INSTRUCTION MANUAL FOR
83-467-001 Revision B
MODEL
SERIAL NUMBER
LAMBDA EMI
405 ESSEX ROAD, NEPTUNE, NJ 07753
TEL: (732) 922-9300
FAX: (732) 922-9334
TCR 3 Phase OPERATING SYSTEM MANUAL
TABLE OF CONTENTS
I. GENERAL INFORMATION Page
1.1 INTRODUCTION 1
1.2 SPECIFICATION 2
II. INSTALLATION
2.1 INITIAL INSPECTION 6
2.2 POWER REQUIREMENTS 6
2.3 LOCATION 6
III. OPERATION INSTRUCTION
3.1 TURN-ON CHECK OUT PROCEDURE 7
3.1.1 Over-Voltage Output 8
3.2 GENERAL OPERATION 9
3.3 MODES OF OPERATION 9
3.3.1 Normal Operation 10
3.3.2 Remote Sensing 10
3.3.3 Remote Programming 11
3.3.4 Remote Programming by External Resistance 12
3.3.5 Remote Programming by External Voltage 13
3.3.6 Remote Programming by External Current 14
3.3.7 Parallel Programming 14
3.3.8 Parallel Operation - Master/Slave 16
3.3.9 Series Operation 16
3.3.10 Remote Meters 17
3.3.11 Remote Turn-On 17
IV. THEORY OF OPERATION
4.1 GENERAL 19
4.2 POWER FLOW 19
4.3 SIGNAL FLOW 20
4.4 SCR FIRING CIRCUIT 22
4.5 REMOTE TURN-ON 22
4.6 OVERVOLTAGE PROTECTION OPTION 23
4.7 DIGITAL METER A100 PCB 23
V. MAINTENANCE
5.1 GENERAL 24
5.2 INSPECTION AND CLEANING 24
5.3 CALIBRATION 24
5.3.1 Ammeter Calibration 25
5.3.2 Firing Balance 25
5.4 TROUBLESHOOTING
5.4.1 Overall Troubleshooting Procedure 25
5.4.2 Troubleshooting Chart 26
5.4.3 Overvoltage Troubleshooting 28
5.5 PRIMARY DIODE REPLACEMENT 28
5.6 FAN REPLACEMENT 29
3 Phase 15kW addendum 29
LIST OF ILLUSTRATIONS
Figure A: Front Panel Controls and Indicators 7
Figure 1: Normal Operation 10
Figure 2: Remote Sensing 11
Figure 3: Remote Programming by External Resistance, Voltage Mode 12
Figure 4: Remote Programming by External Resistance, Current Mode 12
Figure 5: Remote Programming by External Voltage, Voltage Mode 13
Figure 6: Remote Programming by External Voltage, Current Mode 13
Figure 7: Remote Programming by External Current, Voltage Mode 14
Figure 8: Remote Programming by External Current, Current Mode 14
Figure 9: Master/Slave Power Connection 15
Figure 10: Parallel Operation Master/Slave 16
LIST OF TABLES
Table 1: Rating Table 5
I GENERAL INFORMATION
I.1 INTRODUCTION
This manual contains operation and maintenance instructions covering the TCR 3
Phase Power Supply series manufactured by Electronic Measurements, Inc. of
Neptune, NJ.
All models provide AC turn on/off and circuit protection by means of a UL rated input
circuit breaker. Output control is provided by a 10 turn voltage control and a 1 turn
current control which are monitored by front panel meters. These meters are an
optional selection between either an analog or digital display.
Input AC is applied to 3 pairs of bi-directional connected SCRs placed within the
delta connected primary of the main power transformer. The secondary of this
transformer is rectified and double LC filtered to provide a low ripple DC output. It
also has a dual-amplifier - one for voltage channel and one for current channel. In
addition, it also has adjustment controls that will furnish full rated output voltage at
the maximum rated output current or can be continuously adjusted throughout most
of the output range.
These supplies may also be controlled locally at the front panel or remotely by
external voltage, current or resistance on rear mounted programming terminals.
VOLTAGE PROGRAMMING -
Voltage Programming -
Current Programming -
Resistance Programming -
CURRENT PROGRAMMING -
Voltage Programming -
Current Programming -
Resistance Programming -
0 to 5Vdc
Programs from 0 to full voltage output.
0 to 1mA (into 5000 ohms)
Programs 0 to full voltage output.
0 to 5000 ohms
Programs 0 to full voltage output.
0 to 100mV
Programs 0 to full current output.
