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Operating Manual for XKW 3kW Series Power Supply

Power Supply Safety Markings

Alternating Current

Off (Supply)

Earth (Ground) Terminal

Caution (Hot Surface)

Protective

Conductor

Terminal

Caution (Check manual for
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On (Supply)

TM-25OP-01XN.book Page viii Monday, April 5, 2004 8:58 AM

Summary of Contents for XKW 12-150

Page 1: ...Operating Manual XKW 3000 Watt Series Programmable DC Power Supply XKW 8 350 XKW 10 300 XKW 12 150 XKW 20 150 XKW 40 75 XKW 55 55 XKW 60 50 XKW 80 37 XKW 150 20 XKW 300 10...

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Page 3: ...Operating Manual for XKW 3000 Watt Series Programmable DC Power Supply...

Page 4: ...improved design in the repair or replacement If Xantrex repairs or replaces a product its warranty continues for the remaining portion of the original Warranty Period or 90 days from the date of the...

Page 5: ...product exchanged under warranty What does this warranty not cover This Limited Warranty does not cover normal wear and tear of the product or costs related to the removal installation or troubleshoo...

Page 6: ...ILL XANTREX BE LIABLE FOR ANY SPECIAL DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES LOSSES COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMI...

Page 7: ...ur product user manual for limitations on uses of the product Specifically please note that this power supply is not intended for use in connection with life support systems and Xantrex makes no warra...

Page 8: ...us energy for some time after power is removed CAUTION Operate the power supply in an environment free of flammable gases or fumes To ensure that the power supply s safety features are not compromised...

Page 9: ...input and output power as well as the observance of safe techniques while making supply or pin connections and any changes in switch settings Main Sections Section 1 Features and Specifications Descr...

Page 10: ...g Manual for XKW 3kW Series Power Supply Power Supply Safety Markings Alternating Current Off Supply Earth Ground Terminal Caution Hot Surface Protective Conductor Terminal Caution Check manual for ad...

Page 11: ...ecifications 25 Section 2 Installation Introduction 27 Basic Setup Procedure 27 Inspection Cleaning and Packaging 28 Initial Inspection 28 Periodic Cleaning 28 Returning Power Supplies to the Manufact...

Page 12: ...ch and Connector 51 Resetting Jumpers and Switch 51 Making J3 Connections 53 Remote Programming of Output Voltage and Current Limit 54 Remote Programming Options 54 Programming Output Voltage and Curr...

Page 13: ...Calibration Setup 79 Service Environment and Precautions 79 Accessing Calibration Potentiometers 79 Calibrating for Programming Accuracy 82 Voltage Programming Circuit Calibration 82 Current Programm...

Page 14: ...xii Operating Manual for XKW 3kW Series Power Supply...

Page 15: ...ource 58 Figure 3 7 Programming Output Voltage with a 0 1mA Source 58 Figure 3 8 Programming Output Voltage with a 5k ohm Resistance 59 Figure 3 9 Programming Output Current Limit with a 0 5Vdc Source...

Page 16: ...iv Operating Manual for XKW 3kW Series Power Supply Figure 3 25 Split Supply Operation of Multiple Supplies 76 Figure 3 26 Split Supply Operation of Multiple Supplies 77 Figure 4 1 Calibration Adjustm...

Page 17: ...8 Table 3 1 Remote Programming Options 54 Table 3 2 Switch Settings for TTL Shutdown Circuit Logic 66 Table 3 3 Switch Settings for AC DC Shutdown Circuit Logic 67 Table 3 4 Relay and Switch Settings...

Page 18: ...List of Tables xvi Operating Manual for XKW 3kW Series Power Supply...

Page 19: ...S 232 control It is designed for a broad range of development system and burn in applications and uses high frequency switching regulator technology to achieve high power density in a small package si...

Page 20: ...d current or voltage and operated in master slave mode Remote sensing to compensate for losses in power leads up to 1 V per lead Adjustable Over Voltage Protection OVP External TTL AC or DC shutdown R...

Page 21: ...igure 1 1 Power Supply Front Panel Over Temperature LED OTP Remote Programming LEDs for units with optional programming interface installed Over Voltage LED OVP Indicates when the output voltage excee...

Page 22: ...or are located on the rear panel The program and monitor function selector switch SW1 is located internally on the main PCB See Figure 1 2 on page 20 for locations Refer to Section 2 Installation for...

Page 23: ...or 0 100 load variation with constant nominal line voltage 8 mV 350 mA 10 mV 300 mA 12 mV 250 mA 20 mV 150 mA 40 mV 75 mA Meter Accuracy Voltage Current 0 09 V 4 5 A 0 11 V 4 0 A 0 13 V 3 5 A 0 2 V 1...

