AMETEK CW-M User Manual

CW-M SERIES

AC POWER SOURCE

Operation Manual

This manual covers models:

CW 801M
CW 1251M
CW 2501M

October 2013 Document No. M161570-01 Rev H

Contact Information

Telephone: [phone] (toll free in North America)
858 450 0085 (direct)
Fax: [phone]
Email:
Domestic Sales: [e-mail]
International Sales: [e-mail]
Customer Service: [e-mail]
Web: www.programmablepower.com

About AMETEK

AMETEK Programmable Power, Inc., a Division of AMETEK, Inc., is a global leader in the design
and manufacture of precision, programmable power supplies for R&D, test and measurement,
process control, power bus simulation and power conditioning applications across diverse
industrial segments. From bench top supplies to rack-mounted industrial power subsystems,
AMETEK Programmable Power is the proud manufacturer of Elgar, Sorensen, California
Instruments and Power Ten brand power supplies.

AMETEK, Inc. is a leading global manufacturer of electronic instruments and electromechanical
devices with annualized sales of $2.5 billion. The Company has over 11,000 colleagues working
at more than 80 manufacturing facilities and more than 80 sales and service centers in the United
States and around the world.

Trademarks

AMETEK is a registered trademark of AMETEK, Inc.
Other trademarks, registered trademarks, and product names are the property of their respective
owners and are used herein for identification purposes only.

Notice of Copyright

CW-M Series AC Power Source, Operation Manual

All rights reserved.

© 2010 AMETEK Programmable Power, Inc.

Exclusion for Documentation

UNLESS SPECIFICALLY AGREED TO IN WRITING, AMETEK PROGRAMMABLE POWER, INC.
(“AMETEK”):

(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY

TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER
DOCUMENTATION.

(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR

EXPENSES, WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL,
WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH
INFORMATION WILL BE ENTIRELY AT THE USER’S RISK, AND

(c) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH,

ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE
TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED AMETEK CONTENT
IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION, WHICH IS POSTED AT
WWW.PROGRAMMABLEPOWER.COM.

Date and Revision

October 2013 Revision H

Part Number

M161570-01

Contact Information

Telephone: [phone] (toll free in North America)
858 450 0085 (direct)
Fax: [phone]
Email: [e-mail]
[e-mail]
Web: www.programmablepower.com

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ii

WARNING

Hazardous voltages may be present when covers are removed. Qualified
personnel must use extreme caution when servicing this equipment.
Circuit boards, test points, and output voltages also may be floating above
(below) chassis ground.

WARNING

The equipment used contains ESD sensitive ports. When installing
equipment, follow ESD Safety Procedures. Electrostatic discharges might
cause damage to the equipment.

Important Safety Instructions

Before applying power to the system, verify that your product is configured properly for your
particular application.

Only qualified personnel who deal with attendant hazards in power supplies, are allowed to perform
installation and servicing.

Ensure that the AC power line ground is connected properly to the Power Rack input connector or
chassis. Similarly, other power ground lines including those to application and maintenance
equipment must be grounded properly for both personnel 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 voltages within the chassis.

However, depending on the user’s application configuration, HIGH VOLTAGES HAZARDOUS TO
HUMAN SAFETY may be normally generated on the output terminals. The customer/user must

ensure that the output power lines are labeled properly as to the safety hazards and that any
inadvertent contact with hazardous voltages is eliminated.

Guard against risks of electrical shock during open cover checks by not touching any portion of the
electrical circuits. Even when power is off, capacitors may retain an electrical charge. Use safety
glasses during open cover checks to avoid personal injury by any sudden component failure.

Neither AMETEK Programmable Power Inc., San Diego, California, USA, nor any of the subsidiary
sales organizations can accept any responsibility for personnel, material or inconsequential injury,
loss or damage that results from improper use of the equipment and accessories.

SAFETY SYMBOLS

iii

Product Family: CW 801M, CW 1251M, CW 2501M

Warranty Period: One Year

WARRANTY TERMS

AMETEK Programmable Power, Inc. (“AMETEK”), provides this written warranty covering the

Product stated above, and if the Buyer discovers and notifies AMETEK in writing of any defect in
material or workmanship within the applicable warranty period stated above, then AMETEK may,
at its option: repair or replace the Product; or issue a credit note for the defective Product; or
provide the Buyer with replacement parts for the Product.

