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Wayne Kerr AP10030, User & Service Manual

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Wayne Kerr AP10030 User & Service Manual Download Page 62

AP 1kW Power Supplies • Issue 2 

 

Page 62 

11. CIRCUIT DIAGRAMS 

3ZV0993211 

Connection  

2ZX0993201 

Power Conversion Section 

1SZX0320 Sheet 1 Control Board 

3SZX0320 Sheet 2 Control Board Component Variation Table 

2ZW0993210 

AP 1kW Schematic 

CZX0993201 

Front panel board. 

Summary of Contents for AP10030

Page 1: ...AP3080 AP6050 AP10030 AP3080 AP6050 AP10030 AP3080 AP6050 AP10030 AP3080 AP6050 AP10030 User Service Manual User Service Manual User Service Manual User Service Manual Part N 9HAP1kW Wayne Kerr Elect...

Page 2: ...ce is implied for the use of any patented feature It must not be reproduced in whole or in part or used for tendering or manufacturing purposes except under an agreement or with the consent in writing...

Page 3: ...13 5 4 RACK MOUNTING 13 6 OPERATING INSTRUCTIONS 15 6 1 FIRST TIME OPERATION 15 6 2 CONNECTING THE LOAD 16 6 3 PROTECTIVE CIRCUITS 17 6 4 OPERATING MODES 20 6 5 LINE IMPEDANCE TEST 30 6 6 CURRENT MONI...

Page 4: ...d NEUTRAL terminal to BLUE lead EARTH terminal to GREEN YELLOW lead The user must also ensure that the protective earth lead would be the last to break should the cable be subject to excessive strain...

Page 5: ...sitive parts must wear a wrist strap which provides a leaky path to ground impedance not greater than 1 megaohm 4 Components or circuit board assemblies must be stored in or on conductive foam or mat...

Page 6: ...B2529 1 Note In the event of damage in transit or shortage in delivery separate notices in writing should be given to both the carriers and Wayne Kerr Electronics Limited within three days of receipt...

Page 7: ...voltage availability Overvoltage Limit To protect the load from the inadvertent application of an excessive voltage the power supply incorporates an Overvoltage Limit OVL this causes the supply to dow...

Page 8: ...ilable for voltage and current ranges 10 20 30 20 40 60 80 34A 40A 50A 66 7A 80A 20 40 60 50 30 10 10 20 30 40 50 16 7A 20A 25A 33 5A 40A 50A 100 80 60 40 20 10A 12 5A 16 7A 20A 25A 30A 10 20 30 34 Fi...

Page 9: ...100 90 of maximum current Programming Response Time Maximum time for output voltage to change from 2 volts to maximum or from maximum to 2V and settle within 200mV band UP Full load 3 4 120ms No load...

Page 10: ...ption is fitted BUS indicates the unit is under bus control LSN indicates receiving data from the bus TLK indicates transmitting data on the bus and SRQ indicates that a service request has been initi...

Page 11: ...rear of unit in rack Panel Symbols Used Refer to handbook Alternating current Earth ground terminal CAUTION Risk of electric shock On Off ORDER CODES AP30 80 11AP3080 As above with IEEE488 2 interfac...

Page 12: ...minutes to allow capacitors to discharge 2 Remove the three fixing screws from each side trim 3 Remove side trims 4 Working from the front and for each cover slide backwards to clear recess in front...

Page 13: ...circuit breakers The power supplies are intended for use with mains wiring capable of supplying the rated input current without undue voltage drop See specification for maximum input currents The prot...

Page 14: ...ger Note orientation of insert with styling cut out opposite cut out in handle Insert screwdriver into other end and repeat procedure This will relieve the small tapered pins of the insert from the th...

Page 15: ...fitted with the IEEE488 option ensure that the Bus connector is disconnected and the Bus Local switch is in the Local position Both items are located on the back panel Fig 6 1 Front panel controls and...

Page 16: ...fully anticlockwise position and rotate the current control fully anticlockwise Depress the output enable switch and confirm that the CI legend is illuminated thus indicating that the power supply is...

Page 17: ...us area being lit The green output enable LED will be illuminated The over range condition occurs when the output power demanded from the supply exceeds 1000W The output does not shut down but will be...

