Lambda EMS 10-60, EMS 7.5-130, EMS 10-200, EMS 10-100, EMS 10-250 Operator's Manual

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TDK Lambda EMS 15-300-2-D Manual

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OPERATOR MANUAL FOR

EMS

POWER SUPPLY

83-473-000 Revision J

MODEL SERIAL NUMBER

405 ESSEX ROAD, NEPTUNE, NJ 07753

LAMBDA EMI

TEL: (732) 922-9300

FAX: (732) 922-9334

Table of Contents

1 GENERAL INFORMATION

2 INSPECTION AND INSTALLATION

3 OPERATING INSTRUCTIONS

4 THEORY OF OPERATION

1 - 1 1 - 11.1 INTRODUCTION 1 - 11.2 SAFETY PRECAUTIONS 1 - 21.3 SPECIFICATIONS 1 - 21.3.1 INPUT POWER 1 - 21.3.2 AC INRUSH CURRENT 1 - 31.3.3 REGULATION 1 - 41.3.4 TRANSIENT RESPONSE 1 - 41.3.5 STABILITY 1 - 41.3.6 REMOTE PROGRAMMING 1 - 51.3.7 METER TOLERANCE 1 - 51.3.8 PHYSICAL SPECIFICATIONS 1 - 51.4 OVERALL EFFICIENCY 1 - 61.5 ENVIRONMENTAL SPECIFICATIONS 1 - 61.5.1 ELECTRICAL INSTALLATION CATEGORIES 1 - 61.5.2 OPERATING TEMPERATURE 1 - 61.6 OVER TEMPERATURE PROTECTION 1 - 61.7 OVERVOLTAGE PROTECTION (FOR OUTPUTS ≤ 300 VDC) 1 - 61.8 RSTL CONTROLLER BOARD 1 - 71.9 COOLING 1 - 71.10 MODEL NUMBER 1 - 81.11 RETURNING EQUIPMENT 2 - 1 2 - 12.1 VISUAL INSPECTION 2 - 12.2 LOCATION 2 - 22.3.1 EMC REQUIREMENTS 2 - 32.4 ELECTRICAL INSPECTION 3 - 1 3 - 13.1 FRONT PANEL 3 - 23.2 OPERATING MODES 3 - 23.2.1 CONSTANT VOLTAGE MODE 3 - 23.2.2 CONSTANT CURRENT MODE 3 - 23.2.3 OUTPUT NULLING 3 - 23.3 PROGRAMMING MODES 3 - 33.3.1 LOCAL PROGRAMMING 3 - 43.3.2 REMOTE PROGRAMMING OF VOLTAGE CHANNEL 3 - 63.3.3 REMOTE PROGRAMMING OF CURRENT CHANNEL 3 - 83.4 PARALLEL OPERATION

3 - 93.5 PARALLEL OPERATION - MASTER/SLAVE 3 - 103.6 SERIES OPERATION 3 - 113.7 SERIES OPERATION MASTER/SLAVE 3 - 113.8 REMOTE METERS (P.S. WITH OUTPUT OF 300V OR LESS) 3 - 123.9 REMOTE SENSING (P.S. WITH OUTPUT VOLTAGE 300V OR LESS) 3 - 123.9.1 REMOTE SENSING (P.S. WITH OUTPUT VOLTAGE OVER 300V ) 3 - 123.10 REMOTE TURN ON 3 - 133.11 LOAD CONNECTION

