KEPCO RKW 1500W User Manual

OPERATOR’S MANUAL

RKW 1500W SERIES

POWER SUPPLY

SINGLE OUTPUT, UNIVERSAL INPUT

KEPCO INC.

An ISO 9001 Company.

IMPORTANT NOTES:

1) The contents of this manual are protected by copyright. Reproduction of any part can be
made only with the specific written permission of Kepco, Inc.

2) Data subject to change without notice.

SINGLE PHASE, 0.99 POWER FACTOR

MODEL

RKW 1500W SERIES

POWER SUPPLY MODELS

RKW 3.3-375K, RKW 5-300K, RKW 12-125K,
RKW 15-100K, RKW 24-65K, RKW 28-55K,
RKW 48-32K

KEPCO®

©2010, KEPCO, INC
P/N 228-1503-REV 5

KEPCO, INC. ! 131-38 SANFORD AVENUE ! FLUSHING, NY. 11355 U.S.A. ! TEL [phone] ! FAX [phone]

email: [e-mail] ! World Wide Web: http://www.kepcopower.com

THE POWER SUPPLIER™

TABLE OF CONTENTS

SECTION PAGE

1. Introduction........................................................................................................................................................ 1

1.1 Scope of Manual............................................................................................................................................. 1

1.2 Description...................................................................................................................................................... 1

2. Specifications .................................................................................................................................................... 1

3. Optical Coupler Output Alarm Circuit ........................................................................................................... 5

4. Operation........................................................................................................................................................... 6

4.1 Voltage Adjustment ........................................................................................................................................ 7

4.2 Remote Voltage Control ................................................................................................................................. 8

4.3 Remote Turn On-Turn Off............................................................................................................................... 8

5. Alarm Functions................................................................................................................................................. 8

5.1 Overvoltage And Overtemperature Protection................................................................................................ 8

5.2 Overcurrent Protection ................................................................................................................................... 9

5.3 Fan Failure ..................................................................................................................................................... 9

5.4 Undervoltage .................................................................................................................................................. 9

6. Load Connection ............................................................................................................................................... 9

6.1 Connecting The Load Using Local Sensing................................................................................................... 9

6.2 Connecting The Load Using Remote Sensing................................................................................................ 9

6.3 Parallel Connection ...................................................................................................................................... 10

6.4 Series Connection ........................................................................................................................................ 12

6.5 Preliminary Electrical Check......................................................................................................................... 12

7. Fan Maintenance............................................................................................................................................. 13

LIST OF FIGURES

FIGURE TITLE PAGE

1 Mechanical Outline Drawing Of The RKW 1500W Power Supply............................................................ 4

2 Output Alarm Circuit Optically Isolated....................................................................................................... 5

3 RKW 1500W Power Failure Timing Diagram ............................................................................................. 5

4 Power Rating Vs. Temperature.................................................................................................................. 6

5 Mounting Positions For The RKW 1500W Power Supply .......................................................................... 6

6 Locations Of Operating Controls, Indicators and Terminals....................................................................... 7

7 Connections For Remote Voltage Control.................................................................................................. 8

8 Correct and incorrect Methods of Load Connection................................................................................. 10

9 Parallel Connection with Current Balancing ............................................................................................. 10

10 Parallel Connection, Master-Slave, Multiple Loads.................................................................................. 11

11 Parallel Connection, Master-Slave, Single Load ...................................................................................... 11

12 Series Connection.................................................................................................................................... 12

13 Functional Checkout................................................................................................................................. 13

LIST OF TABLES

TABLE TITLE PAGE

1 Output Ratings and Specifications ............................................................................................................. 1

2 Power Supply Ratings and Specifications .................................................................................................. 2

i 228-1503 REV 2 060110

1. INTRODUCTION

1.1 SCOPE OF MANUAL

This Operator's Manual covers the installation and operation of the Kepco RKW 1500W Series of
PFC (Power Factor Corrected), RoHS (Reduction of Hazardous Substances) compliant, switching
power supplies. For service information, write directly to: Kepco Inc., 131-38 Sanford Avenue,
Flushing, New York, 11355, U.S.A. Please state Model Designation and Serial Number of your
RKW Power Supply. This information can be found on the nameplate of the unit.

1.2 DESCRIPTION

The Kepco RKW 1500W Series consists of seven models of switching power supplies, each with
a single output as shown in Table 1. Units may be operated with a nominal 100V a-c to 240V a-c
(input voltage range 85 to 265 Va-c), 50-60 Hz (input frequency range 47-66Hz). They will also
operate on 110V to 370V d-c input. The RKW 1500W Series employs a light weight ferrite core
with a switching frequency of about 140 KHz (about 100 KHz for the 3.3 volt model). Regulation is
provided by pulse width modulation. A power stage with two MOSFETS on each side of the pri­mary winding, operating in the forward mode provides a smooth isolated d-c output. A thyristor cir­cuit prevents excessive turn-on current surge. Overvoltage, overcurrent, undervoltage,
overtemperature and fan failure protections, an isolated remote TTL ON-OFF control, a power fail
signal and current balancing (for parallel operation) are provided. An LED “output voltage ON”
light and an output voltage adjust trimmer are visible near the output bus bars (right side of the
case). Units are manufactured on a steel frame with a steel cover.

