KEPCO RAX 1500W User Manual

INSTRUCTION MANUAL

KEPCO

1500 WATT SINGLE OUTPUT

An ISO 9001 Company.

RAX

SWITCHING POWER SUPPLIES

CAUTION: UNIT IS SET

I — INTRODUCTION

SCOPE OF MANUAL.

For service information, please refer to the Service Manual for the RAX 1500W Series, which can be purchased either from your Kepco Representa­tive, or by writing directly to: Kepco Inc. 131-38 Sanford Avenue, Flushing, New York 11352, U.S.A. When ordering a Service Manual, please state

Model Designation and Serial Number of your RAX power supply

DESCRIPTION.

may be operated with either 120V a-c or 220-240V a-c, 47-440Hz input. They will also operate on 240V to 370V d-c input. The RAX 1500W Series
employs a light weight ferrite core with 165
in the forward conversion mode provides a smooth isolated d-c output. A thyristor “soft-start” circuit prevents excessive turn-on current surge. Over­voltage protection and optically isolated remote TTL on-off control is provided. Current limiting with automatic recovery from short circuit is featured.
Units are enclosed in a wrap-around aluminum case with an LED “output present” light visible on the terminal side of the case.

Table 1 contains specifications and operating limits of individual RAX 1500W Series models. Section II (following) contains specifications and operat­ing limits common to all RAX 1500W Series Models.

This instruction manual covers the installation and operation of the Kepco RAX 1500W Series of Switching Power Supplies.

. This information can be found on the nameplate of the unit.

The Kepco RAX 1500W Series consists of four models of switching power supplies, with a single output as shown in Table 1. Units

Hz switching frequency. Regulation is provided by pulse width modulation. A FET power stage, operating

K

II — SPECIFICATIONS

The following specifications are at nominal input voltages at 25°C unless otherwise specified.

TABLE 1. OUTPUT RATINGS AND SPECIFICATIONS, RAX 1500W SERIES

MODEL

OUTPUT VOLTS, d-c

ADJUSTMENT RANGE

MAXIMUM

OUTPUT

RATINGS

(AMPS, WATTS)

EFFICIENCY

CURRENT LIMIT (AMPS)

OVP RANGE (VOLTS)

RIPPLE

AND

(1)

NOISE

(mV p-p)

(1) Source component 2x source frequency, and switching component approximately 165KHz.
(2) Measured with a 50 MHz bandwidth, p-p.

INPUT VOLTAGE:

50° C amb.
60° C amb.
71° C amb.

source (typ)

source (max)

switching (typ)

switching (max)

spike noise (max)

(2)

(Jumper selectable from front panel, see Section III):
120V a-c nominal, range: 85 -132V a-c
220-240V a-c nominal, range: 170 -264V a-c,
320V d-c nominal, range: 240 -370V d-c
For d-c input, remove shorting link from left side barrier strip terminals.

INPUT SOURCE FREQUENCY:

Nominal 50/60 Hz; Range 47-440 Hz. (At 440 Hz the leakage current exceeds the VDE safety specification limit.)

BROWNOUT VOLTAGE:

120V a-c input selection, 80V a-c min.
220-240V a-c input selection, 160V a-c min.
320V d-c input selection, 220V d-c min.

INPUT CURRENT:

(At 25°C with nominal output power):

RAX 5-300K RAX 12-125K RAX 24-65K RAX 48-30K

5V 12V 24V 48V

4.0 - 5.5V 8.4 - 13.2V 16.8 - 26.4V 32.6 - 52.8V

300.0A/1500W 125.0A/1500W 65.0A/1560W 30.0A/1440W

210.0A/1050W 87.5A/1050W 45.5A/1092W 21.0A/1008W

120.0A/600W 50.0A/600W 26.0A/624W 12.0A/576W
79% 81% 83% 84%

315.0 - 350.0 130.0 - 140.0 68.0 - 72.0 32.0 - 35.0

6.0 - 6.9 13.7 - 15.7 27.0 - 30.5 55.0 - 59.0
5 152535

20 30 40 90

50 60 60 70
120 150 150 150
200 250 300 500

TO 115V AC OPERATION

120 V a-c input selection 25A - 32A 21A -41A max.

220-240V a-c input selec­tion

d-c input selection 7.0A max. (320V input) 9.0A max. (240V input)

KEPCO, INC. !"! 131-38 SANFORD AVENUE !" FLUSHING, NY. 11352 U.S.A.!" TEL [phone]!"