0 to 1mA (into 100 ohms)
Programs 0 to full current output.
0 to 100 ohms
Programs 0 to full current output.
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83-467-001 Rev. A
Output voltage and current are continuously monitored by two front panel meters.
Input power is connected to a four screw terminal at the rear of the unit. The output
terminals are heavy busbars mounted on the rear of the unit. A 17 screw terminal
block at the rear of the unit provides expansion of the operational capabilities of the
instrument. A brief description of these capabilities are given below:
I.1.1 remote sensing
Separate output sensing terminals are provided to remotely sense the power supply
output at a distant load. This feature compensates for the voltage drop in the power
distribution system and provides specified regulation at the point of load.
I.1.2 remote programming
The power supply output voltage or current can be controlled from a remote location
by means of an external voltage source or resistance.
I.1.3 parallel operation
The power supply output can be operated in parallel with another unit when greater
output current capability is required. The parallel operation permits one "master"
supply to control the other supplies.
I.1.4 series operation
Two power supplies can be used in series when a higher output voltage is required in
the constant voltage mode of operation or when greater voltage compliance is
required in the constant current mode of operation.
I.1.5 Remote turn on
The power supply may be remotely turned on or off by application of a combination of
external voltages or interlock control. The open interlock potential is the applied
external voltage level. If the interlock function is used without an external control
level the open interlock potential is 24 Vdc.
I.2 SPECIFICATIONS
I.2.1 AC input
Standard AC input is 208/220/230 volts.
A three-phase, three-wire system which will operate within full specification form 190
to 253 volts or optional voltage as specified. Input AC phase rotation sequence is not
critical to this supply.
The phase to phase voltage balance requirement is ± 2% to achieve ripple
specification.
Current Draw Per Phase
at full load
2.5kW Units
5kW Units
10kW Units
AC line current is proportional DC load current.
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83-467-001 Rev. A
12 Amps
23 Amps
46 Amps
I.2.2 option aC
All models are available with optional AC inputs of:
INPUTS:
I.2.3 line frequency: 47-63hz
I.2.4 aC inrush
All models are "soft-started" so that during initial activation or reapplication on
interrupted power the input SCRs slowly "phase in" from non-conduction mode.
Since the SCRs are in series with the transformer primary there is no magnetic inrush
current due to core memory.
I.2.5 phase loss
Loss of a phase voltage will inhibit power supply output and illuminate the front panel
phase loss light. The power supply is not damaged when the phase voltage is
restored and normal operation will automatically resume.
I.2.6 regulation
Voltage Mode - For line voltage variations or load current variations within the rating
of the supply, the output voltage will not vary more than 0.1% of the maximum
voltage rating depending upon the unit.
200V ± 10%
380V ± 10%
415V ± 10%
460/480V (414-505V)
400V ± 10%
Current Mode - For line voltage variations or load voltage variations within the rating
of the supply, the output current will not vary more than 0.1% of the maximum current
rating depending upon the unit.
On those units in which the percentage of voltage or current ripple exceeds the
specified regulation, the regulation will appear to be degraded because of the effect
of this ripple on the measurement.
I.2.7 stability
The output voltage or current will remain within .05% of full output for 8 hours after
warm-up under fixed line load and temperature conditions.
I.2.8 transient response
A 30% step increase in power demanded by the load will cause a transient in the
regulation output which will typically recover to within 2% of final value within 75
milliseconds.
I.2.9 temperature coefficient
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83-467-001 Rev. A
Voltage - The temperature coefficient of the output voltage set point is 0.02% per
degree centigrade of the maximum output voltage.
Current - The temperature coefficient of the output current set point is 0.03% per
degree centigrade of the maximum rating of the supply.
I.2.10 ambient temperature
0° C to +40° COperating:
-40° C to +85° CNon-Operating:
Critical circuitry is thermostat protected so that in the event of an over-temperature
condition the unit is turned off until a safe temperature returns.
I.2.11 cooling
All units are air cooled and thermostatically protected. Air enters at the front right
side and exits at the front left side and rear.
I.2.12 ripple
The output voltage ripple specified in the Rating Table is the worst case ripple under
any resistive load condition with the power line within specification. Typically the
highest ripple occurs at 50% output voltage/current and is lower at maximum output
voltage and power is approached. Output ripple voltage and current is 31% higher
than shown when supply is operated at 50Hz line frequency.
