AMETEK DCS-E 3kW Series User Manual

DCS-E 3kW Series DC

Power Supplies

Operation Manual

This manual covers models:

DCS8-350E DCS55-55E DCS12-250E DCS60-50E DCS20-150E DCS80-37E DCS40-75E DCS150-20E

M362295-01 Rev C 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 electromec hanical 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 3kW Series DC Power Supplies Operation Manual

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

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

December 2008 Revision B

Part Number

M362295-01

Contact Information

Telephone: 800 733 5427 (toll free in North America) 858 450 0085 (direct) Fax: 858 458 0267 Email: sales@programmablepower.com service@programmablepower.com Web: www.programmablepower.com

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Important Safety Instructions

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

WARNIN

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.

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.

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

SAFETY SYMBOLS

iii

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Product Family: DCS-E 3kW 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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ABOUT THIS MANUAL

This manual has been written expressly for the Sorensen DCS-E 3kW Series of power supplies, which have been designed and certified to meet the Low Voltage and Electromagnetic Compatibility Directive Requirements of the European Community. Units that comply with the directive are designated by an ‘E’ after the model designator (e.g., DCS 60-50E indicates that the model is certified) when configured for 230 VAC input only.

Since the goal of the Low Voltage Directive is to ensure the safety of the equipment operator, universal graphic symbols have been used both on the unit itself and in this manual to warn the operator of potentially hazardous situations (see Safety Symbols on page ii).

This manual is designed for the user who is familiar with basic electrical laws especially as they apply to the operation of power supplies. This implies recognition of Constant Voltage and Constant Current operating modes and the control of input and output power, as well as the observance of safety techniques while effecting supply or pin connections and any changes in switch and jumper settings. The more knowledgeable user will find that the detailed schematics and circuit descriptions available on our website, www.programmablepower.com will enable greater flexibility in troubleshooting and in configuring new applications.

Section 1 Introducing the DCS-E Series 3kW Supply describes the power supply, lists its features, and provides specifications .

Section 2 Installation reviews safety and inspection procedures, then goes through the basic set up procedures. Directions for the assembling of the AC input connector, for the testing of basic functions, and for connecting the load are also included.

Section 3 Basic Operation provides procedures for local programming mode operation (Constant Voltage and Constant Current) and remote sensing.

Section 4 Advanced Operation covers remote programming mode operation as well as procedures for using advanced programming features such as Over Voltage Protection (OVP), Output Power ON/OFF, and Remote Monitoring. This section also provides procedures for using multiple supplies in series, in parallel, and in split supply configurations.

Section 5 Theory of Operation provides a block diagram of the power supply, an explanation of the functions within each block, and more detailed descriptions of the circuitry.

Section 6 Maintenance covers service, calibration and repairs, and includes parts lists. Section 7 Application Notes is reserved for additional system information.

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viii

CONTENTS

SECTION 1 INTRODUCING THE DCS-E SERIES 3KW SUPPLY....1-1

1.1 Description.......................................................................................................1-1

1.2 Features........................................................................................................... 1-1

1.3 Specifications...................................................................................................1-2

1.3.1 Electrical Specifications1......................................................................1-2

1.3.2 Mechanical Specifications....................................................................1-3

SECTION 2 INSTALLATION .........................................................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

2.3 Initial Inspection...............................................................................................2-3

2.3.1 Physical Check ....................................................................................2-3

2.4 Location, Mounting, and Ventilation................................................................. 2-3

2.4.1 Unit Dimensions...................................................................................2-3

2.4.2 Rack Mounting.....................................................................................2-4

2.5 AC Input Power................................................................................................ 2-4

2.5.1 AC Input Power Connection.................................................................2-4

2.5.2 AC Input Power Requirements ............................................................2-4

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Contents Sorensen DCS-E Series 3kW Supplies