4 - 1

4 - 14.1 PRINCIPLES OF OPERATION

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83-473-000 Revision H

5 CALIBRATION AND TROUBLESHOOTING

4 - 14.2 INPUT SECTION

4 - 14.3 A200 INVERTER BOARD

4 - 24.4 OUTPUT SECTION

4 - 24.5 A100 CONTROL BOARD

4 - 24.5.1 SUPERVISORY FUNCTIONS

4 - 34.5.2 OVER CURRENT PROTECTION

4 - 44.5.3 SET-POINT REFERENCE

4 - 44.5.4 VOLTAGE CONTROL CHANNEL

4 - 44.5.5 CURRENT CONTROL CHANNEL

4 - 44.5.6 AUTOMATIC CROSSOVER

4 - 44.5.7 PULSE WIDTH MODULATOR FOR THE 600W/1KW

4 - 54.5.8 PULSE WIDTH MODULATOR FOR THE 2.5KW/5KW

4 - 54.5.9 TRANSISTOR DRIVE FOR THE 600W/1KW

4 - 54.5.10 TRANSISTOR DRIVE FOR THE 2KW/2.5KW AND 5KW

5 - 1

5 - 15.1 INTRODUCTION

5 - 15.2 INSPECTION AND CLEANING

5 - 15.3 CALIBRATION

5 - 15.3.1 ANALOG METER ZERO CALIBRATION

5 - 25.3.2 VOLTAGE CHANNEL AND VOLTMETER CALIBRATION

5 - 25.3.3 CURRENT CHANNEL AND AMMETER CALIBRATION

5 - 35.4 TROUBLESHOOTING

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83-473-000 Revision H

List of Figures

FIGURE 3.5: REMOTE PROGRAMMING BY EXTERNAL RESISTANCE,

VOLTAGE MODE

FIGURE 3.6A: REMOTE PROGRAMMING BY EXTERNAL VOLTAGE,

VOLTAGE MODE

FIGURE 3.6B: REMOTE PROGRAMMING BY EXTERNAL

VOLTAGE,VOLTAGE MODE (AS PER 0 - 10V OPTION).

FIGURE 3.7: REMOTE PROGRAMMING BY EXTERNAL CURRENT, VOLTAGE

MODE.

FIGURE 3.8: REMOTE PROGRAMMING BY EXTERNAL RESISTANCE,

CURRENT MODE

FIGURE 3.9A: REMOTE PROGRAMMING BY EXTERNAL VOLTAGE,

CURRENT MODEL

FIGURE 3.9B: REMOTE PROGRAMMING BY EXTERNAL VOLTAGE,

CURRENT MODE (AS PER OPTION)

FIGURE 3.10: REMOTE PROGRAMMING BY EXTERNAL CURRENT,

CURRENT MODE

2 - 2FIGURE 2.1: DELTA TO WYE CONNECTION

3 - 1FIGURE 3.1: FRONT PANEL, (5KW MODEL SHOWN)

3 - 2FIGURE 3.2: OPERATING MODES

3 - 3FIGURE 3.3 REAR PANEL “D” CONNECTOR

3 - 3FIGURE 3.4: LOCAL PROGRAMMING

3 - 4

3 - 5

3 - 6

3 - 7

3 - 8

3 - 9FIGURE 3.11: PARALLEL OPERATION 3 - 10FIGURE 3.12: PARALLEL OPERATION, MASTER/SLAVE 3 - 10FIGURE 3.13: SERIES OPERATION 3 - 11FIGURE 3.14: SERIES OPERATION, MASTER/SLAVE 3 - 12FIGURE 3.15: REMOTE SENSING

4 - 1FIGURE 4.1: SIMPLIFIED EMS POWER SUPPLY

List of Tables

1 - 2TABLE 1.1: INPUT POWER

1 - 4TABLE 1.3: RIPPLE FOR THREE PHASE

1 - 5TABLE 1.4: REMOTE PROGRAMMING ACCURACY

1 - 5TABLE 1.6: PHYSICAL SPECIFICATIONS

1 - 7TABLE 1.7: MODEL NUMBER

3 - 1TABLE 3.1: FRONT PANEL CONTROLS AND LEDS

3 - 3TABLE 3.2: TB1/J1 3 - 13TABLE 3.3: RECOMMENDED WIRE SIZE FOR LOAD CONNECTION

5 - 3TABLE 5.1: TROUBLESHOOTING GUIDE

83-473-000 Revision H

iii Table of Contents

1 GENERAL INFORMATION

1.1 INTRODUCTION

This manual contains instructions for the operation and maintenance of the 600W, 1KW, 2KW, 2.5KW, and 5KW EMS power supply series manufactured by Lambda EMI, Inc. of Neptune, NJ. The EMS series has been developed specifically for laboratory test and burn-in applications. The EMS supply produces a well regulated adjustable DC voltage or current source.

NOTE: This manual contains information, instructions and diagrams which apply to a variety of standard constructions. If special features or modifications have been installed, the specific instructions peculiar to that modification are contained in Addenda and take precedence where conflicts exist. Please take care to refer to the correct information for your unit.

