 Set jumper JMP1 to its A B location 2 Remove the jumpers connecting pins 8 to 9 and 20 to 21 on connector J3 3 Connect the extern...

Page 44: ...ng the front panel current limit control sets the output current limit Figure 4 6 Programming Output Voltage with a 0 1 mA Source Programming Output Voltage with a 0 5k Resistance 1 Remove the jumpers...

Page 45: ...th 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 connector J3 3 Connect t...

Page 46: ...ting 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 Limit with a 0 5k Resistance 1 Remov...

Page 47: ...ssing 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 2 Press the OVP C...

Page 48: ...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 6 or to the chassis us...

Page 49: ...nt 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 Programming the Shutd...

Page 50: ...ch 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 Negative logic HIGH ON LOW...

Page 51: ...n 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 the table below Switch S...

Page 52: ...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 See Figure 4 18 through...

Page 53: ...hutdown 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 Shutdown with Contact C...

Page 54: ...tput Signal Range 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 to 100 of the model ra...

Page 55: ...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 string of power supplies is...

Page 56: ...multiple supplies in parallel the operating mode of each supply will depend on the load current being drawn For example with two DCS 60 50 power supplies operating in parallel with a 75A load one supp...

Page 57: ...minal 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 connection while the n...

Page 58: ...cal 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 Use extreme caution whe...

Page 59: ...assive components such as op amps transistors resistors capacitors diodes transformers and inductors Basic Functional Blocks The DCS 3kW Series supply is a single isolated output switch mode power sup...

Page 60: ...aw high voltage DC supplied by the A6 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 curre...

Page 61: ...controls or remote programming 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 hea...

Page 62: ...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 Circuit Power Transfo...

Page 63: ...ides 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 resistors R1 When the DC...

Page 64: ...ging 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 applying a high signal from U...

Page 65: ...ut 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 programmer to provide feedback to U1 A pin 2 to maintain a constant curren...

Page 66: ...eases the voltage on pin 5 increases until at a raw supply voltage of approximately 240 Vdc the voltage at pin 5 exceeds the reference voltage and the output of U14 B goes high This turns ON transisto...

Page 67: ...lifier to decrease which reduces the output pulse width from the PWM and reduces the voltage and current output to the selected level A complementary reaction occurs if the power supply output attempt...

Page 68: ...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 according to the followin...

Page 69: ...R27 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 remote voltage sources ju...

Page 70: ...e 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 supply without shutting...

Page 71: ...sistors R19 R20 R21 and R25 The input to the op amp is from the current shunt amplifier through the divider formed by resistors R22 and R26 Fan Control and Over temperature Shutdown Circuit The fan co...

Page 72: ...ent 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 divided down by resistors R15...

Page 73: ...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 description of the programming...

Page 74: ...ower 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 and the outp...

Page 75: ...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 frequency Correct any...

Page 76: ...ut 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 75A for Model 40 75 See Note 2...

Page 77: ...ssemblies consist of parts common to all DCS Series 3kW model assemblies as well as parts which are model specific or differential Each of the parts and assemblies listed whether complete common or di...

Page 78: ...PWM A3 5360351 03 5360111 01 5360351 02 5360111 01 5360351 02 5360111 01 5360351 02 5360111 01 5360351 02 5360111 01 5360351 02 5360111 01 5360351 02 5360111 01 5360351 02 5360111 01 Power Stage A4 A...

Page 79: ...1 A7 Filter PCB Assembly 1065812 008 Bus Bar Assembly 1068590 150 A7 Filter PCB Assembly 1065812 012 Bus Bar Assembly 1068768 008 A1 Display PCB Assembly 1065812 020 Bus Bar Assembly 1068768 012 A1 D...

Page 80: ...CHEMATICS Please click on the link below to access assembly drawings schematics bills of materials and latest updates to this manual To view these documents you must be connected to the Internet DRAWI...

Page 81: ...lowing table as a reference Peak Charging Current Maximum Voltage Diode Type 250 350A 40V Two 2 parallel MBR30045CT 60 249A 40V One 1 MBR30045CT 25 59A 100V One 1 MUR7015 10 24A 300V One 1 MUR3040PT 5...

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