2.5.3 AC Input Connector Assembly.............................................................2-5

2.5.4 Strain Relief Assembly.........................................................................2-6

2.6 Initial Functional Tests .....................................................................................2-8

2.6.1 Power-on Check...................................................................................2-8

2.6.2 Voltage Mode Operation Check...........................................................2-8

2.6.3 Current Mode Operation Check ...........................................................2-9

2.6.4 Front Panel Function Checks...............................................................2-9

2.7 Load Connection............................................................................................2-10

2.7.1 Load Wiring........................................................................................2-10

2.7.2 Making the Connections.....................................................................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 Crossover ........................................3-1

3.2.2 Local Programming Mode Operation ...................................................3-3

3.3 Using Remote Sensing ....................................................................................3-4

3.3.1 Connecting Remote Sense Lines.........................................................3-4

SECTION 4 ADVANCED OPERATION .......................................... 4-1

4.1 Introduction ......................................................................................................4-1

4.2 Configuring for Remote Programming, Sensing, and Monitoring.....................4-2

4.2.1 Programming, Monitoring, and Control Functions................................4-2

4.2.2 Locating Jumpers, Switch, and Connector...........................................4-4

4.2.3 Resetting Jumpers and Switch.............................................................4-5

4.2.4 Making J3 Connections........................................................................4-6

4.3 Remote Programming: Output Voltage and Current Limit..................................4-7

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Sorensen DCS-E Series 3kW Supplies Contents

4.3.1 Programming Output Voltage and Current Limit with the REM/LOC Switch 4-8

4.3.2 Programming Output Voltage ..............................................................4-9

4.3.3 Programming Output Current Limit....................................................4-12

4.4 Using Over Voltage Protection (OVP) ...........................................................4-14

4.4.1 Front Panel OVP Operation...............................................................4-14

4.4.2 Resetting the OVP Circuit..................................................................4-14

4.4.3 Programming OVP with an External Voltage Source......................... 4-15

4.5 Using the Shutdown Function........................................................................4-16

4.5.1 STANDBY Switch ..............................................................................4-16

4.5.2 Programming the Shutdown Function................................................ 4-16

4.5.3 Shutdown Application - Contact Closure ...........................................4-19

4.6 Remote Monitoring of Readback Signals and Status Indicators.................... 4-21

4.6.1 Readback Signals..............................................................................4-21

4.6.2 Status Indicators................................................................................4-21

4.7 Using Multiple Supplies .................................................................................4-22

4.7.1 Configuring Multiple Supplies for Series Operation...........................4-22

4.7.2 Configuring Multiple Supplies for Parallel Operation .........................4-23

4.7.3 Configuring Multiple Supplies for Split Supply Operation ..................4-24

4.8 Output Voltage Biasing..................................................................................4-25

SECTION 5 THEORY OF OPERATION ..........................................5-1

5.1 Introduction......................................................................................................5-1

5.2 Basic Functional Blocks...................................................................................5-1

5.2.1 AC Input and RFI Filter (A5 PCB)........................................................5-2

5.2.2 AC Input Rectifier and Inrush Limiting Circuit (A6 PCB)......................5-2

5.2.3 PWM, Sync and Power Transformer Drive Circuit (A3 PCB)...............5-2

5.2.4 Power Transformer, Output Rectifiers, Output Filter Inductor and

M362295-01 Rev C

Capacitors, and Local Sense Connections (Power Stage, A7 PCB and

A8 PCB)...............................................................................................5-2

Contents Sorensen DCS-E Series 3kW Supplies

5.2.5 Output Current Shunt, Shunt Amplifier, and Down Programmer (A4 PCB) 5-2

5.2.6 Control, Programming, OVP, Shutdown, Monitoring, and Auxiliary Supply

Circuits (A2 PCB).................................................................................5-3

5.2.7 Front Panel Displays and Local Operating Mode Controls (A1 PCB) ..5-4

5.3 Detailed Circuit Descriptions............................................................................5-4

5.3.1 AC Input and RFI Filter Circuit (A5 PCB) .............................................5-5

5.3.2 Input Rectifier and Inrush Limiting Circuit (A6 PCB) ............................5-5

5.3.3 PWM, Sync Circuit, Power Transformer Drive Circuit, and Power

Transistor Bridge (A3 PCB)..................................................................5-5