Page 24: ...mA 60 mV 50 mA 80 mV 37 mA 150 mV 20 mA 300 mV 10 mA Meter Accuracy Voltage Current 0 65 V 0 65 A 0 7 V 0 6 A 0 9 V 0 47 A 1 6 V 0 30 A 3 1 V 0 20 A OVP Adjustment Range 2 75 60 5 V 3 66 V 4 88 V 7 5...

Page 25: ...rogramming source and a resistive load 2 Time for the output voltage to recover within 1 band for 30 step load change from 70 to 100 or 100 to 70 Rated AC Input Voltage with Maximum Input Current 200...

Page 26: ...istances 0 5V 0 10V sources 0 1mA sources OVP programming 0 5V 0 10V sources Maximum Remote Sense Line Drop Compensation 1 V max Operating Temperature Range 0 50 C From 50 70 C derate output 2 per C S...

Page 27: ...nput Connector Type IEC Output Connector Nickel plated copper busbars Sense Connector Part of J3 Analog Programming Connector Part of J3 Cooling Fan cooled Air exhausts to rear Over temperature shutdo...

Page 28: ...Features and Specifications Specifications 26 Operating Manual for XKW 3kW Series Power Supply...

Page 29: ...front panel operation OVP OTP shutdown and using multiple supplies You will also find remote programming and monitoring described in the same section Step Description Action Reference 1 Safety Read a...

Page 30: ...d and its components if you suspect internal damage If the unit is damaged save all packing materials and notify the carrier immediately See packing instructions on page 29 Periodic Cleaning No routin...

Page 31: ...es on page 30 preferably using the original box and packing materials Please ensure that your product is shipped fully insured in the original packaging or equivalent This warranty will not apply wher...

Page 32: ...he power supply in its original container If the original container is not available seal the unit in a plastic bag and then pack it in a 200 lb 90 kg test corrugated cardboard carton large enough to...

Page 33: ...ear of the unit Rack Mounting The power supply is designed to fit in a standard 19 in equipment rack Bolt holes in the chassis sides are provided for rack mount slides such as the ZERO C300S18 slides...

Page 34: ...y is connected to a grounded AC outlet with the recommended AC input connector configured for the available voltage as described in this section WARNING Disconnect AC power from the unit before removi...

Page 35: ...e base of the strain relief from the helix shaped body Insert the base through the outside opening in the AC input cover and from the inside screw the locknut securely onto the base 4 Slide the helix...

Page 36: ...ock washers provided Figure 2 2 Stripped Wire Installed in Strain Relief Table 2 2 AC Connections for Single and Three Phase Input Input Line Impedance The maximum input line impedance for operation a...

Page 37: ...ter a short power on delay the front panel meters should light up with both displays reading zero Figure 2 3 Connector J3 Configuration for Local Operation Voltage Mode Operation To check voltage mode...

Page 38: ...he model rated output voltage plus 10 2 Turn OVP SET potentiometer counter clockwise and check that the voltmeter reading decreases Continued turning up to 20 turns will see the reading decrease to ap...

Page 39: ...output Load Connection Reliable performance of the power supply can be obtained if certain basic precautions are taken when connecting it for use on the lab bench or installing it in a system To obta...

Page 40: ...ting in free air Where load wiring must operate in areas with elevated ambient temperatures or bundled with other wiring use larger gauges or wiring rated for higher temperatures Table 2 3 Current Car...

Page 41: ...er Supply Rear Panel on page 20 The power supply provides three load wiring mounting holes on each bus bar terminal as specified in the following table Connecting Single Loads Figure 2 5 and Figure 2...

Page 42: ...GAUGE LOAD LINES LOAD NEGATIVE LOAD POSITIVE LOAD TERMINAL TERMINAL POWER SUPPLY TERMINAL TERMINAL RETURN SENSE OUTPUT RETURN POSITIVE OUTPUT POSITIVE SENSE REMOTE SENSE LINE SEE SECTION 3 3 FOR POSS...

Page 43: ...d for distribution Connecting the sense leads to these terminals will compensate for losses and minimize the effect of one load upon another Inductive Loads To prevent damage to the power supply from...

Page 44: ...OAD POSITIVE LOAD POSITIVE LOAD TERMINAL TERMINAL TERMINAL TERMINAL POWER SUPPLY TERMINAL TERMINAL RETURN SENSE OUTPUT RETURN POSITIVE OUTPUT POSITIVE SENSE REMOTE SENSE LINE SEE SECTION 3 3 FOR POSSI...