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83-467-001 Rev. A
RATING TABLE
OUTPUT RATINGS
@50° C
0-7.5
0-6
0-6
0-10
0-10
0-10
0-20
0-20
0-20
0-30
0-30
0-40
0-40
0-40
0-50
0-80
0-80
0-100
0-300
0-600
0-900
0-250
0-500
0-750
0-125
0-250
0-500
0-100
0-200
0-60
0-125
0-250
0-200
0-30
0-60
0-100
Voltage @ Full Load
35mV
30mV
30mV
35mV
35mV
35mV
20mV
20mV
20mV
15mV
15mV
15mV
15mV
15mV
18mV
25mV
25mV
40mV
HeightRMSCurrent (A)Voltage (V)
7"
8.75"
12.25"
7"
8.75"
12.25"
7"
8.75"
12.75"
7"
8.75"
7"
8.75"
12.25"
12.25"
7"
8.75"
12.25"
MODEL TCRPANELOUTPUT RIPPLE
7.5T300
6T600
6T900
10T250
10T500
10T750
20T125
20T250
20T500
30T100
30T200
40T60
40T125
40T250
50T200
80T30
80T60
100T100
0-120
0-120
0-160
0-160
0-160
0-250
0-250
0-250
0-500
0-500
0-500
The TCR units have a panel width of 19 inches and a depth of 22 inches.
0-20
0-40
0-15
0-30
0-60
0-10
0-20
0-40
0-5
0-10
0-20
40mV
40mV
60mV
60mV
60mV
90mV
90mV
90mV
125mV
125mV
125mV
TABLE 1
7"
8.75"
7"
8.75"
12.75"
7"
8.75"
12.85"
7"
8.75"
12.25"
120T20
120T40
160T15
160T30
160T60
250T10
250T20
250T40
500T5
500T10
500T20
II INSTALLATION
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83-467-001 Rev. A
II.1 INITIAL INSPECTION
Before 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. Check for broken knobs or connectors, that the
external surface is not scratched or dented, meter faces are not damaged and that
all controls move freely. Any external damage may be an indication of internal
problems.
NOTE: If any damage is found, follow the "Claim for Damage in Shipment:
instruction in the warranty section of this manual.
II.2 POWER REQUIREMENTS
This power supply requires a three-phase input, of the specified voltage and
frequency, with nominal voltage line-to-line (three-wire system).
Phase rotation need not be observed when connecting power line to the input
terminals of the power supply. No neutral connection is required, but for safety, the
chassis ground terminal marked GRD must be connected to earth ground in
accordance with electrical code requirements.
All AC input connections are made at the rear terminal block, TB2, with the insulated
rectangular covering. Install the three-phase line to terminals marked ØA, ØB and
ØC. Connect the ground line to terminal marked GRD. Reinstall cover plate. The
user should ensure that the AC input wires are of the proper gauge. For example,
the line current is 50 ampere (maximum) for a 230 VAC input, dictating that each
conductor be at least number 8 gauge wire. The safety ground wire must be the
same gauge as the AC input wires to ensure that it does not open and create a
safety hazard. Load wires to be connected to the POS and NEG output terminals
must be heavy enough leads to prevent substantial IR drops between the output
terminals and the load. Remote sensing can be used to compensate for IR drops.
Reference Section 3.3.2.
II.3 LOCATION
This instrument is fan cooled. Sufficient space must be allotted so that a free flow of
cooling air can reach the sides of the instrument when it is in operation. It must be
used in an area where the ambient temperature does not exceed 40° C.
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83-467-001 Rev. A
III OPERATING INSTRUCTIONS
1
POWER
PHASE LOSS
TCR POWER SUPPLY
4 5
VOLTAGE CURRENT
O.V.
ADJUST
7
8
2
FIGURE A: FRONT PANEL CONTROLS AND INDICATORS
III.1 TURN-ON CHECK OUT PROCEDURE
1) The front panel surface contains all the controls and indicators necessary to
operate the supply in its normal mode. The following checkout procedure
describes the use of the front panel controls and indicators (Figure A) and
ensures that the supply is operational. This preliminary check of the supply is
done without a load connected.
2) Check the barrier jumper straps on the back of the unit, as shown in Figure 1,
showing TB2 strip-normal operation.
3) Set all controls completely counterclockwise.
4) Turn the CIRCUIT BREAKER (1) on/off switch to "on". The fans will start
immediately but there is a 10 to 15 seconds delay before voltage or current
output will occur. This is caused by the soft start circuit.
9
3 6
Rev.A
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83-467-001 Rev. A
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