AMETEK DCS-E 1KW Series User Manual
DCS-E 1kW Series &
DCS-E 1.2kW Series
DC Power Supplies
Operation Manual
This manual covers models:
DCS8-125E DCS33-33E DCS60-18E DCS150-7E
DCS8-140E DCS33-36E DCS60-20E DCS150-8E
DCS10-100E DCS40-25E DCS80-13E DCS300-3.5E
DCS10-120E DCS40-30E DCS80-15E DCS300-4E
DCS20-50E DCS50-20E DCS100-10E DCS600-1.7E
DCS20-60E DCS50-24E DCS100-12E DCS600-2E
M362500-01 Rev H 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
DCS-E 1kW Series & DCS-E 1.2kW Series DC Power Supplies Operation Manual
AMETEK Programmable Power, Inc. All rights reserved.
© 2006-2008
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
January 2015 Revision H
Part Number
M362500-01
Contact Information
Telephone: 800 733 5427 (toll free in North America)
858 450 0085 (direct)
Fax: 858 458 0267
Email: sales.ppd@ametek.com
service.ppd@ametek.com
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 parts. 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
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Product Family: DCS-E 1kW Series & DCS-E 1.2kW Series DC Power Supplies
Warranty Period: Five Years
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: 800-733-5427, 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.
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vi
CONTENTS
SECTION 1 FEATURES AND SPECIFICATIONS .................................. 1-1
1.1 Description ..................................................................................................... 1-1
1.2 Operating Modes ............................................................................................ 1-1
1.3 Power Supply Features .................................................................................. 1-1
1.4 Specifications ................................................................................................. 1-3
1.4.1 Electrical Specifications for 1kW Models .......................................... 1-3
1.4.2 Electrical Specifications for 1.2kW Models ....................................... 1-4
1.4.3 Physical Specifications ..................................................................... 1-5
1.4.4 Mechanical Specifications ................................................................ 1-6
SECTION 2 INSTALLATION AND OPERATION ................................... 2-1
2.1 General .......................................................................................................... 2-1
2.2 Initial Inspection ............................................................................................. 2-1
2.3 Installation ...................................................................................................... 2-1
2.3.1 Input Voltage Selection..................................................................... 2-1
2.3.2 Input Line Impedance ....................................................................... 2-2
2.3.3 Ventilation Requirements ................................................................. 2-2
2.3.4 Output Voltage Biasing ..................................................................... 2-2
2.3.5 Rack Mounting ................................................................................. 2-3
2.4 Controls, Connectors, and Indicators ............................................................. 2-5
2.4.1 Front Panel ....................................................................................... 2-5
2.4.2 Rear Panel ....................................................................................... 2-5
2.4.3 J3 Program, Sense and Monitor Connector Description ................... 2-6
2.5 Initial Functional Tests .................................................................................... 2-7
2.6 Standard Operation ........................................................................................ 2-8
M362500-01 Rev H vii
Contents Sorensen DCS Series 1kW and 1.2kW Supplies
2.6.1 Load Conductor Ratings ................................................................... 2-8
2.6.2 Load Connection and Grounding ...................................................... 2-8
2.6.3 Inductive Loads ................................................................................ 2-9
2.6.4 Remote Sensing ............................................................................. 2-10
2.6.5 Negative Output Operation ............................................................. 2-11
2.7 Single Supply Operation (Local Mode) ......................................................... 2-11
2.8 Multiple Supplies .......................................................................................... 2-12
2.8.1 Series Operation ............................................................................. 2-12
2.8.2 Parallel Operation ........................................................................... 2-12
2.8.3 Split Supply Operation .................................................................... 2-13
2.9 Over Voltage Protection (OVP) ..................................................................... 2-13
2.9.1 Front Panel OVP Operation ............................................................ 2-13
2.9.2 Remote Programming of OVP With External Voltage Sources ....... 2-14
2.9.3 Remote Programming of OVP with an External Resistance ........... 2-15
2.9.4 Remote Programming of OVP with External Current Sources ........ 2-16
2.9.5 Remote OVP Sensing..................................................................... 2-17
2.10 Remote ON/OFF .......................................................................................... 2-17
2.10.1 Remote ON/OFF by Contact Closure ............................................. 2-18
2.11 Remote Programming of Output Voltage and Current Limit ......................... 2-18