5.3.4 Power Transformer, Output Rectifiers, Output Filter Inductor and Capacitor, 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)57

5.3.6 Front Panel Displays and Controls (A1 PCB).....................................5-14

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

6.1 Introduction ......................................................................................................6-1

6.1.1 Units Under Warranty...........................................................................6-1

6.2 General Service and Repair.............................................................................6-1

6.2.1 Periodic Maintenance...........................................................................6-1

6.2.2 Servicing Precautions...........................................................................6-2

6.2.3 Parts Replacement and Repairs ..........................................................6-2

6.2.4 Unusual or Erratic Operation................................................................6-2

6.3 Calibrating for Programming Accuracy ............................................................6-2

6.3.1 Voltage Programming Circuit Calibration.............................................6-3

6.3.2 Current Programming Circuit Calibration .............................................6-3

6.4 Replaceable Parts............................................................................................6-4

6.4.1 Parts Replacement and Modifications..................................................6-4

6.4.2 Ordering Parts......................................................................................6-4

6.4.3 DCS-E 3kW Parts Lists by Model Number...........................................6-5

vi M362295-01 Rev Cl

Sorensen DCS-E Series 3kW Supplies Contents

SECTION 7 APPLICATION NOTES ...............................................7-1

7.1 Battery Charging.............................................................................................. 7-1

7.2 Load Considerations........................................................................................7-1

7.2.1 Inductive Loads....................................................................................7-1

LIST OF FIGURES

Figure 1-1 DCS-E Series (3kW) Supply Front Panel Controls and Indicators............1-4

Figure 1-2 DCS-E Series (3kW) Supply Rear Panel Connectors and Terminals

(including optional internal GPIB Interface)..............................................1-5

Figure 2-1 AC Connector and Contacts ..................................................................... 2-5

Figure 2-2 Wire Preparation.......................................................................................2-5

Figure 2-3 Contact Orientation...................................................................................2-6

Figure 2-4 AC Wire Locations .................................................................................... 2-6

Figure 2-5 Strain Relief, as Supplied.......................................................................... 2-7

Figure 2-6 Strain Relief Assembly.............................................................................. 2-7

Figure 2-7 Connector J3 Default Configuration.......................................................... 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 Sensing........................................................ 2-13

Figure 2-12 Multiple Loads with Remote Sensing....................................................2-13

Figure 3-1 Operating Modes.......................................................................................3-2

Figure 3-2 Local Mode Default Configuration.............................................................3-3

Figure 3-3 Connecting Remote Sense Lines..............................................................3-5

Figure 4-1 Connector J3 Pin Descriptions (for Remote Programming,

Remote Monitoring, and Sense Connections).......................................... 4-3

Figure 4-2 Internal Jumpers and Switch (Default Settings Shown)............................4-4

Figure 4-3 Programming Output Voltage and Current Limit Using the

Figure 4-4 Programming Output Voltage with a 0-5 Vdc Source ...............................4-9

M362295-01 Rev C

REM/LOC Switch......................................................................................4-8

vii

Contents Sorensen DCS-E Series 3kW Supplies

Figure 4-5 Programming Output Voltage with a 0-10 Vdc Source............................4-10

Figure 4-6 Programming Output Voltage with a 0-1 mA Source...............................4-10

Figure 4-7 Programming Output Voltage with a 5k ohm Resistance........................4-11

Figure 4-8 Programming Output Current Limit with a 0-5 Vdc Source .....................4-12

Figure 4-9 Programming Output Current Limit with a 0-10 Vdc Source ...................4-12

Figure 4-10 Programming Output Current Limit with a 0-1 mA Source ....................4-13

Figure 4-11 Programming Output Current Limit with a 5k ohm Resistance..............4-13

Figure 4-12 Remote Programming of OVP with a 0-5 Vdc External

Voltage Source.....................................................................................4-15