Page 45: ...gramming sensing and monitoring See Configuring for Remote Programming Sensing and Monitoring on page 48 Figure 2 9 Local Mode Default Configuration Setting Output Voltage and Current Limit After inst...

Page 46: ...sense lines refer to Figure 2 10 and to the following procedure 1 Ensure the power supply is turned OFF Allow five 5 minutes to elapse to dissipate stored energy before altering J3 connector pin conne...

Page 47: ...regulation will be degraded and or erratic Figure 2 10Connecting Remote Sense Lines POS LOAD WIRE LOAD WIRE ONE LOCATION ONLY LOCATIONS ALTERNATE SEE TEXT FOR OUTPUT NEGATIVE GROUND SHIELD IN SNS SNS...

Page 48: ...Installation Using Remote Sensing 46 Operating Manual for XKW 3kW Series Power Supply...

Page 49: ...8 provides a reference to the function and location of these controls and procedures for making any required changes Feature Reference Remote Programming of Output Voltage and Current Limit with 0 5V...

Page 50: ...ntrol Functions Front Panel REM LOC Switch You can use the REM LOC Remote Local Programming switch for remote programming When set to REM Remote Programming control of BOTH output voltage AND current...

Page 51: ...mote Programming Sensing and Monitoring Revision A 49 Figure 3 1 J3 Program Sense and Monitor Connector Description 15 NOT USED NOT USED CALIBRATED OUTPUT VOLTAGE MONITOR 0 5V AND 0 10V OUTPUT REPRESE...

Page 52: ...and Current Monitor Range Shutdown Circuit Logic Figure 3 2 Internal Jumpers and Switch Default Settings Shown SELECTS CURRENT LIMIT A B 0 10V A B 0 10V B C 0 5V B C 0 5V RANGE RANGE PROGRAMMING INPU...

Page 53: ...r changing connections to the J3 connector Figure 3 3 Locating Jumpers Switch and Connector Resetting Jumpers and Switch Most applications will use the default factory settings of the internal jumpers...

Page 54: ...e jumpers and switches are located The option board must be removed to allow access to them 5 Unplug any external mating connector and attached wiring 6 Use a nutdriver to remove the jack screws which...

Page 55: ...ent sources or resistance Follow the procedures in this section whenever the rear panel connector J3 is to be reconfigured The steps to follow are Dissipating stored energy Making the connections Powe...

Page 56: ...ess options for programming output voltage and current limit with the input scales supported for the power supply Refer to Programming Output Voltage and Current Limit with the REM LOC Switch on page...

Page 57: ...o access internal jumpers JMP1 and JMP2 to change their settings Programming Output Voltage and Current Limit with the REM LOC Switch The front panel REM LOC Remote Local Programming switch will allow...

Page 58: ...to their A B locations before connecting the voltage and current limit programming inputs 2 Resetting internal jumpers may require a recalibration of the programming circuit to maintain programming ac...

Page 59: ...0 10V Source 1 Set internal 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 external voltage programming source between pins 9 vo...

Page 60: ...20 and 21 of connector J3 2 Connect the external programming source between pin 9 voltage programming input positive and pin 12 return of connector J3 Varying the current source from 0 to 1mA will va...

Page 61: ...model rating The output current limit is set locally by adjusting the front panel current limit control Figure 3 8 Programming Output Voltage with a 5k ohm Resistance Programming Output Current Limit...

Page 62: ...tage from 0 to 10Vdc will cause the output current limit to vary from 0 to 100 of the model rating The output voltage is set locally by adjusting the front panel voltage control Note Resetting interna...

Page 63: ...ol Figure 3 11Programming Output Current Limit with a 0 1mA Source Programming Output Current Limit with a 0 5k Resistance 1 Remove the jumpers connecting pins 10 to 11 and pins 22 to 23 on connector...

Page 64: ...hecked at 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 zer...

Page 65: ...between pin 3 positive and pin 12 return on the J3 connector on the rear panel See Figure 3 13 and Figure 3 14 The use of shielded twisted pair wiring is recommended Ground the shield to J3 connector...

Page 66: ...perature of a supply heatsink using a temperature sensor and will activate the internal shutdown circuit whenever the maximum temperature is exceeded The red OTP LED on the front panel lights up when...

Page 67: ...e Shutdown circuit uses either a TTL compatible signal or a 12 250Vac or 12 130Vdc input to disable or enable the power supply output Connections for either TTL AC or DC input signals are made at conn...