1.2 SAFETY PRECAUTIONS

All EMS power supplies are designed to minimize the risk of fire or shock hazard operation. This instrument received comprehensive mechanical and electrical inspection prior to shipment. Nevertheless, certain safety precautions must be observed. Only technically competent personnel familiar with the principles of electrical safety should operate this supply. To prevent fire or shock hazard, the power supply should not be exposed to water or moisture. Electrical safety should be maintained at all times.

Lethal voltages are developed within the power supply's enclosure. Therefore, the power supply must always be unplugged prior to removing the cover. If the input to the power supply is hardwired, the circuit breaker must be secured and the line fuses removed.

Of course, dangers are inherent in high voltage equipment. However, a power supply with a low voltage output is also potentially dangerous considering the amount of energy (current) the supply is capable of delivering. In addition to the steady state energy available, power supplies are typically terminated by very large capacitors, which can deliver huge surge currents capable of vaporizing metallic objects such as screwdrivers or jewelry. This could result in molten metal being sprayed. Proper care and judgment must always be observed.

1. Ensure all covers are in place and securely fastened and the required ground is connected prior to supplying input AC power.

2. Proper grounding from the input AC power is required to reduce the risk of electric shock. Ensure that the ground connected has at least the same gauge wire as the supply leads.

3. Where high leakage exists and there is a warning label on the rear panel, the protective earth ground must be connected. ( Symbol for protective earth ground).

4. Use extreme caution when connecting input AC power and never apply the incorrect input voltage, refer to ratings label.

1 - 1 General Information

83-473-000 Revision J

5. Use extreme caution when connecting the high voltage output cable including the

4.11411.0

396-484

47-63

4.11412.0

360-440

47-63

10.4

1025.3

180-220

47-63

1412.4

374-456

47-63

4.1

1413.5

342-418

47-63

10.4

24.0

190-250

47-63

10.4

27.4

180-220

47-63

2.5K

1216.5

190-250

47-63

2.5K10

21.9

180-220

47-63

10.4

1020.8

190-25

47-63

4.1

1410.4

190-25

47-63

22.0

90-110

47-63

6.5

1218.8

105-125

47-63

4.1

1413.2

90-110

47-63

600

2.6

166.3

190-25

47-63

600

4.1

1411.3

105-125

47-63

600

for AC

input

separate ground connecting the supply to the load.

6. Ensure all load capacitors are completely discharged prior to connection. Never handle the output cable when the power supply is operating.

7. Always replace fuses with the same type and Volt/Amp ratings.

8. Never attempt to operate the power supply in any manner not described in this manual.

9. Never remove DANGER and WARNING labels from the power supply, and replace lost or damaged labels immediately.

10. The power supply should only be serviced by Lambda EMI factory qualified personnel.

1.3 SPECIFICATIONS

All performance specifications, unless otherwise stated, are defined in the local programming configuration. Ripple, programming speed, transient response and stability are optimized with the power supply so configured.

1.3.1 INPUT POWER

The following provides the maximum input current at a given output power, phase, input voltage and the recommended wire size to be used for input connection.

Rating of Supply

(W)

PhaseOutput Power

Frequency

(Hz)

Input voltage

(Vrms)

Max. Input

Current

Recommended Wire Size

AWG

mm2

Table 1.1: Input Power

1.3.2 AC INRUSH CURRENT

Soft start is standard on all EMS models. Input line current during turn-on, turnoff, power interruption, or reapplication is less than that at full load.

1 - 2 General Information

83-473-000 Revision J

1.3.3 REGULATION

A. A regulation of less than 0.1 % of the maximum rated output is maintained over the

entire range of the input line voltage given in table 1.1

B. Voltage Mode: A load change of 100% (from full load to no load) will cause an output

voltage deviation of less than 0.1% of maximum output voltage.

C. Current Mode: A load change of 100% (from full load to a short) will cause an output

current deviation of less than 0.1% of maximum output current.

