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DCS 40-25E

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1.
2. Ensure that the unit is switched off and disconnected from any power source 2 Remove the Phillips head screws which secure the cover and then remove the cover from the unit 3 Remove the 230Vac voltage selector jumper located at the front center of the PCB from its mating header designated P1 on the PCB and install the attached 115Vac jumper in its place 4 Remove the adhesive backed 115V AC 20A label from fan and cover 230VAC 10A input specification above the rear panel AC connector 2 1 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL 5 Reinstall the cover and replace screws 6 Install a 125Vac 20Amp plug and cord ensuring that the neutral white wire and line black wire are connected in the correct positions and that the safety ground wire is connected to the ground screw To provide protection for personnel in the case of unit failure and to ensure proper power supply operation the safety ground wire of the AC input line cord must ALWAYS be connected to the ground screw provided 2 32 Input Line Impedance The maximum input line impedance for operation at full rated output is 1 ohm Higher source impedances can be tolerated by raising the input line voltage or by reducing the output voltage and or current 2 3 3 Ventilation Requirements The DCS power supply may be used in rack mounted or benchtop applications In either case sufficient space must be allowed for cooling air to reach the ventilation inpu
3. DCS E SERIES POWER SUPPLIES Instruction Manual This manual covers models 8 125E 60 18E 20 50E 80 13E 33 33E 150 7E 40 25E 300 3 5E 50 20E 600 1 7E SORENSEN Division of Elgar 9250 Brown Deer Road San Diego CA 92121 2294 1 800 525 2024 Tel 858 450 0085 Fax 858 458 0267 Email sales sorensen com www sorensen com 1998 by Sorensen Division of Elgar Electronics Corporation This document contains information proprietary to Sorensen Elgar Electronics Corporation The information contained herein is not to be duplicated or transferred in any manner without prior written permission from Sorensen April 28 1998 Document No M360761 Rev D SORENSEN FIVE YEAR WARRANTY Sorensen a division of Elgar Electronics Corporation warrants its products to be free from defects in material and workmanship This warranty is effective for five years from the date of shipment of the product to the original purchaser Liability of Sorensen under this warranty shall exist provided that the Buyer exposes the product to normal use and service and provides normal maintenance on the product Sorensen is promptly notified of defects by the Buyer and that notification occurs within the warranty period the Buyer receives a Return Material Authorization RMA number from Sorensen s Repair Department prior to the return of the product to Sorensen for repair phone 800 458 4258 the Buyer returns the defective product in the original
4. 23 3 Ventilation Requirements ee eoe ol ee Eee 2 2 2 3 4 Output Voltase Bidsings eet enthielt dien m eed 2 2 23 9 RACK MOUNUNG ITE 2 2 2 4 INITIAL FUNCTIONAL TESTS cccccccssessssecccccceceensececccccsucesseescccccseeeensescececsueennsesccccesseennseseccceseeeensssesecesseeanneeseceeeees 2 4 2 5 CONTROLS CONNECTORS AND INDICATORS cccccccccccssseseccccecceassececccceeseauaeseececeesesuueeeeecceessaaaneecceeeessuaneeeeceeeeeaas 2 5 2 5 I2Eront Panel vb c einst muniti eae 2 5 2 3 2 Rear P liel l iie Re f En fe tu tine tu teet 2 5 2 0 STANDARD OPERATION eo RR RO ARRANGE RUE NR OSEE EUR 2 7 2 6 1 Load Conductor Ratings ee e e e Ete e e i be eget de ee epe nente eR 2 7 2 6 2 Load Connection and Ground ig i iiie ea eee ene i c ere c prae s 2 7 QOS Inductive Doadssa site te tette te cete teeth hte te eO b e EON 2 7 2 6 4 Remote Sensihig caede nee ontetentee rie en ob enietenbbenimeimioenieteniter ero 2 8 2 6 5 Negative Output Operation eet tar etu pe Va Re E ES de Ed aee de vo T ee o ee ee vo aae e uan 2 8 2 7 SINGLE SUPPLY OPERATION LOCAL MODE eene nennen eene eene 2 9 2 85 MULTIPLE SUPPEIBS re ttti oe TENE Pow FANE Poe ANES EET NUS FERE UNES PERS 2 9 2 61 Series Operdlion REO Slashes GU SD nODeUm DU EE 2 10 2 6 2 Parallel Operation RU ES