2.11.1 Programming With External Voltage Sources ................................. 2-19
2.11.2 Programming With an External Resistance .................................... 2-20
2.11.3 Programming With an External Current Source .............................. 2-22
2.12 Remote Monitoring and Status Indicators ..................................................... 2-23
SECTION 3 THEORY OF OPERATION ................................................ 3-1
3.1 Power Circuit (A2 Assembly) .......................................................................... 3-1
3.1.1 Basic Off-Line Switching Regulator Theory ...................................... 3-1
3.1.2 Simplified Full Bridge Converter Theory ........................................... 3-3
3.1.3 Detailed Circuit Description ............................................................... 3-3
3.2 Meter Circuit (A1 Assembly) ........................................................................... 3-9
3.2.1 Voltmeter ........................................................................................ 3-10
3.2.2 Current Meter ................................................................................. 3-10
SECTION 4 MAINTENANCE, TROUBLESHOOTING, AND CALIBRATION
4-1
4.1 General .......................................................................................................... 4-1
viii M362500-01 Rev H
Sorensen DCS Series 1kW and 1.2kW Supplies Contents
ix
4.2 Periodic Service ............................................................................................. 4-1
4.3 Troubleshooting ............................................................................................. 4-1
4.3.1 Preliminary Checks .......................................................................... 4-2
4.3.2 Troubleshooting at the Operation Level ............................................ 4-2
4.4 Calibration ...................................................................................................... 4-3
SECTION 5 PARTS LISTS .................................................................... 5-1
5.1 General .......................................................................................................... 5-1
5.2 Parts Ordering ................................................................................................ 5-1
5.3 Parts Lists ...................................................................................................... 5-2
M362500-01 Rev H
Contents Sorensen DCS Series 1kW and 1.2kW Supplies
LIST OF FIGURES
Figure 2-1 DCS Series Power Supply ................................ ......................................... 2-4
Figure 2-2. Diode Connection ..................................................................................... 2-9
Figure 3-1 Simplified Full Bridge Converter ................................................................. 3-2
x M362500-01 Rev H
Sorensen DCS Series 1kW and 1.2kW Supplies Contents
xi
Figure 4-1 Trimpot Locations ...................................................................................... 4-4
M362500-01 Rev H
Contents Sorensen DCS Series 1kW and 1.2kW Supplies
LIST OF TABLES
Table 2–1 Wire Size and Length ................................................................................. 2-8
Table 4–1 Troubleshooting Guide ............................................................................... 4-2
Table 5–1 DCS 1kW and 1.2kW Fuse Ratings ........................................................... 5-2
Table 5–2 DCS 1kW Parts Lists by Model Number ..................................................... 5-2
Table 5–3 DCS 1kW Parts Lists .................................................................................. 5-3
Table 5–4 DCS 1.2kW Parts Lists by Model Number .................................................. 5-4
Table 5–5 DCS 1.2kW Parts Lists ............................................................................... 5-5
xii M362500-01 Rev H
SECTION 1
FEATURES AND SPECIFICATIONS
1.1 Description
DCS Series power supplies are 1000W and 1200W supplies designed to provide highly stable,
continuously variable output voltage and current for a broad range of development, system, and
burn-in applications. The DCS Series employs high frequency switching regulator technology
to achieve high power density and small package size.
The series consists of twelve 1000W models and twelve 1200W models. The model numbers
are designated by the DCS prefix, followed by the output voltage and current ratings. For
example, the model number DCS 60-18E indicates that the unit is rated at 0-60 Vdc and 0-18
Amps while a model DCS 20-50E is rated at 0-20 Vdc and 0-50 Amps.
1.2 Operating Modes
The DCS Series supply has two basic operating modes: Constant Voltage and Constant
Current. In constant voltage mode the output voltage is regulated at the selected value while
the output current varies with the load requirements. In constant current mode the output
current is regulated at the selected value while output the voltage varies with the load
requirements.
An automatic crossover system enables the unit to switch operating modes in response to
varying load requirements. If, for example, the unit is operating in voltage mode and the load
current attempts to increase above the setting of the current control, the unit will switch
automatically from voltage mode to current mode. If the load current is subsequently reduced
below the setting of the current control the unit will return to voltage mode automatically.
1.3 Power Supply Features
Twelve 1kW models with voltage ranges from 0-8 Vdc to 0-600 Vdc and current
outputs from 1.7A to 125A.
Twelve 1.2kW models with voltage ranges from 0-8 Vdc to 0-600 Vdc and current
outputs from 2A to 140A.
115/230 Vac selectable input voltage, 50-60 Hz single phase,
Installation Category II. For Indoor Use.