Page 18: ...ictions or a too high ambient temperature Refer to instructions for filter cleaning see section 9 1 Resetting Overtemperature Trip When the unit has cooled sufficiently the overtemperature trip can be...

Page 19: ...lts and current flowing IN Output V I Normal CI operation meters read O P volts and current flowing IN Output V I Overrange condition IN Zero Overtemperature trip shutdown IN Zero Overvoltage trip out...

Page 20: ...int has been set higher than the actual current flowing into the load then the CV legend will be illuminated Whenever the load current reaches the previously set current limit figure the power supply...

Page 21: ...occur to the unit The supply can work continuously in this mode without damage but it will not meet specifications In particular the output ripple increases substantially and the output has poor regu...

Page 22: ...ing barrier strip terminals 10 and 11 and 12 and 13 c Connect the sense leads from the sense terminals to the load as shown in the diagram Fig 6 3 d Connect the load and replace the terminal cover e C...

Page 23: ...6 7 7 8 8 9 10 Vprog Common S S Programming resistor 0 4k7 for 0 to full scale O P Optional resistor for lower voltage limit Optional resistor for upper voltage limit 6 Voltage programme input 7 Front...

Page 24: ...rably low source impedance Fig 6 6 Connections for voltage programming output voltage Connecting up a variable voltage source as shown will programme the output voltage of the power supply from zero t...

Page 25: ...event this an upper limit programming resistor should be connected close to the barrier strip terminals The overvoltage limit may also be used to give protection against such occurrences 6 4 4 Auto Pa...

Page 26: ...olled by the master The current controls of the slaves are inoperative The voltage limits of the slaves should be set above the highest output voltage that is required This ensures that all the slaves...

Page 27: ...atively the current readings of the master and all the slaves can be summed necessary if different models are placed in parallel This should be taken into account when programming current limit settin...

Page 28: ...5 6 6 6 7 7 7 8 8 8 9 9 9 10 10 10 11 11 11 12 12 12 13 13 13 Master Load S S S S S S S S S Slave1 Slave 2 y x y x Fig 6 9 Connections for master slave series operation c Calculation Of Resistor Divid...

Page 29: ...g when the total load voltage is at the desired limit point When the master trips the slave units will programme down to minimum output voltage The trips on the slave units can also be set if required...

Page 30: ...vering full output power High a c line impedance can be due to poor mains wiring long extension leads or poor connections somewhere in the system Measuring the a c line voltage is an insufficient test...

Page 31: ...The voltmeter should be connected between terminals Imon and S The output impedance at terminal Imon is 5k 6 7 Inhibit Terminal The INHIB terminal output inhibit is an extra facility which can be use...

Page 32: ...through an R F I filter to the auxiliary transformer fan and mains rectifier diodes The soft start relay RL301 schematic and power conversion diagrams short circuits the soft start resistor R301 sche...

Page 33: ...onstant voltage mode operation the output voltage is divided by R184 P10 R183 and R182 and fed to either the overvoltage trip comparator IC22 control board diagram or the control amplifier IC13 pin 2...

Page 34: ...15 pin 6 is high and IC1 A output is low TR4 will be off The opposite is true of IC1 B controlled by the voltage amplifier Therefore TR5 will be on and constant voltage indicated In the unregulated mo...

Page 35: ...ent when the enable switch is on or the output voltage and current settings when the enable switch is off The voltmeter circuit consists of IC1 and display driver IC2 front panel circuit diagram The a...

Page 36: ...err see section 9 3 or to any approved service depot operated by our agents overseas Fig 8 1 Control Board Pot Positions Fig 8 2 Display board pot positions 8 1 Equipment Needed For Recalibration 25A...

Page 37: ...front panel meter corresponds with the calibrating DVM on AP100 30 a reading of EEE indicates 100V Adjust P1 on the meter board if necessary e Reduce resistance box to 470 and adjust P6 to obtain 0 5...

Page 38: ...ith output enable off adjust the front panel voltage control to obtain 97 5V for AP100 30 58 5V for AP60 50 and 29 25 for AP30 80 on the front panel meter Adjust P5 on the front panel board until the...