Figure 4-13 Remote Programming of OVP with a 0 –10 Vdc External

Voltage Source.....................................................................................4-16

Figure 4-14 Using Shutdown with a TTL Compatible (Positive Logic)......................4-17

Figure 4-15 Using Shutdown with a TTL Compatible (Negative Logic)....................4-17

Figure 4-16 Using Shutdown with an AC or DC Input (Positive Logic).....................4-18

Figure 4-17 Using Shutdown with an AC or DC Input (Negative Logic) ...................4-18

Figure 4-18 Using Shutdown with Contact Closure

of a Normally OPEN Relay (Positive Logic)..........................................4-19

Figure 4-19 Using Shutdown with Contact Closure

of a Normally OPEN Relay (Negative Logic)........................................4-20

Figure 4-20 Using Shutdown with Contact Closure

of a Normally CLOSED Relay (Positive Logic).....................................4-20

Figure 4-21 Using Shutdown with Contact Closure

of a Normally CLOSED Relay (Negative Logic) ...................................4-20

Figure 4-22 Series Operation of Multiple Supplies ...................................................4-22

Figure 4-23 Parallel Operation of Multiple Supplies..................................................4-23

Figure 4-24 Split Supply Operation of Multiple Supplies

(Two Positive Voltages)........................................................................4-24

Figure 4-25 Split Supply Operation of Multiple Supplies

(Positive-Negative Supply) ...................................................................4-25

viii M362295-01 Rev Cl

SECTION 1

INTRODUCING THE DCS-E

SERIES 3KW SUPPLY

1.1 DESCRIPTION

The DCS-E Series System Supplies are 3000–watt 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-E Series employs high frequency switching regulator technology to achieve high power density and small package size.

The series consists of several models designated by the DCS prefix, followed by their output voltage and current ratings. For example, the model number DCS 60-50E indicates that the unit is rated at 0-60 Vdc and 0-50 Amps.

1.2 FEATURES

• Eight models with voltage ranges from 0-8 Vdc to 0-150 Vdc and current outputs from

20A to 350A.

• Input voltage 190-250 Vac, Three Phase, 47-63 Hz or 200-250 Vac, Single Phase, 47-63

Hz. (Output power limited to 2500W for single-phase input.)

• Simultaneous digital display of both DC output voltage and current.

• Ten-turn potentiometer voltage and current controls permit high resolution setting of the

output voltage and current from zero to the model-rated output.

• Front panel push button control of Output Standby Mode, OVP reset, Remote/Local

Programming Mode selection, and preview of voltage, current, or OVP setpoints.

• External indicator signals for Remote Monitoring of OVP Status, Local/Remote

Programming Status, Thermal Shutdown, and Output Voltage and Current.

• Current or Voltage Mode operation with Automatic Mode Crossover to respond to

varying load requirements.

• Flexible output configuration where multiple units can be connected in series or in

parallel to provide increased voltage or increased current.

• Remote Sensing to compensate for losses in power leads up to 1V per lead.

• Adjustable Over Voltage Protection (OVP).

M362295-01 Rev C 1-1

Introduction Sorensen DCS-E Series 3kW Supplies

• External Shutdown using AC, DC, or TTL compatible signals (positive or negative logic).

• Remote Voltage, Current Limit, and OVP Programming with selectable programming

ranges.

• Optional IEEE-488 (GPIB) interface for complete digital remote programming and

readback capability.

1.3 SPECIFICATIONS

1.3.1 Electrical Specifications1

Models

Output Ratings Output Voltage Output Current Output Power

Line Regulation2 Voltage Current

Load Regulation3 Voltage Current

Meter Accuracy Voltage Current

OVP Adjustment Range

Output Noise and Ripple (V) Rms p–p (20 Hz – 20 MHz)

Analog Programming Linearity Voltage Current

Specifications are warranted over a temperature range of 0–50°C with default local sensing. From 50–70°C, derate 2% per °C.

For input voltage variation over the AC input voltage range, with constant rated load.

For 0-100% load variation, with constant nominal line voltage.