The Buyer will, at its expense, return the defective Product or parts thereof to AMETEK in
accordance with the return procedure specified below. AMETEK will, at its expense, deliver the
repaired or replaced Product or parts to the Buyer. Any warranty of AMETEK will not apply if the
Buyer is in default under the Purchase Order Agreement or where the Product or any part
thereof:

 is damaged by misuse, accident, negligence or failure to maintain the same as

specified or required by AMETEK;

 is damaged by modifications, alterations or attachments thereto which are not

authorized by AMETEK;

 is installed or operated contrary to 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 assert any claim that the Products are not in conformity with any warranty
until the Buyer has made all payments to AMETEK provided for in the Purchase Order Agreement.

PRODUCT RETURN PROCEDURE

1. Request a Return Material Authorization (RMA) number from the repair facility (must be

done in the country in which it was purchased):

 In the USA, contact the AMETEK Repair Department prior to the return of the

product to AMETEK for repair:
Telephone: [phone], ext. 2295 or ext. 2463 (toll free North America)

858-450-0085, ext. 2295 or ext. 2463 (direct)

 Outside the United States, contact the nearest Authorized Service Center

(ASC). A full listing can be found either through your local distributor or our
website, www.programmablepower.com, by clicking Support and going to the
Service Centers tab.

2. When requesting an RMA, have the following information ready:

 Model number
 Serial number
 Description of the problem

NOTE: Unauthorized returns will not be accepted and will be returned at the shipper’s expense.

NOTE: A returned product found upon inspection by AMETEK, to be in specification is subject to

an evaluation fee and applicable freight charges.

iv

CONTENTS

1

2

3

INTRODUCTION ............................................................ 1-1

SPECIFICATIONS .......................................................... 2-1

2.1 Output ..................................................................................................... 2-1

2.2 Current .................................................................................................... 2-2

2.3 Measurement .......................................................................................... 2-2

2.4 Front Panel .............................................................................................. 2-3

2.5 Rear Panel Connections ......................................................................... 2-4

2.6 Input ........................................................................................................ 2-4

2.7 General ................................................................................................... 2-5

2.8 Options and Accessories ........................................................................ 2-5

INSTALLATION ............................................................. 3-1

3.1 Unpacking ............................................................................................... 3-1

3.2 Wire Gauge Selection ............................................................................. 3-2

3.3 Mounting Instructions .............................................................................. 3-5

3.4 Cooling ................................................................................................ .. 3-10

3.5 Power In Connections ........................................................................... 3-10

3.6 Power Out Connections ........................................................................ 3-12

3.7 Sense Connections ............................................................................... 3-14

3.8 Parallel Connected Units ....................................................................... 3-16

3.9 Multiphase Connected Units ................................................................. 3-16

4

M161570-01 v

SET-UP .......................................................................... 4-1

4.1 CONFIG Dipswitch .................................................................................. 4-1

4.2 Setting the CONFIG Dipswitch ................................................................ 4-2

4.3 Parallel and Multiphase Configurations ................................................... 4-3

Elgar CW-M Series

4.4 Setting the Phase Angle ......................................................................... 4-8

5

6

OPERATION ................................................................... 5-1

5.1 Parallel and Multiphase Operation .......................................................... 5-4

5.2 Remote Control Signals .......................................................................... 5-5

MAINTENANCE.............................................................. 6-1

6.1 Periodic Service ...................................................................................... 6-1

6.2 Fuse Replacement .................................................................................. 6-1

List of Figures

Figure 1-1. ContinuousWave (Model CW1251M) Front Panel ......................................... 1-2

Figure 3-1. Slide Mounting ............................................................................................... 3-5

Figure 3-2. Mounting Dimensions, Front and Rear Views (CW 801M, CW 1251M) ......... 3-6

Figure 3-3. Mounting Dimensions, Front and Rear Views (CW 2501M) ........................... 3-7

Figure 3-4. Mounting Dimensions, Top and Side Views (CW 801M, CW 1251M) ............ 3-8

Figure 3-5. Mounting Dimensions, Top and Side Views (CW 2501M) ............................. 3-9

Figure 3-6. Input Power Connections ............................................................................. 3-10

Figure 3-7. Output Power Connections ................................ ................................ .......... 3-13

Figure 3-8. Output Voltage Sensing Configuration ......................................................... 3-14

Figure 3-9. Sense Connections ...................................................................................... 3-15

Figure 4-1. CW Rear Panel .............................................................................................. 4-1

Figure 4-2. Config Dipswitch, Factory Default Settings .................................................... 4-1

Figure 4-3. Dipswitch Default Setting, Example 1 ............................................................ 4-2

Figure 4-4. Dipswitch Default Setting, Example 2 ............................................................ 4-2

Figure 4-5. Dipswitch Settings for 3-Phase, 2-Paralleled Each, Configuration ................. 4-3

Figure 4-6. Dipswitch Settings for 6-Parallel Configuration .............................................. 4-4