600 1000 2000 2500

1000 2000 2500

EMS 7.5-75 EMS 7.5-130 EMS 7.5-250 EMS 7.5-300

EMS 10-60 EMS 10-100 EMS 10-200 EMS 10-250

EMS 20-30 EMS 20-50 EMS 20-100 EMS 20-125

EMS 30-20 EMS 30-33 EMS 30-65 EMS 30-80

EMS 40-15 EMS 40-25 EMS 40-50 EMS 40-60

EMS 60-10 EMS 60-18 EMS 60-33 EMS 60-40

EMS 80-7.5 EMS 80-13 EMS 80-25 EMS 80-30

EMS 100-10 EMS 100-20 EMS 100-25

EMS 150-7 EMS 150-13 EMS 150-16

EMS 300-3.5 EMS 300-6 EMS 300-8

EMS 600-1.6 EMS 600-3.3 EMS 600-4

Max. Ripple (mV)p-p CarrierModel NumberWatts

100 75 75 75

100 100 100 100

100 100 100

120 120 120

150 150 150

250 250 250

1 - 3 General Information

Table 1.2: Ripple for Single Phase

83-473-000 Revision J

2500 5000

Model NumberWatts

EMS 7.5-300 EMS 7.5-600

EMS 10-250 EMS 10-500

EMS 20-125 EMS 20-250

EMS 30-80 EMS 30-165

EMS 40-60 EMS 40-125

EMS 60-40 EMS 60-80

EMS 80-30 EMS 80-60

EMS 100-25 EMS 100-50

EMS 150-16 EMS 150-33

EMS 300-8 EMS 300-16

EMS 600-4 EMS 600-8

Max. Ripple (mV)

p-p Carrier

75 75

100 100

120 120

150 150

250 250

Table 1.3: Ripple for Three Phase

1.3.4 TRANSIENT RESPONSE

The voltage transient resulting from switching the load from 70% to 100% of full load will be less than 10% of the maximum output voltage of the supply. The voltage will recover to ±2% of its original value within 650 µs for units up to 20v. For units above 20 volts the recovery time is increased by a factor of V

1.3.5 STABILITY

Maximum deviation in either voltage or current mode for an eight (8) hour period is 0.05% of max. output under conditions of constant line, load and temperature.

1.3.6 REMOTE PROGRAMMING

All EMS models are capable of being remotely programmed by means of an external resistance, external DC voltage source or an external DC Current source. The remote programming controls all switching action in the power supply. The following table provides the remote programming accuracy at full output.

max

/ 20.

1 - 4 General Information

83-473-000 Revision J

CAUTION!

Hazardous voltages may be present on the terminal block or inside the J1

connector. Insure unit is powered off and disconnected prior to servicing.

Refer to Section 1.2

Voltage Mode

Table 1.4: Remote Programming Accuracy

1.3.7 METER TOLERANCE

The tolerance of an analog front panel voltmeter or ammeter at full scale is ±2 % of full scale. The tolerance of a digital front panel voltmeter or ammeter at full scale is ±2 % of full scale.

1.3.8 PHYSICAL SPECIFICATIONS

inches

1.75600W/1KW

3.52KW/2.5KW

44 29

0-10Vdc0-5 VdcProgramming Method

Current Mode

19 19

48 48

0 - 5KΩ

0 - 1 mA

±5%± 2.5 %± 5 %± 2.5 % Output Voltage

0-100 mVdc0-10 Vdc0-5 VdcProgramming Method

0- 100Ω

0 - 1 mA

±5%± 2.5%± 2.5 %± 5 %± 2.5% Output Current

WEIGHTDEPTHWIDTHHEIGHTPOWER (W)

kglbsmminchesmminchesmm 17 18

432 457

18 35

1.4 OVERALL EFFICIENCY

Efficiency ranges from 69% to 85% depending on the output voltage. Units with higher output voltages have higher efficiency. Efficiency is measured at nominal input line voltage and full load (maximum current and maximum voltage).

1 - 5 General Information

5.255KW

133

Table 1.6: Physical Specifications

83-473-000 Revision J

533

1.5

ENVIRONMENTAL SPECIFICATIONS

Ÿ Operating Temperature: 0-50°C without derating Ÿ Storage Temperature: -40 to +85°C Ÿ Operating Humidity: 20 - 95% RH non-condensing Ÿ Storage Humidity: 20-95% RH non-condensing Ÿ Altitude: 10,000 ft.

1.5.1 ELECTRICAL INSTALLATION CATEGORIES

Ÿ Overvoltage Category II Ÿ Pollution Degree 2

1.5.2 OPERATING TEMPERATURE

All EMS power supplies are capable of continuous duty performance without deviation from their specifications in ambient temperatures between 0°C and 50°C. The output voltage temperature coefficient is 0.02%/°C of the rated output voltage. The output current temperature coefficient is 0.03%/°C of the rated output current. For ambient temperatures between 50°C and 70°C the supply's output power is de-rated by a factor of 5% per 1°C. Units may be safely stored at temperatures of -55°C to +85°C.