DCS

8-350E

0-8V 0-350A 2800W

8 mV 350 mA

0.09V

4.5A

0.4-8.8V 0.6-13.2V 1-22V

10 mV 100 mV

80 mV 3500 mA

DCS

12-250E

0-12V 0-250A 3000W

12 mV 250 mA

0.13V

3.5A

10 mV 100 mV

120 mV 2500 mA

DCS

20-150E

0-20V 0-150A 3000W

20 mV 150 mA

0.2V

0.1.6A

10 mV 100 mV

200 mV 1500 mA

DCS

40-75E

0-40V 0-75A 3000W

40 mV 75 mA

0.5V

0.85A

2-44V

20 mV 100 mV

400 mV 750 mA

DCS

55-55E

0-55V 0-55A 3025W

55 mV 55 mA

0.65V

0.65A

2.75-60.5V 3-66V

20 mV 100 mV

550 mV 550 mA

DCS

60-50E

0-60V 0-50A 3000W

60 mV 50 mA

0.7V

0.6A

20 mV 100 mV

600 mV 500 mA

DCS

80-37E

0-80V 0-37A 2960W

80 mV 37 mA

0.9V

0.47A

4-88V

20 mV 100 mV

800 mV 370 mA

DCS

150-20E

0-150V 0-20A 3000W

150 mV 20 mA

1.6V

0.30A

7.5-165V

30 mV 200 mV

1.5V 200 mA

AC Input: 200-250 Vac at 20 Arms Single Phase or 190-250 Vac at 14 Arms Three Phase

(Output power limited to 2500W for single phase input)

Maximum Voltage Differential from output to safety ground: 150 Vdc

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Sorensen DCS-E Series 3kW Supplies Introduction

ADDITIONAL CHARACTERISTICS

Models DCS8-350E DCS12-250E DCS20-150E DCS40-75E DCS55-55E DCS60-50E DCS80-37E DCS150-20E

Stability4 Voltage Current

Temperature Coefficient5 Voltage Current

Maximum Remote Sense Line Drop Compensation

Maximum drift over 8 hours with constant line, load, and temperature, after 90–minute warmup.

Change in input per °C change in ambient temperature with constant and load.

4 mV 175 mA

1.6 mV/°C 105 mA/°C

1V/line 1V/line 1V/line 1V/line 1V/line 1V/line 1V/line 1V/line

6 mV 125 mA

2.4 mV/°C 75 mA/°C

10 mV 75 mA

4 mV/°C 45 mA/°C

20 mV

37.5 mA

8 mV/°C

22.5 mA/°C

27.5 mV

27.5 mA

11 mV/°C

16.5 mA/°C

30 mV 25 mA

12 mV/°C 15 mA/°C

40 mV

18.5 mA

16 mV/°C

11.1 mA/°C

75 mV 10 mA

30 mV/°C

6.0 mA/°C

Operating Ambient Temperature: 0 - 50°C No derating. From 50 - 70°C, derate output 2% per °C

Storage Temperature Range: -55 to +85°C Humidity Range: 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% band for 30% step load change from 70% to 100% or 100% to 70% Remote Start/Stop and Interlock:

TTL Compatible Input, Contact Closure, 12 – 250 Vac or 12 – 130 Vdc

Remote Analog Programming (Full Scale Input)

Parameter Resistance Voltage Current

Voltage 0 - 5k 0 - 5V, 0 - 10V 0 - 1 mA Current 0 - 5k 0 - 5V, 0 - 10V 0 - 1 mA OVP — 0 - 5V, 0 - 10V —

1.3.2 Mechanical Specifications

Size: 87.6 mm H x 482.6 mm W x 508 mm D (3.45 in H x 19 in W x 20 in D) Weight: 16 kg (35 lbs) (approx.) Output Connector:

Nickel-plated copper bus bars: 2.25" x 1.0" x 0.125" (2.25" x 1.0" x 0.25" for 8V & 12V models) Bus bar load wiring mounting holes:

One 0.332" diameter hole;