Figure 4-7. Dipswitch Settings for 6-Phase Configuration ................................................ 4-5

Figure 4-8. Dipswitch Settings for 2-Phase Configuration ................................................ 4-6

Figure 4-9. Dipswitch Settings for 3-Phase Configuration ................................................ 4-7

Figure 5-1. CW Front Panel Controls ............................................................................... 5-1

Figure 5-2. External Control Connector ............................................................................ 5-5

List of Tables

Table 3–1. Recommended Wire Gauge Selection Guide ............................................ 3-3

Table 3–2. Recommended Cables ............................................................................ 3-11

Table 4–1. CONFIG Dipswitch Functions .................................................................... 4-2

Table 4–2. Phase Angles ............................................................................................ 4-8

Table 6–1. Replacement Fuses .................................................................................. 6-1

iv M161570-01

SECTION 1

INTRODUCTION

Elgar's ContinuousWave™ (CW) Series power sources deliver up to 1250

VA in a 2U high (3.5 inches) rackmount chassis, and 2500 VA in a 5.25
inch chassis. This low profile design is also suitable for benchtop use. The
CW Series models have three power ratings: 800 VA, 1250 VA, and 2500
VA. The switchmode, Power Factor Corrected (PFC) design efficiently
delivers clean AC power.

Voltage, current, and frequency settings are quickly adjusted from the front
panel knobs (10–turn potentiometers). Also, the sources can be
programmed remotely from the rear panel analog port. The output is
protected against overvoltage, overcurrent, and overtemperature
conditions. They can be easily paralleled in the field with an additional
parallel cable. A two-speed fan results in quieter operation at lower power
levels.

Key features of the CW Series AC power sources include:High
performance/value design

 Output available at front or rear panel
 Full rated current for two output voltage ranges: 0 to 135 VAC and 0 to

270 VAC

 Low profile 2U (3.5") rack height for CW 801M and CW 1251M, and 5.25"

rack height for CW 2501M

 Single phase AC output: 45 to 500 Hz
 Multi phase and paralleling
 Measures output voltage, current, and frequency
 Side air intake, exhaust to rear
 Two large 4-digit, 7-segment LED displays

M161570-01 1-1

Elgar CW-M Series

 Transformer coupled output, 500 VRMS isolation voltage between either

output terminal to chassis

 Power-up to previous front panel setting or 0 Volts (switch selectable)
 Universal Input:

90–264 VAC (CW 801M),
103–264 VAC (CW 1251M),
180–264 VAC (CW 2501M)

 Optional front panel locking knobs
 1–year calibration interval
 CE Mark

Figure 1-1. ContinuousWave (Model CW1251M) Front Panel

1-2 M161570-01

SPECIFICATIONS

Note: Product specifications are subject to change without notice.

SECTION 2

2.1 OUTPUT

Power

CW 801M: 800 VA
CW 1251M: 1250 VA
CW 2501M: 2500 VA
Power Factor of Load: 0 lag to 0 lead
Phase: All models single phase output

Voltage

Ranges: 0 to 135 VAC RMS or 0 to 270 VAC RMS manual switch

(consult factory for custom output voltages)
Accuracy: 1% of range for voltages >5V
Resolution: 0.1V
Total Harmonic Distortion: 0.65% maximum up to 60 Hz; add 0.05%/10 Hz from

AC Noise Level: <50m VRMS typical for CW 801M and CW 1251M,

60 Hz to 100 Hz; add 0.4%/100 Hz from >100 Hz

100m VRMS typical for CW 2501M

Amplitude Stability: ±0.1% of full scale over 8 hours at constant line,

load and temperature after 15 minute warm-up

M161570-01 2-1

Load Regulation: ±0.1% of full scale voltage for a full resistive load to no load
Line Regulation: ±0.1% of full scale for a ±10% line change from nominal line

Remote Voltage Sense: 5 VRMS total lead voltage drop

2.2 CURRENT

CW 801M: 6.00 ARMS in 135 VAC range or 3.00 ARMS in 270 VAC range
CW 1251M: 9.40 ARMS in 135 VAC range or 4.70 ARMS in 270 VAC range
CW 2501M: 18.60 ARMS in 135 VAC range or 9.30 ARMS in 270 VAC range
Frequency

Range: 45 to 500 Hz
Accuracy: ±0.5% typical

Elgar CW-M Series

voltage

Resolution: 0.1 Hz

2.3 MEASUREMENT

Voltage

Range: 0 to 135/270 VRMS
Accuracy: ±1% of range for voltages >5V, measured at point of sense
Resolution of Display: 0.1V

