OPERATOR MANUAL FOR
Document: 83-510-004 Rev C
405 Essex Road, Neptune, NJ 07753
Tel: (732) 922-9300
Fax: (732) 922-9334
Web: www.lambda-emi.com
i
Table of Contents
1. GENERAL INFORMATION ............................................................... 1-1
1.1 INTRODUCTION .....................................................................................1-1
1.2 SAFETY PRECAUTIONS........................................................................1-2
1.3 SCOPE OF THIS MANUAL .....................................................................1-3
1.4 MODEL NUMBER FORMAT ...................................................................1-3
2. OUT-OF-BOX-INSPECTION ............................................................. 2-1
2.1 VISUAL INSPECTION .............................................................................2-1
2.2 ELECTRICAL INSPECTION....................................................................2-1
2.3 CONTACTING LAMBDA-EMI CUSTOMER SERVICE ...........................2-1
2.4 RETURNING DEFECTIVE UNITS...........................................................2-1
3. INSTALLATION................................................................................. 3-1
3.1 19-INCH RACK MOUNTING ...................................................................3-1
3.2 VENTILATION REQUIREMENTS ...........................................................3-1
3.3 AC POWER CONNECTION....................................................................3-1
3.4 CONNECTING THE LOAD......................................................................3-2
3.5 INTRODUCING THE J1 PROGRAMMING PLUG...................................3-3
3.6 CONNECTING THE IEEE/RS232 INTERFACE......................................3-4
4. CONTROLS, INDICATORS, CONNECTORS.................................... 4-1
4.1 FRONT PANEL LAYOUT ........................................................................4-1
4.2 BACK PANEL LAYOUT...........................................................................4-2
4.3 J1 CONNECTOR PIN DIAGRAM ............................................................4-4
5. PROGRAMMING THE OUTPUT ....................................................... 5-1
5.1 VOLTAGE MODE AND CURRENT MODE .............................................5-1
5.2 LOCAL PROGRAMMING USING FRONT PANEL KNOBS....................5-2
5.3 ANALOG PROGRAMMING USING THE J1 CONNECTOR ...................5-2
5.4 THE IEEE/RS232 PROGRAMMING OPTION.........................................5-3
6. MEASURING THE OUTPUT ............................................................. 6-1
6.1 THE FRONT PANEL DISPLAYS.............................................................6-1
6.2 MEASURING OUTPUT USING THE J1 CONNECTOR..........................6-1
6.3 THE IEEE/RS232 MEASURING OPTION...............................................6-2
7. PROTECTIVE SHUTDOWN .............................................................. 7-1
7.1 THE SHUTDOWN CONDITION ..............................................................7-1
7.2 FRONT PANEL OVER-VOLTAGE PROTECTION (OVP).......................7-1
7.3 REMOTE INHIBIT USING J1 (OPEN CONTACT) ..................................7-2
7.4 REMOTE ENABLE USING J1 (AC AND DC)..........................................7-3
7.5 OVER-TEMPERATURE SHUTDOWN....................................................7-4
7.6 LOW-LINE AC POWER SHUTDOWN ....................................................7-4
7.7 THE IEEE/RS232 PROTECTION OPTION .............................................7-4
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8. PROGRAMMING WITH J1: WIRING DIAGRAMS ............................ 8-1
8.1 WIRING J1: LOCAL PROGRAMMING....................................................8-1
8.2 WIRING J1: PROGRAM VOLTAGE USING REMOTE RESISTANCE...8-3
8.3 WIRING J1: PROGRAM VOLTAGE USING REMOTE VOLTAGE.........8-3
8.4 WIRING J1: PROGRAM VOLTAGE USING REMOTE CURRENT ........8-4
8.5 WIRING J1: PROGRAM CURRENT USING REMOTE RESISTANCE ..8-4
8.6 WIRING J1: PROGRAM CURRENT USING REMOTE VOLTAGE ........8-5
8.7 WIRING J1: PROGRAM CURRENT USING REMOTE CURRENT........8-5
9. REMOTE VOLTAGE SENSING ........................................................ 9-1
9.1 CONNECTING THE REMOTE VOLTAGE SENSE LINES .....................9-1
9.2 ACCURACY AND REMOTE SENSING...................................................9-1
10. CONNECTING MULTIPLE SUPPLIES............................................ 10-1
10.1 PARALLEL OPERATION.......................................................................10-1
10.2 PARALLEL OPERATION, MASTER/SLAVE.........................................10-3
10.3 SERIES OPERATION............................................................................10-4
10.4 SERIES OPERATION, MASTER/SLAVE..............................................10-5
11. QUICK OPERATIONAL TEST......................................................... 11-1
12. ESS SPECIFICATIONS................................................................... 12-1
12.1 DECLARATION OF CONFORMITY ......................................................12-1
12.2 PHYSICAL SPECIFICATIONS ..............................................................12-2
12.3 ENVIRONMENTAL SPECIFICATIONS.................................................12-2
12.4 INPUT POWER .....................................................................................12-3
12.5 PROGRAMMING: STATIC ACCURACY...............................................12-3
12.6 PROGRAMMING: DYNAMIC RESPONSE............................................12-4
12.7 OUTPUT RIPPLE ..................................................................................12-6
12.8 MEASURING ACCURACY....................................................................12-7
12.9 OVER-VOLTAGE PROTECTION..........................................................12-7
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List of Figures
Figure 1. Front Panel Controls and Indicators .................................... 4-1
Figure 2. Back Panel Controls and Connectors.................................. 4-3
Figure 3. J1: Rear-Panel Programming Connector............................. 4-4
Figure 4. Voltage and Current Mode Crossover ................................. 5-1
Figure 5. Wiring J1: Basic Programming Plug.................................... 8-1
Figure 6. Wiring J1: Fully-Loaded Programming Plug ........................ 8-2
Figure 7. Remote Voltage Sensing Diagram ......................................9-2
Figure 8. Connecting Parallel Supplies,............................................ 10-2
Figure 9. Master/Slave: Wiring the Programming Cable................... 10-3
Figure 10. Series Supplies, Master/Slave........................................... 10-6
Figure 11. Wiring J1: Series Master/Slave Mode................................ 10-6
List of Tables
Table 1. Model Number Format......................................................... 1-3
Table 2. Input Power......................................................................... 3-1
Table 3. Wire Sizes for Load Connection ..........................................3-3
Table 4. Front Panel Controls and Indicators .................................... 4-1
Table 5. Back Panel Controls and Connectors.................................. 4-2
Table 6. Output Measurement Schemes Using J1 ............................ 6-1
Table 7. Output Ripple, ESS 2.5 KW, 1-Phase ..............................12-6
Document: 83-510-004 Rev C
Introduction
1. GENERAL INFORMATION
1.1 INTRODUCTION
The ESS 2.5 KW-CE-IEEE Power Supply, manufactured by Lambda EMI of Neptune,
NJ, is a compact high performance device. It has numerous features that have been developed specifically for manufacturing, laboratory test and burn-in applications. It will
drive a load with up to 2.5 Kilowatts of DC power and it is 3½ inches tall in a 19-inch
rack. Standard features include:
• Output Voltage and Current Adjustable From Zero to Full Output
• Constant Voltage Regulation • Constant Current Regulation
• Voltage Control Knob, 10 Turn • Current Control Knob, 10 Turn
• Output Voltage LED, 3½ Digits • Output Current LED, 3½ Digits
• Settable Over-Voltage Protection with Crowbar
• Isolated Power Outputs
1-1
• Series Supply Operation • Parallel Supply Operation
• Remote Sensing of Voltage at Load
• Remote Programming of Voltage by External Voltage, Current or Resis-
tance.
• Remote Programming of Current by External Voltage, Current or Resistance.
• Remote Programming is User Selectable for +5V or +10V Full Scale.
• Voltage Monitor • Current Monitor
• Monitors are User Selectable +5V or +10V Full Scale.
• Low AC Input Shutdown • High Temperature Shutdown
• Four Mode-Indicating LEDs • Front Panel AC Circuit Breaker
• Open-Contact External Inhibit • AC or DC External Enable
• Soft Start to Reduce AC Inrush
• Internal discharge resistors on AC Input and Output terminals
• “Zero Stacking” in mounting rack. Top and Bottom covers have no openings.
• Air Cooled, Fan Driven, in front, out rear.
• Optional IEEE-488 and RS-232 Digital Interface
NOTE: This manual contains information, instructions and diagrams which apply to
standard constructions. If special features or modifications have been installed, the
instructions specific to that modification are contained in Addenda and take precedence if conflicts exist. Please take care to refer to the correct information for your
unit.
Document: 83-510-004 Rev C
1-2
Introduction
1.2 SAFETY PRECAUTIONS
All ESS power supplies are designed to minimize the
risk of fire or shock hazard. This instrument received
comprehensive mechanical and electrical inspection
prior to shipment. Nevertheless, certain safety precautions must be observed. Only TECHNICALLY QUALIFIED SERVICE PERSONNEL
familiar with the principles of electrical safety should operate this supply. The power supply SHOULD NOT BE EXPOSED TO WATER OR MOISTURE OR DUSTY
ENVIRONMENTS. Electrical safety must be maintained at all times.
Lethal voltages are developed within the power supply's enclosure. Therefore, the cover
may not be removed by the user (see Warrantee in preamble section for variance). Also,
the large capacitors in the supply may store power even after the line power is removed.
ALLOW AT LEAST 40 SECONDS DISCHARGE TIME between removing the line power
and opening the cover. ALSO, ALLOW AT LEAST 40 SECONDS between switching the
AC power off and switching it on again.
Dangers are inherent in high voltage equipment. However, power supplies with
LOW VOLTAGE OUTPUTS ARE ALSO POTENTIALLY DANGEROUS. Beyond the
steady state energy available, supply outputs have 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 before switching ON the AC power.
Ensure the JI Programming Plug is attached.
2. Proper grounding from the input AC power is required to reduce the risk of electric
shock. Ensure that the AC Protective Earth Ground (third prong) connection has at
least the same gauge wire as the supply leads shown in Table 2.
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.
5. Use extreme caution when connecting the high voltage output cables 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. Never attempt to operate the power supply in any manner not described in this manual.
8. Never remove DANGER and WARNING labels from the power supply. Replace lost or
damaged labels immediately.
9. The power supply should only be serviced by Lambda EMI factory authorized personnel.
Document: 83-510-004 Rev C
Introduction
1.3 SCOPE OF THIS MANUAL
This manual is used for installing and operating the ESS 2.5 KW Power Supply.
Suggestions and requirements for connecting AC power, load cables and signal cables
are given. Various operating modes and programming modes are described.
Although the Digital Programming (IEEE-488 and RS-232) option is mentioned here, for
a complete description of the programming language, see Lambda EMI document,
“User Manual For Embedded IEEE Option”, document number 83-468-007.
1.4 MODEL NUMBER FORMAT
The model numbering system for the ESS power supply includes symbols for features
and options. They are separated by dashes.
Examples are: ESS 100-25-15-D-TC-CE and ESS 600-4-15-D-TC-CE-IEEE-0950.
Table 1 is a partial listing of the model number format for the ESS Power Supply family.
For additional options, the customer may contact the Sales Department at Lambda EMI.
Special options are typically shown as a four-digit suffix to the model number.
1-3
ESS (Voltage) - (Current) - (Input) - D - TC - CE - (Options)
DC Voltage Range
DC Current Range
AC INPUT VOLTAGE
Output
Power
2.5 KW
Input Suffix
190-253 VAC,
50-60 Hz
1-Phase
-15
Table 1. Model Number Format
STANDARD
Digital Meters -D
Terminal Cover -TC
Units Comply With
CE Requirements
-CE
OPTIONS
Lock Bushings -LB
IEEE / RS232
Programming
Other Options -xxxx
-IEEE
Document: 83-510-004 Rev C
Inspection
2. OUT-OF-BOX-INSPECTION
2.1 VISUAL INSPECTION
Prior to shipment, this instrument was inspected and found to be free of mechanical and
electrical defects. As soon as the unit is unpacked, inspect for any damage that may
have occurred in transit. Verify the following:
A. Check the operation of the front panel controls (knobs should rotate smoothly).
B. Verify that the circuit breaker latches in the ON and OFF positions.
C. Confirm that there are no dents or scratches on the panel surfaces.
D. Check front panel meters and LEDs for any broken or cracked lenses.
If any damage is found, follow the instructions in Section 2.3 and in the "Returning
Equipment" instructions in the preamble section of this manual.
2.2 ELECTRICAL INSPECTION
Before the ESS is installed in a system, verify that no internal damage occurred during
shipping. A simple preliminary electrical test should be performed. This test is described
in Section 11. It takes only a few minutes and the only required equipment is a power
cord and a piece of cable used to short-circuit the ESS output.
If any inconsistency from the above test procedure is noted, do not hesitate to call
Lambda EMI Customer Service for assistance.
2-1
2.3 CONTACTING LAMBDA-EMI CUSTOMER SERVICE
Phone: (732) 922-9300 E-mail: service@lambda-emi.com
Fax: (732) 922-5403
Customer Service, or an approved Service Center, should be contacted if:
• The power supply is mechanically or electrically damaged.
• The power supply requires on-site calibration, routine internal cleaning, or replace-
ment warning decals.
• The customer has questions about a special application which is not described in
this manual.
Normally, the customer may NOT open any chassis covers which have a warranty seal.
Breaking a seal will void the warranty.
At the discretion of Lambda EMI, the customer may be granted permission to break the
warranty seal and open the chassis covers. Customer Service shall confirm the permission by sending a replacement seal. Once the unit has been serviced, the customer
shall close the cover and apply the replacement seal adjacent to (not on top of) the broken seal.
2.4 RETURNING DEFECTIVE UNITS
The procedure for returning defective products is given in the preamble section of this
manual.
Document: 83-510-004 Rev C
Installation
AWG mm
3. INSTALLATION
3.1 19-INCH RACK MOUNTING
This power supply is intended for mounting in a conventional 19-inch rack. Its 3.47
inches height makes it a “2U” size instrument. The rack should enclose the sides, top
and back to protect the operator from electrical shock and protect the supply from environmental contamination.
Never install the ESS so its weight is supported only by the
front panel screws!
The ESS must never be installed so there is no support in the back. This arrangement
can cause the front panel plate to be permanently distorted. Therefore, the ESS must be
mounted on chassis slides or on a shelf inside the rack.
3.2 VENTILATION REQUIREMENTS
This instrument is fan cooled. Sufficient space must be allocated so that a free flow of
cooling air can reach the front, back and sides of the instrument when it is in operation.
Insure these clearances are met for adequate air flow:
3-1
• 4 inches (10 cm) front and rear, and
• 2 inches (5 cm) on each side.
Air enters through the front and side panels. It is forced out the rear panel. See the Outline Drawing at the end of this manual. This power supply should not be operated with
its cover removed since the cover directs the flow from the internal fan.
3.3 AC POWER CONNECTION
The customer’s AC line connects to the ESS through a terminal strip. It has four SAE #8
screws. Only use a power cable with the correct voltage and current ratings. The recommended wire gauge is listed in this table. The ground wire must be equal to or larger
than the recommended gauge.
Output Power
(Watt)
2.5 KW 1 47-63 190-253 24 10 5.3
Phase Frequency
(Hz)
Table 2. Input Power
The AC input rating is marked on the rear terminal of the power supply. The rating is
also part of the unit’s model number as shown in Table 1.
Input voltage
(Vrms)
Max Input Cur-
rent (Arms)
Recommended Wire
2
The Protective Earth Ground must be connected before
applying AC Line Power to the ESS.
Document: 83-510-004 Rev C
3-2
Installation
3.4 CONNECTING THE LOAD
The load cables between the ESS outputs and the load must be robust. The terminal
connections must be secured tightly. Failure to meet these requirements could cause
substantial voltage losses, terminal over-heating, and insulation degradation
3.4.1 Low Voltage Models
For power supplies with LESS than 101 volts output rating, the POS and NEG bus bars
have single holes for bolting the load cables.
• Hole Diameter: 0.41 Inches (10.3 mm)
• Bolt Size: 3/8 Inch OD (10 mm )
A clear Lexan terminal cover is provided. To attach it, loosen three chassis screws, slide
the cover behind them, then tighten the screws. There are large holes are in the sides of
the cover so the cable bolts may be accessed with a socket wrench.
3.4.2 High Voltage Models
For power supplies with MORE than 101 volts output rating, the POS and NEG outputs
are threaded studs. A nut is used to attach the load cables.
• Stud Thread: SAE 1/4-20 NC
• Stud Length: 1 Inch Long (25 mm )
• Max Torque: 40 Inch-Pounds
A clear Lexan terminal cover is provided. To attach it, loosen three chassis screws, slide
the cover behind them, then tighten the screws.
3.4.3 Load Connection Guidelines
General guidelines for connecting a load are as follows:
• Each pair of cables should be as short as possible.
• On high output current units, connections should be properly torqued. See the bolt
manufacturer’s specification.
• A chassis stud is located near the output terminals so a short jumper may be con-
nected between an output bus bar and chassis ground. The system should NOT be
grounded at more than one point.