/4" hardware (5/16" hardware for 8V and 12V models)

Two 0.190" diameter holes on 0.5" centers; #10 hardware

Input Connector: Chassis-Mounted Part: Housing Tyco 641685-1; Contact pins Tyco 350821-1 Mating Connector Parts: Housing Tyco 643267-1; Contact pins Tyco 350821-1

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Introduction Sorensen DCS-E Series 3kW Supplies

Figure 1-1 DCS-E Series (3kW) Supply Front Panel Controls and Indicators

1-4 M362295-01 Rev C

Sorensen DCS-E Series 3kW Supplies Introduction

Figure 1-2 DCS-E Series (3kW) Supply Rear Panel Connectors and Terminals

(including optional internal GPIB Interface)

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1-6 M362295-01 Rev C

SECTION 2

INSTALLATION

2.1 INTRODUCTION

This section provides recommendations and procedures for inspecting, testing, and installing the DCS-E Series power supply.

1. Read and follow the safety recommendations (Section 2.2)

2. Perform an initial physical inspection of the supply (Section 2.3)

3. Install the supply (bench or rack mount), ensuring adequate ventilation (Section 2.4)

4. Assemble and connect the AC input power connector (Section 2.5.1)

5. Perform initial function tests for voltage mode operation, current mode operation, and front panel controls (Section 2.6)

6. Connect the load (Section 2.7)

Instructions for Local Programming Mode operation (Constant Voltage and Constant Current) are given in Section 3 Basic Operation. Remote Programming operation, monitoring, and programmable functions are described in Section 4 Advanced Operation.

2.2 SAFETY

Please review the following points for both personal and equipment safety while using the DCS-E Series power supplies.

2.2.1 High Energy/High Voltage Warning

Exercise caution when using and servicing power 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 output connector of power supplies that are rated at 40V and over. Filter capacitors store potentially dangerous energy for some time after power is removed.

Use extreme caution when biasing the output relative to the chassis due to potential high voltage levels at the output terminals. The output of the DCS-E Series supplies (3kW models) may be biased up to a maximum of 150 Vdc relative to the chassis.

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Installation Sorensen DCS-E Series 3kW Supplies

2.2.2 AC Source Grounding

Ensure the power supply is connected to an appropriately rated AC outlet with the recommended AC input connector as set out in Section 2.5.1 AC Input Power Connection. There is a shock hazard if the power supply chassis and cover are not connected to an electrical ground via the safety ground in the AC input connector. The third wire in a single phase AC input connector and the fourth wire in a three phase AC input connector must be connected to an electrical ground at the power outlet. Any disconnection of this ground will cause a potential shock hazard to operating personnel.

This power supply is equipped with an AC line filter to reduce electromagnetic interference and must be connected to a properly grounded receptacle, or a shock hazard will exist.

Operating the supply at line voltages or frequencies in excess of those specified may cause leakage currents in excess of 5.0 mA peak from the AC line to the chassis ground.

2.2.3 Operating 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 before

making internal adjustments or replacing components. When performing internal adjustments or servicing the power supply, ensure another person with first aid and resuscitation certification is present. Repairs must be made by experienced technical personnel only.

Be sure to isolate the power supply from the input line with an isolation transformer when using grounded test equipment, such as an oscilloscope, in the power circuit.

The power supply must not be operated where flammable gases or fumes exist.

2.2.4 Parts and Modifications

Do not use substitute parts or make unauthorized modifications to the power supply to ensure that its safety features are not degraded. Contact the manufacturer for service and repair help.

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Sorensen DCS-E Series 3kW Supplies Installation

2.3 INITIAL INSPECTION

On first receiving your DCS-E Series power supply, perform a quick physical check, paying particular attention to front panel controls and indicators as well as rear panel connectors and terminals. See Figure 1-1 and Figure 1-2 for front and rear panel diagrams.

2.3.1 Physical Check

After unpacking, perform an initial inspection to ensure the unit and parts shipped with it have not been damaged in transit. The package should contain the power supply, a manual, one (1) AC input connector, and five (5) contact pins.