Current

Range: 0 to 6.0 ARMS (CW 801M)

0 to 9.4 ARMS (CW 1251M)
0 to 18.6 ARMS (CW 2501M)

Accuracy: ±2% of range for linear loads with current >0.2A for CW 801M and

CW 1251M, >0.4A for CW 2501M

Resolution of Display: 0.1A

Frequency

Range: 45 to 500 Hz
Accuracy: ±0.5% of reading
Resolution of display: 0.1 Hz

2-2 M161570-01

Elgar CW-M Series

2.4 FRONT PANEL

Controls

Power On/Off switch
Output On/Off/Reset switch: Operates output isolation relays. Off also resets

Voltage Range switch: Selects 135 Vmax or 270 Vmax range

Meter Select switch: Current/frequency select
Output Voltage: Adjusted using 10–turn potentiometer
Output Current: Adjusted using 10–turn potentiometer
Output Frequency: Adjusted using 10–turn potentiometer
Overvoltage Protection: Settable 5 to 300 VRMS using a 15–turn screwdriver

Displays

faults.

(Output switch must be off to change range)

adjust potentiometer

Voltage: 4–digit, 7–segment large, green LED display
Current or Frequency: 4–digit, 7–segment large, green LED display

Protection and Isolation

Overvoltage: Set screw adjustable
Overcurrent: 10–turn potentiometer
Accuracy: ±2% of range for linear loads with current >0.2 A for CW801M and

CW1251M, >0.4A for CW2501M.
Overtemperature: Internal monitor
Isolation Rating: 500V between either output terminal and chassis

Indicators

Output On: Green LED
Voltage Mode: Green LED
Current Mode: Green LED
Slave Mode: Green LED
Fault Mode: Red LED

Output Connector

Universal single socket connector for front panel power out on CW 801M and
CW 1251M

Line and neutral terminals can be switched through rear connector interconnect

M161570-01 2-3

2.5 REAR PANEL CONNECTIONS

Input Connector: Covered barrier terminal strip with strain relief
Output Connector: Covered barrier terminal strip with strain relief
Remote output voltage sense: 5 VRMS max total lead voltage drop
Remote Analog Control:

Output voltage control 0 to 5 VDC

Output frequency control 0 to 5 VDC (max slew rate 5V/second)
Dip Switches (see Section SECTION 4 on page 4-1):
Master or Slave field configuration
Output disable/enable at power-up
Overcurrent shutdown enable/disable

2.6 INPUT

Voltage and Frequency

Elgar CW-M Series

CW 801M: 90 to 264 VAC, 47 to 63 Hz, single-phase

CW 1251M: 103 to 264 VAC, 47 to 63 Hz, single-phase

CW 2501M: 180 to 264 VAC, 47 to 63 Hz, single-phase

Neutral should be connected to ground at building entrance

Max neutral to chassis voltage: 132V RMS

Current

CW 801M: 13 ARMS max

CW 1251M: 18.5 ARMS max

CW 2501M: 19.5 ARMS max

Power Factor

>0.95 at full load nominal line

Efficiency

>70% at full load

2-4 M161570-01

Elgar CW-M Series

2.7 GENERAL

Dimensions

CW 801M: 3.5" H (89 mm) x 19" W (483 mm) x 20.6" D (524 mm)
CW 1251M: 3.5" H (89 mm) x 19" W (483 mm) x 20.6" D (524 mm)
CW 2501M: 5.25" H (133 mm) x 19" W (483 mm) x 20.6" D (524 mm)

Weight

CW 801M: 48 lbs. (22 kg)
CW 1251M: 53 lbs. (24 kg)
CW 2501M: 86 lbs. (39 kg)

Shipping Weight

CW 801M: 56 lbs. (25 kg)
CW 1251M: 61 lbs. (28 kg)
CW 2501M: 94 lbs. (43 kg)

Regulatory Compliance

CE mark
LVD: EN61010-1:1993 + Amendment 2
EMC: EN55011:1991 Group 1, Class A, EN50082-1:1992

Environmental

Cooling: Dual fan speed with side air intake, exhaust to rear
Operating Temperature: 0 to 40°C
Storage Temperature: -40 to +70°C
Humidity: 0 to 85% at 25°C derate to 50% above 40°C (non-condensing)
Altitude: Operating full power available up to 6,000 feet, non-operating to 40,000

feet
Installation Category III, Pollution Degree 2
FOR INDOOR USE ONLY

2.8 OPTIONS AND ACCESSORIES

L: Locking knobs (front panel potentiometers)
Rack Slide Kit (Elgar part number K161570-01)
Parallel Cable (Elgar part number 890-497-40)

M161570-01 2-5