5. During local operation current flow through diode CR15 and the front panel voltage control provides a higher voltage at pin 13 the inverting input keeping U8 4 output low During remote programming there is no current flow through diode CR15 and the output of U8 4 goes high illuminating the remote programming indicator through diode CR4 resistor R13 and pin 13 of connector J1 The high signal is also provided at pin 4 of connector J3 for remote monitoring purposes Remote Programming of the Output Current Limit During remote programming of the output current limit with an external voltage source the local operation jumpers connecting J3 pins 10 to 11 and 22 to 23 are removed and the external source 0 100mV 0 5V or 0 10V is connected between pins 10 positive and 12 negative The input signal at J3 pin 10 is buffered via U14 1 to provide noise immunity When using a 0 5V source the reference at pin 2 of U4 1 current control op amp is provided by the external source and divided down to a 0 2V reference by R20 and R146 Use of a 0 10V source requires that switch SW1 1 be closed to add R5 to the voltage divider to limit the control circuit reference voltage to 0 2V For 0 100mV programming switch SW1 1 is opened and switch SW1 2 is closed changing 014 1 from a voltage follower to an amplifier by virtue of feedback resistor R150 and voltage divider resistor R50 For remote programming with an external 5k resistance the jumpers connecting J3 pins
6. ER EI EA 2 10 2 6 3 Split Supply Operati n c oi tede eee ee Cadet de n ette 2 10 2 9 OVER VOLTAGE PROTECTION OVD cbs rites certi tte era eee Pods e ees cous toda RE ua eae Feo e eeu eee Fel o Ru Poe coated 2 10 2 9 1 Front Panel OVP Operation eL hne e boa babe des 2 11 2 9 2 Remote Programming of OVP With External Voltage Sources essen eene nene 2 11 2 9 3 Remote Programming of OVP with an External Resistance eese eene ener nnne 2 13 2 9 4 Remote Programming of OVP with External Current Sources eese eee 2 14 2 9 5 Remote OVP Senstiig iid pne tr D RUSO EHI 2 15 2 10 REMOTE ON OPE iis sence is Sob bes tds en He ee RI 2 15 2 10 1 Remote ON OFF by Contact Closure 2 15 2 11 REMOTE PROGRAMMING OF OUTPUT VOLTAGE AND CURRENT 2 16 2 11 1 Programming With External Voltage Sources esee eee eene nennen enne nnne 2 16 2 11 2 Programming With an External 2 18 2 11 3 Programming With an External Current Source 2 20 2 12 REMOTE MONITORING AND STATUS INDICATORS ccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeegs 2 21 TABLE OF CONTENTS Continued SECTION 3 THEORY OF OPERATION eve eo o eee noo na cocsesssosssessessdeesdsesdseesscocscodsssdsesdessdsesdsessee
7. INPUT FULL WAVE BRIDGE USED ON 150 200 AND 600V MODELS RECTIFICATION CR301 CR304 USED ON 150 AND 300V MODELS CR36 C21 A B C C72 A B C CR300 CR307 USED ON 600V MODELS 8V CONFIGURATION SHOWN OUTPUT POS RF1 51 53 FILTER OUTPUT RTN CURRENT FRONT PANEL CONTROL CURRENT CURCUIT CONTROL U4 1 015 R19 TO AMMETER A1 METER VOLTAGE FRONT PANEL CIRCUIT CONTROL VOLTAGE TO VOLTMETER CIRCUIT CONTROL U5 R20 NOTE THAT PGM RTN IS TIED TO OUTPUT RETURN VIA THE SENSE CIRCUIT IN APPLICATIONS REQUIRING PGM RTN CONNECTION TO POSITIVE OUTPUT AN ISOLATION AMP IS REQUIRED Figure 3 1 NOLLV IAdO 1 IVANVIWN SHISIHS SOA 5 SORENSEN DCS SERIES MANUAL THEORY OF OPERATION A current shunt R91 in the output return line develops a voltage dependent on the output current This current information is compared to the setting of the front panel current limit control in the current control circuit U4 1 and U15 The output voltage is also monitored and compared to the front panel voltage control setting in the voltage control circuit U5 The outputs of the voltage and current control circuits are OR d and this signal is fed into the PWM error amplifier inverting input providing the negative feedback required to produce a regulated output The output voltage and current information from the current and voltage control