2. SPECIFICATIONS

Table 1 contains specifications and operating limits of individual RKW 1500W Series models.
Table 2 contains specifications and operating limits common to all RKW 1500W Series Models.
These specifications are at nominal input voltages at 25°C unless otherwise specified.

TABLE 1. OUTPUT RATINGS AND SPECIFICATIONS

MODEL RKW 1500W 3.3-375K 5-300K 12-125K 15-100K 24-65K 28-55K 48-32K

Output Volts d-c
Adjustment Range 1.8-3.6 3.5-6.0 7.2-14.4 10.5-18.0 16.8-28.8 19.6-33.6 33.6-52.8
Voltage Setting 3.3 ±0.03 5 ±0.05 12 ±0.12 15 ±0.15 24 ±0.24 28 ±0.28 48 ±0.48

Maximum

Output

Ratings

(A,W)

Overcurrent Setting (Amps)
Current Short Circuit 430 350 152 135 80 70 45

OVP Setting (Volts)

Efficiency

% typical

Ripple &

(3)

Noise

(mV, p-p)

(1) Square type. If overcurrent condition continues for approximately 30 seconds, the output is shut OFF. Recovery is by

removing power and reapplying power after about 40 seconds or by opening and reclosing the RC terminals .

(2) When overvoltage is detected, output is shut OFF. Recovery is by removing power and reapplying power after about 40

seconds or by opening and reclosing the RC terminals (no delay).

(3) Ripple and noise specifications is 1.5 times the indicated values for a temperature range of -10 to 0°C. Ripple and noise

levels above are satisfied when conditions are 0 to 100% load, 0 to 65°C, and bandwith </= 100MHz.

–10°C to

40°C

50°C

amb

60°C,

amb

65°C,

amb

AC Input 100V 73 77 80 82 82 82 84
AC Input 200V 77 82 84 86 86 86 88

ripple 100 100 150 150 200 200 300

ripple noise

Amps 375 300 125 100 65 55 32
Watts 1237.5 1500 1500 1500 1560 1540 1536
Amps 346.88 300 125 100 65 55 32
Watts 1144.69 1500 1500 1500 1560 1540 1536
Amps 300 240 100 80 52 44 25.6
Watts 990 1200 1200 1200 1248 1232 1228.8
Amps 262.5 210 87.5 70 45.5 38.5 22.4
Watts 866.25 1050 1050 1050 1092 1078 1075.2

(1)

(2)

3.3V 5V 12V 15V 24V 28V 48V

390-430 315-350 130-140 105-115 68-72 57.7-63.2 33.6-36.8

4.0 - 4.6 6.2 - 7.0 14.8 - 16.8 18.6 - 21.0 29.8 - 33.6 34.7 - 39.2 55.0 - 59.9

200 200 200 200 300 300 400

228-1503 REV 4 060110 1

TABLE 2. POWER SUPPLY RATINGS AND SPECIFICATIONS

SPECIFICATION DESCRIPTION

Input Voltage 85-265V a-c (0 to 100% load, -10 to 65°C)

110-370V d-c Polarity insensitive (0 to 100% load, -10 to 65°C) Safety

agency approval applies only to a-c input operation.

Input Source Frequency 50-to 60 Hz 47-440 Hz. (At 440 Hz the leakage current exceeds the

UL leakage safety specification limit).

Input Current: (Maximum Load At
25°C with Nominal Output Voltage)

Input Protection A limiting resistor in series with a resistor fuse (in parallel with a thyristor circuit) reduces start-

Input Surge cold start,

interval > 30 sec

Leakage Current: 0.5mA typ., 0.8mA max. at 120V a-c, 60Hz (per IEC 950 and UL1950)

Power Factor 0.99 typical 100 - 120V a-c, rated output

Stabilization Typical Maximum

Remote Error Sensing: Compensation up to 0.4 Volts per load wire (0.15 Volts for RKW 3-375, 0.25 Volts for RKW

Transient Recovery
characteristic

Start-up Time 500 msec maximum, 280 msec

Output Hold-up Time 35 msec typical, 20 msec mini-

Thermal Protection When the Power Supply goes into thermal protection, the output is cut OFF. To restart (reset)

(1)

22A rms max. (18A rms max for the 3.3V model)

11A rms max. (9A rms max for the 3.3V model)

up surge. Units are protected against shorts by an input fuse. Fuse value 30.0A At 250 Volts

15A typ., 20A max. first surge 100 - 120V ac

30A typ., 40 max. first surge 200- 240 V ac

1.1mA typ., 1.6mA max. at 240V a-c, 60Hz (per IEC 950 and UL1950)

0.95 typical 200 - 240V a-c, rated output

Source Effect (min - max) (85 to
132 V a-c, 170 to 265V a-c)

Load Effect, measured at sensing
terminals (0%-100% load change)

Temperature Effect (–10° to 65°C) 0.5% 1.0%

Combined Effect (envelope,
Source, Load and Temperature)

Drift (8 hours at 25°C) 0.2% 0.5%

5-300K) (see Figure 8).

excursion ±4% maximum 50% to 100% load,

recovery time 1 ms maximum

typical.