Page 39: ...oad to obtain 30A 0 05A for AP100 30 50A 0 05A for AP60 50 and AP30 80 d Adjust P4 I sense balance on control board until front panel meter reads 30 0A 0 1A for AP100 30 50 0A 0 1A for AP60 50 and AP3...

Page 40: ...osed on the low frequency ripple waveform The peak peak ripple figure is measured as the voltage between the peaks of the brightest part of the waveform Higher frequency noise may not be visible 10mSe...

Page 41: ...nal whilst the unit is delivering the desired output and checking for any reading on the oscilloscope Noise generated by the power supply will tend to be short spikes or bursts of high frequency noise...

Page 42: ...cloth Should it be required weak detergents can be used No water should enter the power supply If the insides of the unit become clogged with dust a service will be required do not attempt to wash do...

Page 43: ...ceptional circumstances and at the discretion of the Service Manager a charge for labour and carriage costs incurred may be made Our responsibility is in all cases limited to the cost of making good t...

Page 44: ...decade blocks delimited by colons second and subsequent numbers within a decade block represent only the unit value of the location the tens and hundreds values being implied e g for a component locat...

Page 45: ...ATSINK B 2 00F 3SUBA3922 DG12PI600 600V 12A 50NS DO220I 2 29S STTA1206DI D1 2 JIG 223 ENSURE COMP IS BYT12PI600 MF3888 CRAYOTHERM INSULATOR B 6 72C 4SUOO3888 SR090L06 T TRIP STUD 90C N C 300MM LDS 2 3...

Page 46: ...REW M3 X 8 PAN HD POZI 2 05T KP3M8 KP4M10 SCREW M4 X 10 PAN HD POZI 2 05T KP4M10 KP4M20 SCREW M4 X 20 PAN HD POZI 1 05T KP4M20 RF16R02NJ 6R0 6R0 DUAL 5 11W0 1 17V 226 216 R301 SR20016 HI V POWER 12VDC...

Page 47: ...1K80FF 1K80 1 0W60 50PPM 250V 5 18P MRS25 R45 152 3 77 8 RM42K20FF 2K20 1 0W60 50PPM 250V 4 18P MRS25 R63 96 129 220 RM42K70FF 2K70 1 0W60 50PPM 250V 3 18P MRS25 R111 32 56 RM43K30FF 3K30 1 0W60 50PPM...

Page 48: ...N C63 95 CR44N70LJ 4n70F 5 0 100V KT 3X08 R05 0 1 159W FKS2MIN C62 CR533N0KM 33n0F 20 63V MKT 3X08 R05 0 1 159W MKS2 C53 CR6100NKM 100nF 20 63V MKT 3X08 R05 0 1 159W MKS2MIN C65 CR6100NLM 100nF 20 100...

Page 49: ...F 33K0 1 0W60 50PPM 250V 2 18P MRS25 R14 9 SA16700 SWITCH CAP GREY 2 24M 16 700 SB15500 PUSH BUTTON SWITCH BLK PB 1 24M 15 501 BLK PB SW1 SB15550 PUSH B SW 15 550 LATCH RED PB 1 24M 15 551 03 SW2 TIH2...

Page 50: ...ST253A90 CCT BREAKER 25 33A 250V 2POLE 1 21C BA2 B0 24 625 212 D CB401 TL72332 JUMPER LINK 6 26V 7204 3502 A120 WF3M FLAT WASHER M3 2 05T WF3M WN8B FLAT WASHER 8BA M2 5 NYLON 66 2 40P 011 0763 WS3M SP...

Page 51: ...B CL42N20WM1 2n20F 20 1K0V 1 47L 106 362 C4 CRA1U00SM 1U00F 20 400V A 3 03A E1A10204A C1 3 DAOMIT DIODES OMITTED 2 00F DAOMIT D1 2 MC2 CERAMIC BEAD LARGE 4 57M IPB2 R1 2 FIT X1 PER LEG RM233R0FF 33R0...

Page 52: ...52 CR510N0LJ 10n0F 5 0 100V KT 3X08 R05 0 24 159W FKS2 C13 7 8 22 38 40 3 5 8 51 6 8 70 2 6 9 80 8 90 2 CR510N0LM 10n0F 20 100V KT 3X08 R05 0 2 159W FKS2MIN C41 96 CR6100NLM 100nF 20 100V MKT 3X10 R07...