8. SELECT REMOTE SELECTS REMOTE CURRENT LIMIT RESISTIVE OVP PROGRAMMING SCALE PROGRAMMING SCALE SELECTS REMOTE NOT USED VOLTAGE LIMIT SELECTS REMOTE OVP PROGRAMMING SCALE PROGRAMMING SCALE SW1 1 SW1 2 SW1 3 SW1 4 SW1 5 SW1 6 SW1 7 SW1 8 Switch SW1 SWI 1 Used to select 5V or 10V programming of remote current limit SWI 2 Used to select 100mV programming of remote current limit SWI 3 Used to select 5V or 10V programming of remote voltage limit SWI 4 Used to select remote OVP programming scale SWI 5 Not used SWI 6 Not used SWI 7 Not used SWI 8 Used to select remote resistive OVP programming scale Switch SW1 Functions Note set switch SWI shut the unit off disconnect it from its AC source and remove the cover Make the appropriate switch settings then reinstall the cover and reconnect the unit to its AC source 2 11 1 Programming With External Voltage Sources The output voltage can be programmed using either a 0 5Vdc or 0 10Vdc external voltage source To program the output voltage with a 0 5Vdc source set switch SW1 3 open default factory setting and remove the jumpers connecting pins 8 to 9 and 20 to 21 on connector J3 Connect the external source between pins 9 positive and 12 return Varying the external voltage from 0 5V will cause the output to vary from 0 100 of rated output 2 16 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION SWITCH SW1 CONNECTOR J3 O
9. or equivalent shipping container if upon examination of such product by Sorensen it is disclosed that in fact a defect in materials and or workmanship does exist that the defect in the product was not caused by improper conditions misuse or negligence and that Sorensen QA seal and nameplates have not been altered or removed and the equipment has not been repaired or modified by anyone other than Sorensen authorized personnel This warranty is exclusive and in lieu of all other warranties expressed or implied including but not limited to implied warranties of merchantability and fitness of the product to a particular purpose Sorensen its agents or representatives shall in no circumstance be liable for any direct indirect special penal or consequential loss or damage of any nature resulting from the malfunction of the product Remedies under this warranty are expressly limited to repair or replacement of the product CONDITIONS OF WARRANTY To return a defective product contact an Sorensen representative or the Sorensen factory for an RMA number Unauthorized returns will not be accepted and will be returned at the shipper s expense For Sorensen products found to be defective within thirty days of receipt by the original purchaser Sorensen will absorb all ground freight charges for the repair Products found defective within the warranty period but beyond the initial thirty day period should be returned prepaid to Sorensen
10. DC input and 2 return of connector J3 will disable the output of the supply A red LED on the front panel indicates when the shutdown circuit is activated The input lines are optically isolated and can therefore be accessed by circuits with a voltage differential of up to 600Vdc 2 10 1 Remote ON OFF by Contact Closure An external relay may be used to operate the ON OFF control circuit as follows Connect one side of a normally open relay to pin 15 of connector J3 12V Connect the other side of the relay to pin 14 TTL Shutdown Also connect J3 pin 2 Shutdown return to pin 6 Ground Using this configuration the power supply will be OFF when the relay coil is energized and ON when the relay is de energized If a normally closed relay is substituted for the normally open relay in the configuration described above the power supply will be ON when the relay coil is energized and OFF when the relay is de energized 2 15 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL 2 11 Remote Programming of Output Voltage and Current Limit The output voltage and current limit of the power supply can be remotely programmed through the rear panel J3 connector using external voltage sources current sources and resistances Switch SW1 on the A2 printed circuit board controls the programming as diagrammed below When the supply is controlled by remote programming the green REMOTE led on the front panel is illuminated OPEN min CLOSED