©2000, KEPCO, INC
Data subject to change without notice

INPUT SOURCE NOMINAL INPUT VOLTAGE MINIMUM INPUT VOLTAGE

16A - 18A 18A -36A

!

FAX [phone]!!

http://www.kepcopower.com "! email: [e-mail]

228-1229 REV 2

1

INPUT PROTECTION AND SOFT START:

fuse. Fuse value 50A.

INPUT SURGE:

NOTE: There are two input surges at turn-on:

At 25°C from cold start:

INPUT SOURCE FIRST SURGE (1/2 of first input cycle) SECOND SURGE (3ms max.)

120 V a-c input selection 20A max. 130A typ.

220-240V a-c input selection 40A max. 160A typ.

320V d-c input selection 40A max. 160A typ.

STABILIZATION:

CHARACTERISTIC TYPICAL MAXIMUM

Source Effect (min - max) 0.2% 1.0%

Load Effect, measured at sensing terminals (10% - 100% load change) 0.3% 1.0%

Temperature effect (0 to 71°C) 0.2% 1.2%

Combined effect (envelope) 0.7% 3.0%

Drift (8 hr. at 25°C after half-hour warm-up) 0.2% 0.5%

A thyristor soft start circuit reduces start-up surge. Units are protected against shorts by an input

TRANSIENT RECOVERY:

Recovery to 1% of the original voltage is less than 1 millisecond. The step load change should be greater than 200ms; Tr, Tf should be greater
than 3ms.

OUTPUT HOLDING TIME:

AMBIENT OPERATING TEMPERATURES:

STORAGE TEMPERATURE:

HUMIDITY:

20% to 95% relative humidity, noncondensing

A step load change from 50% to 100% of rated load current, produces no more than 4% output voltage excursion, .

Output is maintained for 20 milliseconds minimum upon input interruption (30 milliseconds typical).

See Table 1.

-20°C to + 75°C.
LINKS

(SEE NOTE)

ALTITUDE:

Operating: 10,000 feet (3048.0m)
Nonoperating: 35,000 feet (10,668m)

ISOLATION:

(at 20°C ambient, 85% relative

humidity):

Between input and output terminals,

3.75 KV a-c for 1 minute
(with Y-capacitors removed).

Between input and output or chassis,

2000V a-c for 1 minute.

Between output terminals and chassis,

50 0V a-c for 1 min ut e.

INSULATION RESISTANCE:

Between output
and chassis, 100 megohms minimum
( 5 0 0 V d - c ) .

LEAKAGE CURRENT:

1.0mA max at 120V a-c (U.L. Method)

2.0mA max at 240V d-c (U.L./VDE Method)

VIBRATION:

5-10Hz., 10 mm amplitude , 10-55Hz., 2g

Three Axes: 1 hour each axis, nonoperating

FI GU RE 1. LOA D CO NNE CTIO N - REMOTE SENSING

NOTE:
THE SENSE LEADS MUST NEVER BE DISCONNECTED FROM THE OUTPUT. IF THE
SENSE LEADS ARE ALLOWED TO FLOAT FREE OF THE OUTPUT, THE OUTPUT VOLT­AGE WILL RISE TO THE OVERVOLTAGE POINT AND THE UNIT WILL SHUT DOWN.

•

FOR REMOTE SENSING CONNECT THE SENSE TERMINALS TO THE LOAD AS
SHOWN, AND REMOVE THE TWO SENSING LINKS.