400 msec maximum, 180 msec
typical.

mum.

40 msec typical, 20 msec mini­mum.

the unit after it has cooled, it is necessary to remove the a-c input power, wait about 40 sec­onds, and then to reconnect the a-c input power or to open and then reclose the RC terminals.

(0.15% for 3.3V Model)

(0.45% for 3.3V Model)

(±1.1% for 3.3V Model)

0.1%

0.3%

±0.9%

100V a-c

240V a-c

100V a-c

240V a-c

100 - 120V a-c

200 - 240V a-c

0.2%

(0.3% for 3.3V Model)

0.6%

(0.9% for 3.3V Model)

±1.8%

(±2.2% for 3.3V Model)

transient time >50

µsec

(1) First surge only, not including current flow into EMI filter

2 228-1503 REV 4 060110

TABLE 2. POWER SUPPLY RATINGS AND SPECIFICATIONS (CONTINUED)

SPECIFICATION DESCRIPTION

Remote Control ON/OFF: "High", 2.4V to 24V (or open), unit OFF- Fan Off ; "Low", 0.0V to 0.4V (or closed), unit ON.

Operating Temperature: -10 to 65°C (see Figure 4)

Startup Temperature -20 to -10°C (see Figure 4)

Storage Temperature: -30°C to +75°C

Withstanding voltage : (at 15-35°C
ambient, 10-85% relative humidity)

Insulation Resistance: (at 15-35°C
ambient, 10-85% relative humidity)

Humidity: 10% to 95% relative humidity, noncondensing, Wet Bulb tem-

Vibration: 5-10 Hz., 10mm amplitude,

Shock:
(non-operating, 1/2 sine pulse,
three shocks on each axis, Power
Supply is fixed on its bottom side)

Safety: All units designed to meet UL1950, CSA Electrical Bulletin 22.2 No.950-95 (certified by UL),

EMI Conducted: Designed to meet FCC Class A, VCCI-Class A, EN55011-A, EN55022-A.

EMI Radiated: Designed to meet FCC Class A, VCCI-Class A, EN55011-A, EN55022-A

Input current harmonics: Designed to meet EN61000-3-2.

Immunity: Designed to meet EN50082-2.

ESD immunity: EN61000-4-2, level 4 normal operation

Fast transient burst immunity: EN61000-4-4 level 3 normal operation

Surge immunity: EN61000-4-5, level 4 no damage

Power Frequency Magnetic Field
immunity:

Radiated field immunity: EN61000-4-3 level 3 normal operation

Conducted noise immunity: EN61000-4-6 level 3 normal operation

Voltage dips interruptions and
variations

Dimensions: 3.62 in. (92 mm) x 7.48 in. (190 mm) x 11.81 in. (300 mm)

Mounting: Four No. M4 tapped holes on the sides and the bottom

Maximum Screw Penetration: 0.24 in. (6 mm)

Cooling: Forced air flow - two fans

Frame Material/Cover Material: Steel

Weight 13.2 lbs, 6.0Kgs. maximum

Source current is 1.6mA maximum at low level, and sink current is 1.0 mA maximum at high
level. The ±RC terminals are isolated from the a-c input terminal and the DC output terminals.
When remote ON/OFF is not in use, ±RC terminals must be shorted (use shorting link sup­plied) for unit to operate.

2000Va-c for 1 minute. Cutout current is 20mA Between input and ground

500Va-c for 1 minute. Cutout current is 300mA Between output and ground

3000Va-c for 1 minute. Cutout current is 20mA Between input and output

terminal

Between output and ground, input and ground, and input and output, 100 Megohms minimum
(500Vdc)

operating and non-operating

perature</=35°C

non-operating 1 hr. on each
of 3 axes, sweep time 10

10-200 Hz., acceleration 64.3ft./s

2

( 19.6m/s2) (2g)

minutes

Acceleration: 964.6ft./s

2

(294m/s2 ) (30g),

Pulse Duration: 11ms ± 5 msec

and TÜV Rheinland EN60950 (ambient temp. 50°C max., 3.3V Model: 40°C max.). RKW
1500W units are CE marked per the Low Voltage Directive (LVD), 73/23/EEC and 93/68/EEC.
[The standards do not apply with DC input operation.]

With filter P/N 245-0031: FCC Class B, VCCI-Class B, EN55011-B, EN55022-B

With filter P/N 245-0031: FCC Class B, VCCI-Class B, EN55011-B, EN55022-B

EN61000-4-8, level 4 normal operation

EN61000-4-11 normal operation

228-1503 REV 4 060110 3