11. VOLTAGE AT U8 16 LOW LOW REMOTE SHUTDOWN HIGH CHECK d OR CHECK THE DC VOLTAGE AT THE LOW CHECK Ut CATHODE OF DIODE CR18 e REPLAGEUG HIGH LOW HIGH Y LESS THAN 5V THERMAL SHUTDOWN CHECK 1mA CURRENT CHECK RT1 08 3 9 CHECK ANODE CR27 CONNECTOR De ENSE ID EL ia SOURCES Qe APPROX 5V LOW Y AC AUXILIARY HIGH INPUT LOW LOW CHECK CHECK CHECK ANODE CR32 CHECK THE VOLTAGE AT THE LL VOLTAGE CONTROL CIRCUIT CR29 Q5 T4 ANODE OF DIODE CR18 U5 U7 2 HIGH LOW HIGH Y 12V LOCKOUT MEE CHECK ANODE CR33 CHECK CURRENT CONTROL CIRCUIT Figure 4 1B HONVNALNIVN IVANVIN SHISIHS SOA 5 SORENSEN DCS SERIES MANUAL MAINTENANCE AA oR110R8 o R46 o R47 o R48 AA o R52 R7 o R53 AA R180 R15 J J Figure 4 2 A A Refer to About This Manual for an explanation of these symbols 4 5 SORENSEN DCS SERIES MANUAL PARTS LISTS SECTION 5 PARTS LISTS 5 14 General This section provides parts lists for the following assemblies Front panel assembly A2 Power assembly Chassis and cover Most assemblies consist of parts common to all series models as well as parts which are model specific or differential 5 2 Parts Ordering Do not substitute parts without first checking with Sorensen s Service Department Parts may be ordered from the factory with the information in the following sections Order parts from SORENSEN Division of ELGAR
12. been removed via external means all circuits and or terminals to be touched must be safety grounded to the chassis After the unit has been operating for some time the metal near the rear of the unit may be hot enough to cause injury Let the unit cool before handling Qualified service personnel need to be aware that some heat sinks are not at ground but at high potential These operating instructions form an integral part of the equipment and must be available to the operating personnel at all times All the safety instructions and advice notes are to be followed Neither Sorensen San Diego California USA nor any of the subsidiary sales organizations can accept any responsibility for personal material or consequential injury loss or damage that results from improper use of the equipment and accessories SAFETY SYMBOLS CO b e CAUTION Risk of Electrical Shock CAUTION Refer to Accompanying Documents Off Supply Standby Supply On Supply ABOUT THIS MANUAL Protective Conductor Terminal Direct Current DC Alternating Current AC Three Phase Alternating Current Fuse Earth Ground Terminal This manual has been written expressly for the Sorensen DCS 1KW series of power supplies which have been designed and certified to meet the 1997 Low Voltage and Electromagnetic Compatibility Directive Requirements of the European Community Units that comply with the directive are designated b
13. circuits is also fed to the front panel A1 assembly where it is displayed on the digital voltage and current readouts Transformer T4 rectifier CR42 and regulators U9 U13 provide the necessary auxiliary supply voltages for the PWM circuit the voltage and current control circuits the A1 metering board and the raw DC supply for drive transformer T2 A 6 2 volt reference is also derived from the 12V supply for use in metering circuits by diode and resistor R2 Transformers T1 T3 and T4 provide output isolation from the line potentials in the primary circuit the PVM circuit and the auxiliary supply circuits respectively 3 1 3 Detailed Circuit Description This section is intended to provide further detail for troubleshooting purposes Please read the previous section as an overview and then refer to the detailed assembly schematic in Section 6 CAUTION Potentially LETHAL VOLTAGES exist on the A2 circuit board on the primary side of the isolation barrier Troubleshoot with care preferably with power off and recognizing that filter capacitors store potentially LETHAL and DESTRUCTIVE ENERGY even for some time AFTER POWER is REMOVED Always use an isolation transformer connected ONLY to the power supply input when making test measurements on the primary side circuits Input Rectifier and Inrush Limiting Input ac power passes from the rear panel ac connector TB1 through an RFI filter consisting of C1 6 R122 L1 and L2 to th