•

FOR LOCAL SENSING LEAVE THE SENSING LINKS IN PLACE AND CONNECT THE
LOAD DIRECTLY TO THE BUS BAR.

SHOCK

EMI CONDUCTED:

SAFETY:

: Three axes, 20g, 11+/- 5 ms pulse duration, 3 shocks each axis, nonoperating

FCC Class A

All units designed to meet UL 1950D3, UL 478, CSA Electrical Bulletin 1402C (RAX 48-30K Level 1, other RAX models Level 5),
VDE 0806, TÜV Rheinland EN60950 and IEC 950 Safety Standards. RAX are CE marked per the Low Voltage Directive (LVD),
EN60950. [The standards do not apply with DC input operation].

III — OPERATION UNIT WILL NOT WORK WITH SENSE LEADS DISCONNECTED (SEE FIG. 1).

INSTALLING THE POWER SUPPLY:

are provided for each mounting configuration. The air surrounding the power supply must not exceed the ambient values given in Table 1.
Allow at least 1.0” free space at the rear of the unit to insure free air movement from the fans

CONNECTING THE LOAD:

The load is connected as shown in Figure 1. Error sensing may be done at the load terminals when it is nec­essary to compensate for voltage loss in the connecting wires. The jumper links must then be removed from the sense terminals. The unit
will compensate for up to 0.4 volts loss per connecting wire. In the RAX 5-300K it is 0.25 volts.

KEPCO, INC. !"! 131-38 SANFORD AVENUE !" FLUSHING, NY. 11352 U.S.A.!" TEL [phone]!"

092200 228-1229 REV 2

Refer to Figure 3. The unit may be mounted on one of the three mounting surfaces. Mounting holes

.

!

FAX [phone]!!

http://www.kepcopower.com "! email: [e-mail]

2

PARALLEL CONNECTION:

SELECTING INPUT VOLTAGE:

operation.

Remove shorting link from left side barrier strip terminals

REMOTE TURN-ON TURN-OFF

remote turn-on/off terminals operates at TTL logic levels (2.4V “high” from the unit and 0.0 to 0.4V short to ground, “low”). The unit is turned off by
bringing the remote turn-on/off terminals to “low” logic level with a switch or solid state device. If the remote on/off feature is not desired, the terminals
should be left open.

VOLTAGE ADJUSTMENT:

operating load, then monitor the + and - sense terminals with a precision voltmeter and turn the voltage control to the desired operating value. Refer
to Table 1 for Adjustment Range.

FUSE PROTECTION:

removed; refer to Figure 3. The following fuse is specified.
KEPCO P/N: 541-0105 or Manufacturer Fuji P/N CR2LS-50/UL, 50A, 250V ;
The Unit also employs internal fuses for safety and protection against catastrophic failures. These fuses are only accessible when the unit is disas­sembled for repair. Two soft start fuses Kepco P/N 541-0104, or manufacturer Uchihashi P/N 121, 2A, 250V; and a switcher fuse Kepco P/N 541­0048 or Manufacturer Bussman ABC 15A, 15A, 250V.

Refer to Figure 2. Connect the Current Balance (CB) terminals as shown.

Input voltage is selected with a shorting link. Refer to Figure 1. The power supply is delivered for 115V a-c

to operate the unit from a nominal 220-240V a-c or 320V d-c source.

When power is on at the source the unit may be turned on or off with the remote control feature. The output of the

Refer to Figure 3. Voltage is adjusted from the front panel as marked. To adjust voltage, first place the unit under an

The user is provided with a 50A input fuse for protection during normal operation. The fuse is accessible after the cover is

IV — CONTROLS, TERMINATIONS, AND ADJUSTMENTS

The following controls, terminations and adjustments are available to the user.

D-C OUTPUT.