1.6 OVER TEMPERATURE PROTECTION

Automatic protection against excessive temperatures is provided by a thermostat mounted on the heat sink. If the heat sink temperature reaches allowable maximu m temperature, the unit will shut down to prevent damage. An automatic restart circuit will be activated once safe operating temperature levels are restored.

1.7 OVERVOLTAGE PROTECTION (FOR OUTPUTS ≤ 300 VDC)

The Overvoltage protection circuitry, adjustable from the front panel, is standard on all EMS models. This circuitry will short circuit (crowbar) the power supply's output to protect the load, and turns the control circuitry off if the output voltage reaches the preset value. This protection is effective regardless of the cause of the overvoltage.

1.8 RSTL CONTROLLER BOARD

This is an optional board that can be installed at the customer’s request. Units which have RSTL installed have all the features of a standard unit except Remote Sense. The installation of the RSTL would require an additional 1.75” to the height of the power supply. The board is designed for remote computer control, functionally duplicating the controls on the front panel of the power supply. These controls select the programming levels (Voltage and Current), and provide metering of the supply’s output. The RSTL, when set in the REMOTE mode, disables the front panel controls (the meters still read), and asserts control of the power supply. RSTL is not currently available in CE models. Contact the factory for further information.

1 - 6 General Information

83-473-000 Revision J

1.9

COOLING

All units are forced air cooled with air entering through the front and sides and exiting

1. No charge for Digital Meters

REFER TO AC INPUT SECTION FOR

ADDITIONAL INFORMATION

Digital

5 KWOMIT

Analog

PANEL METERS

5 KW10

5 KW9

415 ±

41VAC

47-63Hz

5 KW8

380 ±

38VAC

47-63Hz

5 KW7

200 ± 20VAC 47-63Hz 3

2.5 KW7

2.5 KW5

2 KWCE

Units compl

with CE

requirements

600 watts & 1

RSTL

RS232/IEEE 488 PROGRAMMER

600 watts & 1

KWTVOUTPUT TERMINAL COVERS

600 watts & 1

10T

10 TURN CURRENT CONTROL

600 watts & 1

EMS

XXX

- X - X -

- XX

through the rear. A thermostat protects the unit from excessive ambient temperature as well as inadequate forced air cooling. Restart is automatic upon removal of thermal overload.

1.10 MODEL NUMBER

The following chart explains the model number for the EMS Power Supply family. The options provided by Lambda EMI are not limited to the chart. For example, 0-10 V programming of the voltage channel, 0-5 V and 0-10 V of the current channel are not listed in the chart. For any additional options not covered by the chart, the customer can contact the Sales Department at Lambda EMI.

DC VOLTAGE RANGE

DC CURRENT RANGE

FOR THIS

OUTPUT WATTAGE

WITH THIS INPUT VOLTAGE

115 ± 10VAC 47-63Hz 1 220 ± 30VAC 47-63Hz 1 100 ± 10VAC 47-63Hz 1

USE THIS

SUFFIX

OPTIONSAC INPUT VOLTAGE SELECTION

SUFFIXFEATURE

LOCK BUSHING

CONSULT FACTORY

1KW, 2 KW & 2.5KW

230 ± 23VAC 47-63Hz 1

220 ± 30VAC 47-63Hz 1 200 ± 20VAC 47-63Hz 1φ

220 ± 30VAC 47-63Hz 3

225VAC ± 25VAC 47-63Hz 1φ

USER SELECTABLE

200 ± 20VAC 47-63Hz 1φ 480 ± 48VAC 47-63Hz 3 440 ± 44VAC 47-63Hz 3 400 ± 40VAC 47-63Hz 3

OR CONSULT FACTORY

Table 1.7: Model Number

EXAMPLES: EMS 30-30-1-D, EMS 10-500-2-RSTL,

EMS II 20-250-2-LB, EMS 10-250-2-LB-10T

2. 600W & 1KW Units - Digital Meters only.

1.11 RETURNING EQUIPMENT

1 - 7 General Information

83-473-000 Revision J

+ 27 hidden pages

Lambda EMS 10-60, EMS 7.5-130, EMS 10-200, EMS 10-100, EMS 10-250 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual