TDK 500A User Manual
INSTRUCTION MANUAL FOR
500A/102A/152A/202A
POWER SUPPLY
Document: 83-493-001 Rev. K
TDK-Lambda Americas
405 Essex Road, Neptune, NJ 07753
Tel: (732) 922-9300
Fax: (732) 922-9334
Web: www.US.TDK-Lambda.com/HP
THIS PAGE INTENTIONALLY BLANK
ONE YEAR WARRANTY
TDK-Lambda Americas, Inc. (405 Essex Road, Neptune, N.J. 07753), warrants that the unit is free from defects in
material or workmanship for a period of ONE YEAR from the date of initial shipment. TDK-Lambda Americas Inc. will
service and, at its option, repair or replace parts which prove to be defective. This will be done free of charge during
the stated warranty period. This warranty excludes defects resulting from misuse, unauthorized modification,
operation outside the environmental or safety specifications of the power supply, or improper site preparation or
maintenance. The customer shall contact TDK-Lambda Americas Inc., for warranty service or repair as described in
the RETURNING EQUIPMENT section. The customer shall prepay shipping charges. If the unit is covered under the
foregoing warranty, then TDK-Lambda Americas Inc. shall pay the return shipping charges.
The “WARRANTY”, “CLAIM FOR DAMAGE IN SHIPMENT”, and “RETURNING EQUIPMENT” information applies to
equipment purchased directly from TDK-Lambda Americas Inc. End users receiving equipment from a third party
should consult the appropriate service organization for assistance with these issues.
THIS LIMITED WARRANTY IS IN LIEU OF, AND TDK-LAMBDA AMERICAS INC. D ISCLAIMS AND EXCLUDES,
ALL OTHER WARRANTIES, STATUTORY, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, OR OF CONFORMITY TO
MODELS OR SAMPLES.
CERTIFICATION
All test and measuring equipment used by TDK-Lambda Americas Inc. for Final Acceptance Testing are traceable to
primary standards certified by the National Institute of Standards and Technology.
LETHAL VOLTAGES PRESENT!
All power supplies contain hazardous voltage and energy. The power supply must only be operated by qualified
personnel who have read this operator’s manual and are familiar with the operation, hazards and application of the
power supply. Proper care and judgment must always be observed.
1. Before connecting input AC power, ensure all covers are in place and securely fastened. Ensure the required
safety ground to chassis is installed and sufficient cooling is supplied.
2. Proper grounding from the input AC power is required to reduce the risk of electric shock, and to comply with
safety agency and code requirements.
3. Use extreme caution when connecting input AC power. Only apply the input voltage specified on the rating label.
4. Use extreme caution when connecting any high voltage cables. Never handle any output cables when the power
supply is operating.
5. After a power supply is switched OFF, its output section will retain a charge which may be lethal. Allow sufficient
time for self-discharge before handling anything connected to the output. The discharge time specified in the
Safety Notes does NOT include extra time required to discharge the energy stored in the user’s load.
6. When user serviceable fuses are present, always replace fuses with the same type and Volt/Amp rating.
7. Never attempt to operate the power supply in any manner not described in this manual.
8. Never remove DANGER or WARNING labels from the power supply. Replace lost or damaged labels
immediately. Contact TDK-Lambda Americas Customer Service for replacement labels.
9. The power supply may be serviced only by TDK-Lambda Americas Inc. factory qualified service personnel.
Breaking the warranty seal will void the warranty. Prior to opening the power supply, contact TDK-Lambda
Americas Inc. Customer Service for a written Service Waiver and a replacement warranty seal.
83-000-005 Rev F
TDK-Lambda
MANUFACTURER'S PRODUCT DECLARATION
INTENDED PURPOSE (USE)
The Power Supplies described by this manual are defined by TDK-Lambda Americas Inc.
as a
component for use in the composition of an apparatus as defined in Article 1 (1) of
the EMC Directive (89/336/EEC). These products, as individual components, do not
perform in themselves a direct function for the user of the end product. They are not
intended
products described by this manual are
(89/336/EEC, with amendment 92/31/EEC).
The products described by this manual are intended for incorporation into a final product
by a professional assembler. It is the responsibility of the assembler to ensure that the
final apparatus or system incorporating our products complies with all relevant EMC
standards for that final product.
to be placed on the market with a direct function to a final user! As such, the
not subject to the provisions of the EMC Directive
OPERATING ENVIRONMENT
The operating environment as defined by TDK-Lambda Americas Inc., for the products
described by this manual is stated as follows:
The Power Supplies described by this manual are intended for use in a protected
industrial environment or in proximity to industrial power installations. These locations are
often referred to as industrial locations containing establishments that are not
to the low voltage public mains network.
Industrial locations are characterized by the existence of one or more of the following
conditions:
• 1) industrial, scientific and medical (ISM) apparatus are present;
• 2) heavy inductive or capacitive loads are frequently switched;
• 3) currents and associated magnetic fields are high;
• 4) location supplied by their own transformer.
These components are not intended for connection to a public mains network, but are
intended to be connected to a power network supplied from a high or medium-voltage
transformer dedicated for the supply of an installation feeding manufacturing or similar
operations. They are suitable for use in all establishments other than domestic and those
directly connected to a low voltage power supply network which supplies buildings used
for domestic purposes.
connected
Page: 83-000-006 Rev D
TDK-Lambda
Description of symbols used in product labeling
SYMBOL PUBLICATION DESCRIPTION
EC Council
Directive 93/68/EEC
European Community
Conformity Assessment
Product Mark
IEC 348 Attention, consult
Accompanying documents
IEC 60417-1-5036 Dangerous voltage
IEC 60417-1-5019 Protective earth
(e.g. power line earth ground)
IEC 60417-1-5017 Functional earth
(e.g. chassis ground)
IEC 60417-1-5134 Electrostatic Discharge
(ESD) Sensitive Device
Page: 83-000-007 Rev E
ELECTRICAL STANDARDS
All company primary standards are either certified or are traceable to certification by the
National Institute of Standards and Technology.
CLAIM FOR DAMAGE IN SHIPMENT
This instrument received comprehensive mechanical and electrical inspection before
shipment. Immediately upon receipt from the carrier, and before operation, this instrument
should be inspected visually for damage caused in shipment. If such inspection reveals
damage in any way, a claim should be filed with the carrier. A full report of damage should
be obtained by the claim agent and this report should be forwarded to us. We will then
provide a disposition of the equipment and arrange for repair or replacement.
When referring to this equipment, always include the model and serial numbers.
The “WARRANTY”, “CLAIM FOR DAMAGE IN SHIPMENT”, and “RETURNING
EQUIPMENT” information applies to equipment purchased directly from TDKLambda Americas Inc. End users receiving equipment from a third party should
consult the appropriate service organization for assistance with these issues.
RETURNING EQUIPMENT
Before returning any equipment to the factory, the following steps shall be taken.
1. Notify TDK-Lambda Americas Inc. at 732-918-6888 or follow the instructions at
www.US.TDK-Lambda.com/HP/service.htm. Give a full description of the difficulty
including the model and serial number of the unit in question. Upon receipt of this
information, we will assign a Return Material Authorization (RMA) number and
provide shipping instructions.
2. The customer shall prepay shipping charges. Equipment returned to us must be
packed in a manner to reach us without damage. The shipping container must be
marked with the RMA number in an area approximate to the shipping label with
numbers that are easy to read. All returned units that do not show the RMA number
on the outside of the container will be refused.
If the equipment is repaired within the warranty agreement, than TDK-Lambda
Americas Inc. shall pay for the return shipping to the customer.
3. For non-warranty repairs, we will submit a cost estimate for your approval prior to
proceeding. The customer shall pay return shipping charges.
MECHANICAL INSTALLATION
Most power supplies are heavy and, when rack mounted, they should be supported by
rails along the sides of the supply from front to rear. The rails must adequately support the
unit and not block airflow. Do not support the power supply from the front panel only.
Page: 83-000-011 Rev K
TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION ........................................................................................................................1
1.1 DESCRIPTION.......................................................................................................................................1
CHAPTER 2 SPECIFICATIONS .....................................................................................................................2
2.1 AVERAGE CHARGING RATE ...............................................................................................................2
2.2 PEAK CHARGING RATE .......................................................................................................................2
2.3 NUMBER OF MODELS IN SERIES .......................................................................................................2
2.4 STANDARD VOLTAGE RANGES..........................................................................................................2
2.4.1 LINEARITY......................................................................................................................................2
2.4.2 ACCURACY ....................................................................................................................................2
2.5 POLARITY..............................................................................................................................................2
2.6 HIGH VOLTAGE ASSEMBLY ................................................................................................................2
2.7 INPUT CONNECTOR.............................................................................................................................2
2.8 INPUT CHART .......................................................................................................................................2
2.9 POWER FACTOR ..................................................................................................................................3
2.10 EFFICIENCY ........................................................................................................................................3
2.11 STORED ENERGY ..............................................................................................................................3
2.12 STABILITY ...........................................................................................................................................3
2.13 PULSE TO PULSE REPEATABILITY ..................................................................................................3
2.14 TEMPERATURE COEFFICIENT .........................................................................................................3
2.15 AMBIENT TEMPERATURE .................................................................................................................3
2.16 HUMIDITY ............................................................................................................................................3
2.17 PROTECTION......................................................................................................................................3
2.18 AGENCY APPROVALS........................................................................................................................3
2.19 TRANSIENT LINE PROTECTION........................................................................................................3
2.20 ESD ......................................................................................................................................................3
2.21 NOTE FOR PFC UNITS .......................................................................................................................3
2.22 ACCESSORIES ...................................................................................................................................4
2.23 OPTIONS .............................................................................................................................................4
2.23.1 Suffix –SYS ..................................................................................................................................4
2.23.2 Suffix –LH......................................................................................................................................4
2.23.3 SUFFIX –EN .................................................................................................................................4
2.23.4 Suffix -5V.......................................................................................................................................4
2.23.5 Suffix –LP......................................................................................................................................4
2.23.6 SUFFIX -110 .................................................................................................................................4
2.24 ORIENTATION.....................................................................................................................................4
CHAPTER 3 INSTALLATION .........................................................................................................................9
3.1 INITIAL INSPECTION ............................................................................................................................9
3.2 MOUNTING AND COOLING REQUIREMENTS....................................................................................9
3.3 INPUT AC POWER ................................................................................................................................9
3.4 POWER CORD SPECIFICATION:.......................................................................................................10
3.5 CONNECTING HIGH VOLTAGE OUTPUT..........................................................................................11
3.6 GROUNDING THE PRODUCT ............................................................................................................12
3.6.1 GROUNDING OF INPUT LINE.....................................................................................................12