M362500-01 Rev H 1-1
Features and Specifications Sorensen DCS Series 1kW and 1.2kW Supplies
Simultaneous digital display of both voltage and current.
Automatic mode crossover into current or voltage mode.
Ten turn potentiometer voltage and current controls permit high resolution setting of
the output voltage and current from zero to the rated output.
Flexible output configuration: multiple units can be connected in parallel or series to
provide increased current or voltage.
High frequency switching technology allows high power density, providing increased
power output in a small, light package.
Remote sensing to compensate for losses in power leads.
Adjustable Over-Voltage Protection (OVP)
External TTL, AC or DC shutdown
Remote voltage, resistive, current limit and OVP programming with selectable
programming constants.
External indicator signals for remote monitoring of OVP status, local/remote
programming status, thermal shutdown, and output voltage and current.
Optional IEEE-488 interface for complete remote programming and readback
capability.
1-2 M362500-01 Rev H
Sorensen DCS Series 1kW and 1.2kW Supplies Features and Specifications
Models
8-125
10-100
20-50
33-33
40-25
50-20
60-18
80-13
100-10
150-7
300-3.5
600-1.7
Output Ratings:
Output Voltage
Output Current
Output Power
0-8V
0-125A
1000W
0-10V
0-100A
1000W
0-20V
0-50A
1000W
0-33V
0-33A
1089W
0-40V
0-25A
1000W
0-50V
0-20A
1000W
0-60V
0-18A
1080W
0-80V
0-13A
1040W
0-100V
0-10A
1000W
0-150V
0-7A
1050W
0-300V
0-3.5A
1050W
0-600V
0-1.7A
1020W
Line Regulation:1
Voltage
Current
8 mV
125 mA
10 mV
100 mA
20 mV
50 mA
33 mV
33 mA
40 mV
25 mA
50 mV
20 mA
60 mV
18 mA
80 mV
13 mA
100 mV
10 mA
150 mV
7 mA
300 mV
3.5 mA
600 mV
1.7 mA
Load Regulation:2
Voltage
Current
8 mV
125 mA
10 mV
100 mA
20 mV
50 mA
33 mV
33 mA
40 mV
25 mA
50 mV
20 mA
60 mV
18 mA
80 mV
13 mA
100 mV
10 mA
150 mV
7 mA
300 mV
3.5 mA
600mV
1.7 mA
Meter Accuracy:
Voltage
Current
0.09V
1.35A
0.11V
1.1A
0.3V
0.6A
0.43V
0.43A
0.5V
0.35A
0.6V
0.30A
0.7V
0.28A
0.9V
0.23A
1.1V
0.11A
1.6V
0.08A
4.0V
0.045A
7.0V
0.018A
OVP Adjustment Range
0.4-8.8V
0.5-11V
1.0-22V
1.65-36.3V
2-44V
2.5-55V
3-66V
4-88V
5-110V
7.5-165V
15-330V
30-660V
Output Noise/Ripple(V)3
Rms
p-p
(20Hz-20MHz)
4 mV
60 mV
4 mV
60 mV
4 mV
60 mV
4 mV
60 mV
4 mV
60 mV
4 mV
60 mV
4 mV
60 mV
4 mV
60 mV
6 mV
60 mV
12 mV
160 mV
20 mV
200 mV
50 mV
300 mV
Stability:4
Voltage
Current
4 mV
62.5 mA
5 mV
50 mA
10 mV
25 mA
16.5 mV
16.5 mA
20 mV
12.5 mA
25 mV
10 mV
30 mV
9 mA
40 mV
6.5 mA
50 mV
5 mA
75 mV
3.5 mA
150 mV
1.75 mA
300 mV
0.85 mA
Temperature
Coefficient:5
Voltage
Current
1.6 mV
37.5 mA
2 mV
30 mA
4 mV
15 mA
6.6 mV
9.9 mA
8 mV
7.5 mA
10 mV
6 mA
12 mV
5.4 mA
16 mV
3.9 mA
20 mV
3 mA
30 mV
2.1 mA
60 mV
1.05 mA
120 mV
0.51 mA
Maximum Remote
Sense Line Drop6
Compensation/line
4V 4V 4V 4V 4V 4V 4V 4V 4V 4V 4V 4V
1.4 Specifications
1.4.1 Electrical Specifications for 1kW Models
Specifications are warranted over a temperature range of 0-50°C with default local sensing.
From temperatures of 50-70°C, derate output 2% per °C.