+ SENSE, – SENSE.

ing. The unit is delivered with removable links on the front panel that connect the sense leads directly to the output bus terminals. The links may be
removed and the sense leads connected directly to the load. This compensates for voltage drop in the leads to the load. Refer to Figure 1

MONITOR.

MONITOR LIGHT.

VOLTAGE ADJUST (R156).

specified in this manual.

REMOTE CONTROL (RC).

control. Use of remote control is optional.

REMOTE VOLTAGE ADJUST (RV).

from a remote location. Its use is optional. For RAX 48-30K use a 10K ohm external potentiometer. All other models use 5K ohm. When the external
voltage adjustment feature is used the panel voltage adjustment should be turned fully clockwise.

CURRENT BALANCE (CB).

tion the CB terminals are connected together as shown in Figure 2. Output voltage tolerance 5% per unit, current balance tolerance 10% max., out­put current range nominal 20-90%.

A-C INPUT VOLTAGE.

V - SHUT-DOWN PROTECTION AND REMOTE CONTROL

REMOTE CONTROL:

as long as the condition is maintained. Output resumes immediately when the remote terminals are reopened.

FAN FAILURE:

long as the condition exists.

OVERCURRENT AND SHORT CIRCUIT:

voltage falls to less than 70% of nominal for 20 seconds, the output is shut down but the fans remain operating. If the cause of the overcurrent is
removed within 20 seconds, output returns to normal. If overcurrent remains beyond 20 seconds, a restart cycle is required as described in the fore­going. The unit must remain off for 30 seconds before restarting.

OVERTEMPERATURE:

off and remains off as long as the temperature remains above 120° C.

The output appears on heavy bus bars at the front center of the unit.

These leads compensate for voltage error and must be placed directly on the load terminals for the most accurate error track-

The monitor leads are placed across the output and may be connected to a precision voltmeter to monitor output.

This a a green LED that is ON when output is present.

This potentiometer is mounted just below the monitor light. It is used to adjusted the output voltage within the range

The RC leads cause the unit to turn off when the leads are brought to ground potential with a mechanical switch or TTL

A potentiometer placed between the RV terminal and the + Sense terminal may be used to adjust voltage

These terminals are used when up to three RAX 1500 units are connected in parallel. When using a parallel connec-

Labelled terminals are provided on the front panel for selecting input voltage.

Turn-off or shutdown takes place under the following conditions:

Bringing the RC terminals together with either a mechanical switch or logic control causes the unit to turn off and remain off

The Unit will not operate unless both fans are operating. If either fan stops rotation, the unit shuts down and remains shut down as

Overcurrent causes an abrupt voltage drop. Current remains at the maximum value. When the output

A thermistor heat sensor is located in the switcher heatsink. When heatsink temperature reaches 120° C, the output cuts

FIGURE 2. PARALLEL CONNECTION USING CURRENT BALANCE

KEPCO, INC. !"! 131-38 SANFORD AVENUE !" FLUSHING, NY. 11352 U.S.A.!" TEL [phone]!"

092200 228-1229 REV 2

http://www.kepcopower.com "! email: [e-mail]

!

FAX [phone]!!

3

FIGURE 3. OUTLINE DRAWING, RAX 1500W SERIES

5. WEIGHT: 17.6 lbs (8.0 Kg.) max., 16.53 lbs (7.5 Kg) typ.

NOTES: 1. Dimensions in parentheses are in millimeters, others are in inches.

2. TOLERANCES: ±0.04” (±1.0 mm) except as noted.

3. MOUNTING SCREW PENETRATION: 0.024” (6 mm) maximum.

4. MATERIAL AND FINISH: A) Frame is aluminum, phosphate coated; B) CHASSIS, Steel, Cadmium

Plated, Chromate Wash.

KEPCO, INC. !"! 131-38 SANFORD AVENUE !" FLUSHING, NY. 11352 U.S.A.!" TEL [phone]!"

092200 228-1229 REV 2

http://www.kepcopower.com "! email: [e-mail]

!

FAX [phone]!!

4