3.6.2 OUTPUT GROUND CONNECTION .............................................................................................12
3.6.3 FOR UNITS WITH O/P VOLTAGE ≤ 6Kv .....................................................................................12
3.6.4 FOR UNITS WITH O/P VOLTAGE > 6Kv:....................................................................................12
CHAPTER 4 OPERATION ............................................................................................................................13
4.1 REMOTE CONTROL............................................................................................................................13
4.2 INITITIAL CHECK-OUT PROCEDURE................................................................................................15
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CHAPTER 5 APPLICATIONS.......................................................................................................................16
5.1 DETERMINING CAPACITOR CHARGE TIME.....................................................................................16
5.2 VOLTAGE REVERSAL ........................................................................................................................16
5.3 PARALLELING UNITS .........................................................................................................................17
5.4 MEASURING HIGH VOLTAGES .........................................................................................................18
5.5 DETERMINING AC LINE CURRENT ...................................................................................................19
5.6 CONTINUOUS HV DC OPERATION (CONSTANT VOLTAGE) ..........................................................19
5.7 LONG CHARGE TIME WITH POWER FACTOR CORRECTED (PFC) UNITS ...................................20
CHAPTER 6 MAINTENANCE AND CALIBRATION ....................................................................................21
6.1 SAFETY PRECAUTIONS.....................................................................................................................21
6.2 MAINTENANCE ...................................................................................................................................21
6.3 CALIBRATION .....................................................................................................................................21
LIST OF FIGURES
Figure 1-1 500A/102A/152A/202A Block Diagram.......................................................................... 1
Figure 2-1 Mechanical Dimensions for 500A, 102A, 152A Outputs up to 6KV............................... 5
Figure 2-2 Mechanical Dimensions for 500A, 102A, 152A Outputs from 7KV to 40KV.................. 6
Figure 2-3 Mechanical Dimensions for 202A Outputs up to 6KV.................................................... 7
Figure 2-4 Mechanical Dimensions for 202A Outputs from 7KV to 40KV....................................... 8
Figure 3-1 Input AC Power Connection NON-PFC Version.......................................................... 10
Figure 3-2 Input AC Power Connection, PFC Version.................................................................. 10
Figure 3-3 Output Ground Connection.......................................................................................... 12
Figure 4-1 Example of Interface Connection ................................................................................ 14
Figure 5-1 Output Voltage Waveform .......................................................................................... 16
Figure 5-2 Output Current Measurement..................................................................................... 16
Figure 5-3 HV Bias Measurements............................................................................................... 19
Figure 5-4 Long Charge Time Operation ...................................................................................... 20
TABLES
Table 2-1: High Voltage Cable........................................................................................................ 2
Table 2-2: Input Voltage Chart........................................................................................................ 2
Table 2-3 Power Factor ................................................................................................................. 3
Table 4-1 Control Interface Connection for Standard 500A/102A/152A/202A Series .................. 13
Table 5-1 Output Capacitance ..................................................................................................... 17
83-493-001 Rev. K
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CHAPTER 1 INTRODUCTION
1.1 DESCRIPTION
The Series 500A/102A/152A/202A are High Voltage Switching Power Supplies designed
specifically for charging capacitors in laser systems and other pulsed power applications.
The 500A provides 500 J/s. the102A is 1000 J/s, 152A is 1,500 J/s, and the 202A
provides 2000 J/s of average power and can be paralleled indefinitely for higher total
system power. TDK-Lambda Americas Inc. also offers the 402 Series, 802 Series, and
303 Series rated at 4,000, 8,000 and 30,000 J/s respectively.
The 500A/102A/152A/202A power supplies incorporate a new high-frequency IGBT
parallel resonant inverter topology for efficient generation of the output power. A highperformance control module precisely regulates the output voltage, automatically
compensating for line, load, temperature, and rep rate variations. Normal external fault
conditions such as line dropout open or short circuit load, HV arc and over-temperature
will not damage the unit. The latest development in the parallel resonant inverter
topology and control circuitry also drastically improves pulse-to-pulse repeatability by
reducing the ripple or “bucket effect” even at very high pulse repetition frequencies. The
output voltages of the 500A/102A/152A/202A supplies are fully adjustable over each
range.
INPUT/POWER
Figure 1-1 500A/102A/152A/202A Block Diagram
PFC / Fuses
Inrush Limit
High Freq.
Resonant
Inverter
Control
&
Aux. Power
Step-up
Transformer
HV Rect.
HV Filter
HV OUTPUT
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CHAPTER 2 SPECIFICATIONS
2.1 AVERAGE CHARGING RATE
500J/s, 1000J/s, 1500J/s, 2000J/s at rated Output Voltage
2.2 PEAK CHARGING RATE
550J/s, 1100J/s, 1650J/s, 2200J/s at rated Output Voltage
2.3 NUMBER OF MODELS IN SERIES
12 Standard (others at extra cost)
2.4 STANDARD VOLTAGE RANGES
1kV, 1.5kV, 2kV, 3kV, 4kV, 5kV, 5kV, 10kV, 15kV, 20kV, 30kV and 40kV. All models
continuously variable from 0 to 100% of rated output voltage.