1
For input voltage variation over the AC input voltage range, with constant rated load
2
For 0-100% load variation, with constant nominal line voltage
3
Typical P-P noise and ripple
4
Maximum drift over 8 hours with constant line, load, and temperature, after 20-minute warm-up
5
Change in output per °C change in ambient temperature, with constant line and load
6
Line drop subtracts from the maximum available output voltage at full rated power
AC Input: 200-250 Vac at 9A rms or 100-130 Vac at 18A rms, 47-63 Hz
Maximum Voltage Differential from output to safety ground: 150 Vdc
M362500-01 Rev H 1-3
Features and Specifications Sorensen DCS Series 1kW and 1.2kW Supplies
Models
8-140
10-120
20-60
33-36
40-30
50-24
60-20
80-15
100-12
150-8
300-4
600-2
Output Ratings:
Output Voltage
Output Current
Output Power
0-8V
0-140A
1200W
0-10V
0-120A
1200W
0-20V
0-60A
1200W
0-33V
0-36A
1200W
0-40V
0-30A
1200W
0-50V
0-24A
1200W
0-60V
0-20A
1200W
0-80V
0-15A
1200W
0-100V
0-12A
1200W
0-150V
0-8A
1200W
0-300V
0-4A
1200W
0-600V
0-2A
1020W
Line Regulation:7
Voltage
Current
8 mV
140 mA
10 mV
120 mA
20 mV
60 mA
33 mV
36 mA
40 mV
30 mA
50 mV
24 mA
60 mV
20 mA
80 mV
15 mA
100 mV
12 mA
150 mV
8 mA
300 mV
4 mA
600 mV
2 mA
Load Regulation:8
Voltage
Current
8 mV
140 mA
10 mV
120 mA
20 mV
60 mA
33 mV
36 mA
40 mV
30 mA
50 mV
24 mA
60 mV
20 mA
80 mV
15 mA
100 mV
12 mA
150 mV
8 mA
300 mV
4 mA
600 mV
2 mA
Meter Accuracy:
Voltage
Current
0.09V
1.55A
0.11V
1.3A
0.3V
0.7A
0.43V
0.46A
0.5V
0.40A
0.6V
0.34A
0.7V
0.3A
0.9V
0.25A
1.1V
0.13A
1.6V
0.09A
4.0V
0.05A
7.0V
0.021A
OVP Adjustment Range
0.4-8.8V
0.5-11V
1.0-22V
1.65-36.3V
2-44V
2.5-55V
3-66V
4-88V
5-110V
7.5-165V
15-330V
30-660V
Output Noise/Ripple(V)
9
Rms
p-p
(20Hz-20MHz)
5 mV
60 mV
5 mV
60 mV
5 mV
60 mV
5 mV
60 mV
5 mV
60 mV
5 mV
60 mV
5 mV
60 mV
5 mV
60 mV
10 mV
60 mV
15 mV
160 mV
25 mV
200 mV
50 mV
300 mV
Stability:10
Voltage
Current
4 mV
70 mA
5 mV
60 mA
10 mV
30 mA
16.5 mV
18 mA
20 mV
15 mA
25 mV
12 mV
30 mV
10 mA
40 mV
7.5 mA
50 mV
6 mA
75 mV
4 mA
150 mV
2 mA
300 mV
1 mA
Temperature
Coefficient:11
Voltage
Current
1.6 mV
42 mA
2 mV
36 mA
4 mV
18 mA
6.6 mV
10.8 mA
8 mV
9 mA
10 mV
7.2 mA
12 mV
6 mA
16 mV
4.5 mA
20 mV
3.6 mA
30 mV
2.4 mA
60 mV
1.2 mA
120 mV
0.6 mA
Maximum Remote
Sense Line Drop12
Compensation/line
2V 2V 4V 4V 4V 4V 4V 4V 4V 4V 4V 4V
1.4.2 Electrical Specifications for 1.2kW Models
Specifications are warranted over a temperature range of 0-50°C with default local sensing.
From temperatures of 50-70°C, derate output 2% per °C.
7
8
9
10
11
12
AC Input: 200-250 Vac at 10A rms or 100-130 Vac at 20A rms, 47-63 Hz
Maximum Voltage Differential from output to safety ground: 150 Vdc
1-4 M362500-01 Rev H
For input voltage variation over the AC input voltage range, with constant rated load
For 0-100% load variation, with constant nominal line voltage
Typical P-P noise and ripple
Maximum drift over 8 hours with constant line, load, and temperature, after 20-minute warm-up
Change in output per °C change in ambient temperature, with constant line and load
Line drop subtracts from the maximum available output voltage at full rated power
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