Page 68: ...nel lights up when the Shutdown circuit is activated Figure 3 15Using Shutdown with a TTL Compatible Positive Logic Figure 3 16Using Shutdown with a TTL Compatible Negative Logic Switch SW1 8 Setting...

Page 69: ...select the desired circuit logic as set out in Table 3 3 Table 3 3 Switch Settings for AC DC Shutdown Circuit Logic The red SD shutdown LED on the front panel lights up with the Shutdown circuit is a...

Page 70: ...es to elapse to dissipate stored energy before making connections or resetting switches Refer to Configuring for Remote Programming Sensing and Monitoring on page 48 for instructions for resetting swi...

Page 71: ...sitive Logic Relay Switch SW1 8 Setting Relay Coil State Output Normally Open Relay OPEN Positive Logic Energized OFF De energized ON CLOSED Negative Logic Energized ON De energized OFF Normally Close...

Page 72: ...own with Contact Closure of a CLOSED Relay Positive Logic RELAY COIL DE ENERGIZED OUTPUT OFF RELAY COIL ENERGIZED OUTPUT ON AS SHOWN RELAY NORMALLY OPEN 15 6 2 14 1 25 13 J3 OPEN OFF CLOSED ON 2 3 4 5...

Page 73: ...1 Figure 3 22Using Shutdown with Contact Closure of a CLOSED Relay Negative Logic RELAY COIL DE ENERGIZED OUTPUT ON RELAY COIL ENERGIZED OUTPUT OFF NORMALLY CLOSED AS SHOWN RELAY 15 6 2 14 1 25 13 J3...

Page 74: ...100 of the model rated output Status Indicators Status indicators for thermal shutdown OVP circuit programming mode and operating mode are available via connections on the J3 connector on the rear pa...

Page 75: ...rminal of one supply to the positive output terminal of the next supply See Figure 3 23 The total voltage available is the sum of the maximum voltages of each supply add voltmeter readings The maximum...

Page 76: ...nts of each supply Notes 1 Set the OVP trip level to the same point for all of the paralleled supplies 2 When operating multiple supplies in parallel the operating mode of each supply will depend on t...

Page 77: ...lation one supply always operates in current limit mode and supplies most of the power Figure 3 24Parallel Operation of Multiple Supplies Local sense lines shown are default J3 connections POWER SUPPL...

Page 78: ...a positive voltage relative to the common connection while the negative output terminal of the second supply provides a negative voltage The current limits can be set independently The maximum current...

Page 79: ...hown are default J3 connections COMMON LOAD POWER SUPPLY 2 POWER SUPPLY 1 POSSIBLE AND SHORTEST LENGTH USE THE LARGEST GAUGE LOAD LINES LOAD NEGATIVE LOAD POSITIVE LOAD TERMINAL TERMINAL TERMINAL TERM...

Page 80: ...Operation Using Multiple Supplies 78 Operating Manual for XKW 3kW Series Power Supply...

Page 81: ...ccur Accessing Calibration Potentiometers WARNING Exercise caution when using and calibrating a power supply High energy levels can be stored at the output voltage terminals on a power supply in norma...

Page 82: ...Removing the Option Board when required The power supply may have either of two option circuit boards installed over the A2 circuit board where the jumpers and switches are located The option board mu...

Page 83: ...Calibration Calibration Setup Revision A 81 Figure 4 1 Calibration Adjustment Locations R60 R93 R66 R95 R23 R56 R24 R55...

Page 84: ...is procedure until the voltage programming is adjusted to the desired accuracy Function designation of multiturn trim pots Step Action 1 Disconnect any load Connect a DVM rated at better than 0 5 accu...

Page 85: ...x R where V is the DVM reading I is the current and R is the DC shunt resistance Function designation of multiturn trim pots Step Action 1 Connect a shunt and DVM to the power supply output See Note...

Page 86: ...curacy Note 1 The recommended accuracy rating for the DVMs is four times better than your desired readback accuracy Function Designation of multiturn trim pots Step Action Output Voltage Monitor 1 Dis...

Page 87: ...V is the DVM reading I is the current and R is the DC shunt resistance Function Designation of multiturn trim pots Step Action Output Current Monitor 1 Disconnect any load Connect a shunt and DVM acr...

Page 88: ...rent and voltage Use the following table as a reference 2 Connect the diode in series with either supply output to prevent the battery from discharging through the internal OVP crowbar transistor The...

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Page 90: ...Technology Inc 1 800 670 0707 Tel toll free NA 1 360 925 5097 Tel direct 1 800 994 7828 Fax toll free NA 1 360 925 5143 Fax direct customerservice xantrex com www xantrex com TM 25OP 01XN Printed in...

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