The stud size is SAE 10-32. The nut’s maximum torque is 34 inch-pounds.
• If the load cables are long, they should be bundled together. In areas of high electri-
cal noise, they may have to be twisted together.
• Maximize the separation between the AC power lines and the load cables to reduce
the radiated and conducted electromagnetic emissions.
Document: 83-510-004 Rev C
Installation
Typical cable sizes for load connections are shown below. Use cables that meet requirements for current, voltage, length, temperature and termination.
CURRENT
(Amps)
RECOMMENDED
COPPER WIRE SIZE
CURRENT
(Amps)
RECOMMENDED
COPPER WIRE SIZE
3-3
200 4/0
150 2/0
120 0
80 4
60 6
45 8
30 10
20 12
15 14
10 16
6 18
LESS 20
Table 3. Wire Sizes for Load Connection
3.5 INTRODUCING THE J1 PROGRAMMING PLUG
The J1 connector on the back panel is the key to the ESS’s versatility. A programming
plug must be installed on J1 to enable the power supply. This programming plug may be
rewired to make the following features possible:
• Remote Voltage Sensing. See Section 9.
• Remote Programming via voltage, current or resistance. See Section 5.3
• Output Monitor signals for output voltage or current. See Section 6.2
• External Enable and Inhibit. See Section 7.3 and 7.4
The ESS is shipped with the “default” programming plug. It is made from a standard
DB-25 connector with male pins, a backshell and four wires. Its wiring is configured for
local programming and sensing (see Section 5.2). The connector and backshell are
made of plastic to reduce the chance of arcing in high-voltage power supplies.
If a supply has more than 290 volts output, and if its POS bus
bar is connected to Chassis Ground, then the J1 plug
backshell must NOT be conductive.
Using a metallic backshell under these conditions may cause
electrical arcing from the pins to the backshell.
Some guidelines on constructing a custom J1 Programming Plug:
• Recommended to use 26 AWG wire with 300 Volt insulation.
• There may be a need to “daisy-chain” two wires into one pin. One method is to crimp
or solder wire stubs into the pins and then make a splice at the ends of the stubs.
Insulate the splice!
• Passive components such as resistors, capacitors and diodes may be inserted into
the backshell for the purpose of scaling, filtering and protecting.
Document: 83-510-004 Rev C
3-4
Proper ESD precautions must be taken when taking off the
precautions must be taken when taking off the
232 and IEEE connectors when
Installation
cover and making connection to J1.
3.6 CONNECTING THE IEEE/RS232 INTERFACE
An embedded digital programming card is optional for the ESS. The IEEE-488, RS-232
and Address Switch are accessible through openings in the back panel. If this card is
not installed, a blank panel covers the openings.
For details on connector location and pin orientation, see the Outline Drawing at the end
of this manual.
For further details on the digital interface, see Lambda EMI document, “User Manual For
Embedded IEEE Option”, document number 83-468-007.
cover and making connection to RSused J1.
Proper ESD
Document: 83-510-004 Rev C
Outline Diagrams
4. CONTROLS, INDICATORS, CONNECTORS
4.1 FRONT PANEL LAYOUT
For more details, see the Outline Drawing at the end of this manual.
Figure 1. Front Panel Controls and Indicators
4-1
REF DESCRIPTION NOTE SECTION
1 Power Switch Power-On circuit breaker
2 Voltmeter
Power LED Illuminates red when AC power switched ON
3
Voltage Mode
4
LED
5 Over Voltage LED
Current Mode
6
LED
7 Ammeter
8 Handles Protective, extends further than knobs
Voltage Control
9
10 Over Volt Adjust
11 Current Control
Displays output voltage of power supply.
3.5 digits, fixed decimal point, LED display.
Glows amber when supply is in the voltage
mode (constant voltage operation).
Glows red when shutdown has occurred because output exceeded the OV trip level.
Glows amber when supply is in the current
mode (constant current operation).
Displays output current of power supply.
3.5 digits, fixed decimal point, LED display.
Adjusts the output voltage from zero to full.
Ten turn potentiometer.
Sets Over-Voltage trip level. Single turn.
Recessed slotted potentiometer shaft.
Adjusts the output current from zero to full.
Ten turn potentiometer.
6.1
5.1
7.2
5.1
6.1
5.2
7.2
5.2
12 Ventilation Holes Located in front, back and sides. 3.2
Table 4. Front Panel Controls and Indicators
Document: 83-510-004 Rev C
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