1. Inspect for dents and scratches to the cover and chassis; for scratches and cracks on the front and rear panels; and for any broken controls, connectors, or displays.

2. Turn front panel controls from stop to stop. Rotation should be smooth.

3. Test the action of the power switch. Switching action should be positive.

4. If internal damage is suspected, remove the cover and check for printed circuit board and/or component damage. Reinstall cover.

If damage is found to have occurred, save all packing materials and notify the carrier immediately. Refer to the terms of the warranty. Direct repair problems to the manufacturer.

Note: Section 2.6 Initial Functional Tests 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 but before the load has been connected to the power supply.

2.4 LOCATION, MOUNTING, AND VENTILATION

The DCS-E system supply may be used in rack mounted or in benchtop applications. In either case, you must allow at least 1U (1.75“) clearance for cooling air to reach the ventilation inlets on the top of each unit. You must also allow sufficient space for unobstructed airflow on each side and rear of all units so that the operating ambient temperature is within specification (see Section 1.3, Specifications, in this manual).

Obstructing the air inlets and/or exhaust may cause fire and irreversible damage to the unit.

CAUTION!

2.4.1 Unit Dimensions

Single Unit Height Width Depth Weight

Standard 3.45 in 19 in 20 in 35 lbs Metric 87.6 mm 482.6 mm 508 mm 16 kg

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Installation Sorensen DCS-E Series 3kW Supplies

2.4.2 Rack Mounting

The supply is designed to fit in a standard 19” equipment rack. Bolt holes in the chassis sides are provided for rack mount slides such as the ZERO #C300S18 slides. When installing the unit in a rack, be sure to provide adequate support for the rear of the unit while not obstructing the ventilation on the top, sides and rear of all units. (See Section 2.4, Location, Mounting, and Ventilation in this manual).

16" into the side of the

CAUTION!

Rack mounting bolts must not extend more than power supply.

2.5 AC INPUT POWER

Section 2.5.1 AC Input Power Connection gives instructions for making connections to either single phase or three phase AC power sources. Order replacement AC input connectors and contacts using the following part numbers.

Chassis-Mounted Parts

Mating Connector Parts

Housing Tyco 641685-1 Contact Pins Tyco 350821-1 Connector Housing Tyco 643267-1 Contact Pins Tyco 350821-1

2.5.1 AC Input Power Connection

Before you can use the DCS-E system supply, you must determine your AC input power requirements and assemble an appropriate line cord and connector. The power supply is shipped with a kit of connector and strain relief parts which you assemble using the procedures in this section.

2.5.2 AC Input Power Requirements

This supply may be operated from either a single phase or a three phase AC power source. The specifications for input voltage, current, and frequency are listed below.

AC Input Voltage Range Maximum Input Current Frequency

200-250 Vac Single Phase 20 Arms 47-63 Hz 190-250 Vac Three Phase 14 Arms 47-63 Hz

The maximum output power must be limited to 2500 Watts when the power supply is used with a single phase input to avoid tripping the power

CAUTION!

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supply's input circuit breaker.

Sorensen DCS-E Series 3kW Supplies Installation

2.5.3 AC Input Connector Assembly

Each unit is shipped with a connector and contacts which mate with the chassis-mounted AC connector located on the rear panel. See Figure 2-1 AC Connector and Contacts.

ARTS SUPPLIED

• One (1) connector Part number MI-6432-672, Tyco 643267-1

• Five (5) contacts Part number MC-3508-211, Tyco 350821-1

DDITIONAL PARTS REQUIRED

• 8 to 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 Contacts

IRE PREPARATION

1. Trim outer wire jacket 2". (Necessary for strain relief. See Section 2.5.4.)

2. Strip 0.300" at the end of the insulated AC input wire.

3. Crimp the stripped wire into the contact as indicated in Figure 2-2, then solder the connection.

4. Crimp the contact around the wire insulation as indicated in Figure 2-2.

Figure 2-2 Wire Preparation

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