2.4.1 LINEARITY
Linear to within 1% of full scale.
2.4.2 ACCURACY
1% of rated.
2.5 POLARITY
Available as fixed Positive or Negative
2.6 HIGH VOLTAGE ASSEMBLY
Insulating Medium/Cable
Voltage Medium Output Cable
1kV to 6kV Air Coax. RG58
10kV to 40kV Oil 12 AWG, HV Silicon
Table 2-1: High Voltage Cable
2.7 INPUT CONNECTOR
VDE, UL approved.
2.8 INPUT CHART
Input Voltage selective by Terminal block position
Input Voltage (VAC) Current (No PFC) Current (PFC)
Nameplate
Range
230
50/60Hz
115
50/60Hz
Design
Range
180-253
50/60Hz
90-140
50/60Hz
500A 102A 152A 500A 102A 152A 202A
5A 10A 14.5A 3.5A 6.6A 10A 13.5
10A 20A 30A 7A
*Note: Input current ratings given are maximum when output Repetition Rate is
=>10Hz Consult Factory if model used at less than 10Hz.
Table 2-2: Input Voltage Chart
− − −
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2.9 POWER FACTOR
Non PFC PFC
All models 0.65 0.98
Table 2-3 Power Factor
2.10 EFFICIENCY
Better than 85%
2.11 STORED ENERGY
Less than 0.3 Joules all models
2.12 STABILITY
0.2% TO 300 Hz. For higher repetition rates, consult factory
2.13 PULSE TO PULSE REPEATABILITY
±0.2% TO 300 Hz. For higher repetition rates, consult factory
2.14 TEMPERATURE COEFFICIENT
100ppm per ºC
2.15 AMBIENT TEMPERATURE
Storage -40 to +85ºC. Operating -20 to +45ºC
2.16 HUMIDITY
90%, non-condensing
2.17 PROTECTION
The power supply is protected against Open Circuits, Short Circuits, Overloads and Arcs
2.18 AGENCY APPROVALS
500A/102A/152A are approved to UL 60601-1 and IEC 60601-1, Class I. 202A pending
approvals
.
2.19 TRANSIENT LINE PROTECTION
Meets requirements of IEC 801-4, 801-5
2.20 ESD
All Remote Control Functions meet requirements of IEC 801-2
2.21 NOTE FOR PFC UNITS
When High Voltage is enabled by using either the “HV Enable” Line or deactivation of
the “Inhibit” Line the power supply will reach normal operation mode (and therefore all
other published specifications) within 50 ms.
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2.22 ACCESSORIES
• Detachable 8 feet (2.4 meters) HV Cable (see Table 2.1)
• 15 pin “D” plug mating control connector
• Operating Manual
2.23 OPTIONS
2.23.1 Suffix –SYS
Parallel Operation
2.23.2 Suffix –LH
“Low Inhibit” - A +10 to 15 volt (high) signal will allow power supply operation. A 0 to
+1.5 volt (low) signal will inhibit the supply.
2.23.3 SUFFIX –EN
“Low Enable” - A +10 to 15 volt (high) signal will disable power supply operation. A 0 to
+1.5 volt (low) signal will enable the supply.
2.23.4 Suffix -5V
0 to +5 volt voltage (0 to full-scale output) programming.
2.23.5 Suffix –LP
Latching overload protection.
2.23.6 SUFFIX -110
100 to 120 VAC input option for power factor corrected 102A, 152A (1500 J/s) model.
NOTE: 102A, 152A power supply with suffix 110 at 100-120VAC must be
operated with internal 20A fuses F1 & F2 (on inverter board) replaced by
copper bus provided with the supply. Use external 30A UL/VDC
approved fuse/circuit breaker.