Page 53: ...CN BCMOS 4X 2 I P NAND 14 DP STAT 2 23N CD4093BCN IC4 28 VF540 IRF540 STATIC 1 10I IRF540 TR33 VF9522 FET IRF9522 STATIC 1 10I IRF9520 TR31 VP10218 TRANSISTOR PAD 10218 2 27K EPX003 Z3 4 VS14L IC SKT...

Page 54: ...SSEMBLY A 1 4 5N6050F1 FRONT PANEL DISPLAY C B G 1 5NAPDISA DISPLAY CB AXIAL ASSY A 1 BC235 FRONT PANEL DISPLAY BOARD C 1 01K CBP32B2350 BOARD TO BE ATE TESTED RM15R10FF 5R10 1 0W60 50PPM 250V 2 18P M...

Page 55: ...015 YP3079BLK 14AWG BLACK UL1015 51 09A 14AWG UL1015 YP3079BN 14AWG BROWN UL1015 44 09A 14AWG UL1015 YP3079RD 14AWG RED UL1015 45 09A 14AWG UL1015 YP702GYV 7 0 2 GREY 105 84 08I 30 X 0 1 SOFLEX TQ YP7...

Page 56: ...0C N C 300MM LDS 2 34T L0609005300 THT1 2 VFP450IR 500V 13A 400MR TO3P STATIC 6 10I IRFP450 Q1 6 JIG 182 7NU0993523 HEAT SINK SUPPORT C 1 00F 3BA0993523 7NU0993524 HEAT SINK COVER A B 1 00F 2BA0993524...

Page 57: ...05T WS4M YT18 T C WIRE 18SWG 062 55M 18SWG 5N6050IP I P FILTER CB A 1 5 BC238 FILTER 60 50 S C 1 01K 2BS23B2380 B CAOMIT CAPACITORS OMITTED 2 00F CAOMIT C312 3 CX6470NPM 470NF 20 250V R250 5 13R PME...

Page 58: ...PPM 250V 4 18P MRS25 R57 60 133 207 RM46K80FF 6K80 1 0W60 50PPM 250V 3 18P MRS25 R2 86 131 RM48K20FF 8K20 1 0W60 50PPM 250V 4 18P MRS25 R151 4 76 9 RM49K10FF 9K10 1 0W60 50PPM 250V 2 18P MRS25 R28 9 R...

Page 59: ...KT 3X10 R07 5 1 85S B32511 D3223K 10PCM C65 DAOMIT DIODES OMITTED 1 00F DAOMIT D33 DLINK22 22SWG TC LINK F 1 00F DLINK22 D23 YT22 T C WIRE 22SWG 035 55M 22SWG PM3500RKV 500R 10 PRESET VERT STURN 1 02S...

Page 60: ...SW 15 550 LATCH RED PB 1 24M 15 551 03 SW2 TIH2526NT1L 26 WAY PIN HEADER 1 25V M52 1226 660 SK1 TK30513 PIN LINE SOCKET 3WAY 9 35R 3 0513 10 LED4 7 14 TP7401 12WAY STAKED MALE CONTACT 4 07A 1 163740...

Page 61: ...CAP C150 SIF BLK 2 01S C150 HK15025 KNOB S150250 SIF BLK 2 01S S150250 HL9X30 BLANK 9X30 P120 1 51D P120 HMDEC10 FILTER FOAM DECLON 17mm THICK 01 14D 10PPI 17MM THICK 125 X 115MM HR3 GUIDE RAIL RCG3...

Page 62: ...Page 62 11 CIRCUIT DIAGRAMS 3ZV0993211 Connection 2ZX0993201 Power Conversion Section 1SZX0320 Sheet 1 Control Board 3SZX0320 Sheet 2 Control Board Component Variation Table 2ZW0993210 AP 1kW Schemati...

Page 63: ...AP 1kW Power Supplies Issue 2 Circuit Diagrams Page 63...

Page 64: ...AP 1kW Power Supplies Issue 2 Circuit Diagrams Page 64...

Page 65: ...AP 1kW Power Supplies Issue 2 Circuit Diagrams Page 65...

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