2.24 ORIENTATION
Power supplies >6kV with Oil H.V. section must be operated in an upright position. i.e.,
with the mounting bracket parallel to the ground plane.
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D
Figure 2-1 Mechanical Dimensions for 500A, 102A, 152A Outputs up to 6KV
(for grounding instructions see SECTION 3.6)
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Figure 2-2 Mechanical Dimensions for 500A, 102A, 152A Outputs from 7KV to 40KV
(for grounding instructions see SECTION 3.6)
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Figure 2-3 Mechanical Dimensions for 202A Outputs up to 6KV
(for grounding instructions see SECTION 3.6)
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Figure 2-4 Mechanical Dimensions for 202A Outputs from 7KV to 40KV
(for grounding instruction see SECTION 3.6)
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CHAPTER 3 INSTALLATION
3.1 INITIAL INSPECTION
The shipping container should contain the following items: power supply, HV output
cable, male 15-pin “D” remote control connector and operator’s manual. Examine the
items immediately for damage. Locate the serial number label on the side of the power
supply and verify the model number, the input voltage rating and the output voltage
rating and polarity. In the event of any damage promptly notify the transportation
company and the TDK-Lambda Americas Inc. Customer Service Department.
3.2 MOUNTING AND COOLING REQUIREMENTS
The power supply can be mounted by the chassis support brackets (see Figure 2-1, 2-2,
2-3 and 2-4 for details). The mounting brackets are attached to the supply. The supply
must be mounted using four PHMS 8-32NC X 0.250 screws. Using wrong (longer)
screws may short HV parts to ground, causing permanent damage to power supply. The
power supply can also operate on a bench or table top. Power supplies >6kV with Oil
H.V. section must be operated in upright position i.e. mounting bracket parallel to ground
plane. In all cases adequate clearances must be provided for proper air flow and cable
bends. Keep the minimum HV cable bend radius greater than 4 inches (101.6mm) to
minimize stress on the insulation. Generally, at least 4 inches (101.6mm) of clearance
should be allowed at the inlet of the power supply and 2 inches (50.8mm) at the sides.
When operating in an enclosed system, care must be taken to ensure the ambient inlet
air to the power supply does not exceed the maximum operating temperature of 45ºC.
This often requires addition of a system heat exchanger.
3.3 INPUT AC POWER
Proper grounding from the input AC power is required to reduce the risk of electric
shock. The metal chassis of the power supply is grounded through the green earthing
wire at the input AC power terminal block. A protective ground connection by way of the
grounding conductor in the input terminal is essential for safe operation. Use extreme
caution when connecting input AC power and never apply the incorrect input power.
(Figure 2-1, 2-2, 2-3 & 2-4).
The PFC version and version without PFC should be connected as explained in the
following 2 paragraphs.
A.. Version with no PFC.
For this version, the supply can be connected to either 115VAC for 230VAC input
voltage (See table 2.2). These connections are shown in Figure 3-1.
For 115VAC connect the input line wires to L1 and COM terminals.
For 230VAC connect the input wires to L2 and COM terminals.
B. Version with PFC.
The PFC version connection is shown in Figure 3-2. Connect the input voltage line wires
to L2 and COM terminals.
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WARNING: 102A, 152A AND 202A PFC Models are only available with 220 VAC
Nominal. For 152A Models Suffix 110 at 110-120 VAC must be operated with the
internal fuses F1 and F2 (on the Inverter Board) replaced by copper bus provided
with the supply. Use external 30A UL/VDC Approved Fuse/Circuit Breaker.
NOTE: For Application at less than 10 Hz, please see section 5.7.
TB1
115 VAC
230 VAC
L1
COM
L2
Figure 3-1 Input AC Power Connection NON-PFC Version
TB
L1
115-2 3 0 VAC
COM
L2
Figure 3-2 Input AC Power Connection, PFC Version
3.4 POWER CORD SPECIFICATION:
Use wire with minimum .064 inches (1.6mm) diameter and 600 V insulation.
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