14. output of the power supply and potentiometer R52 is used to adjust the offset on op amp U5 Current Control Circuit The output current is monitored by current shunt resistor R91 which develops a voltage across it proportional to the output current This voltage is amplified and conditioned by the differential op amp U15 and associated components to provide a control ground referenced 0 2V signal at pin 3 of the current control op amp U4 1 This signal is compared to a reference signal gated from the front panel current control to pin 2 of 04 1 by 07 1 As the output current increases the voltage at pin 3 rises until it reaches the reference level set at pin 2 at which time the output of U4 1 goes high and the unit switches from voltage mode to current mode operation The output current is maintained at the desired level by providing negative feedback to the PWM error amplifier as described in the voltage control circuit description above Resistor R27 and capacitor C27 provide compensation for U4 1 Op amp U4 2 and related components scale the current feedback signal to provide a calibrated 0 5V output at pin 7 of connector J3 for external monitoring of the output current The shunt voltage is also fed to the front panel ammeter via pins 8 and 9 of connector J1 Operating Mode Indicator Circuit Op amp 08 2 takes advantage of the fact that diode CR18 is forward biased during voltage mode and reverse biased during current mode to provide a mode indicati
15. 1 Load Conductor Ratings The table below lists the maximum allowable load wiring length in feet for a specified wire gauge and power supply model operating at full rated output The lengths indicated are based on PVC insulated wire with a maximum operating temperature of 105 degrees C To overcome impedance and coupling effects which can degrade the power supply performance the use of leads of the largest gauge and shortest length possible is recommended WIRE SIZE AWG MODEL 2 4 6 8 10 12 14 16 18 8 125 19 12 20 50 30 30 30 23 33 33 30 30 30 30 22 14 40 25 30 30 30 30 30 18 50 20 30 30 30 30 30 23 13 60 18 30 30 30 30 30 26 16 10 80 13 30 30 30 30 30 30 22 20 150 7 30 30 30 30 30 30 28 26 300 3 5 30 30 30 30 30 30 30 30 600 1 7 30 30 30 30 30 30 30 30 30 2 6 2 Load Connection and Grounding Proper connection of distributed loads is an important aspect of power supply application A common mistake is to connect leads from the power supply to one load from that load to the next load and so on for each load in the system In this parallel power distribution method the voltage at each load depends on the current drawn by the other loads and DC ground loops are developed Except for low current applications this method should not be used The preferred way to distribute power is by the radial distribution method in which power is connected to each load individually from a single pair of termina
16. 10 to 11 and 22 to 23 are removed pins 10 and 22 are connected to the counterclockwise end of the external 5k ohm potentiometer and the tap and clockwise end are connected to pin 12 The internal 1mA current source at pin 22 develops a 0 5V potential across the potentiometer depending on the potentiometer setting which is fed to pin 6 of U4 2 During remote programming of the output voltage with an external 0 1mA current source the jumper connecting J3 pins 22 and 23 is removed the front panel voltage control is set fully clockwise and the external current source is connected between pins 11 positive and 12 return Varying the current source from O0 1mA causes 0 5V to develop at the reference pin of the current control circuit The front panel remote programming indicator is controlled by op amp 08 1 during remote current limit programming Operation is the same as that described above in the remote voltage programming section except that diode CR15 is replaced by diode CR16 3 7 THEORY OF OPERATION SORENSEN DCS SERIES MANUAL 3 2 Meter Circuit A1 Assembly The A1 assembly is comprised of the voltmeter and ammeter displays the output voltage and current limit controls the local operation OVP adjusting potentiometer and the indicator LEDs The operation of the voltage and current controls the OVP potentiometer and the indicator LEDs is covered in the A2 description in Section 3 1 Refer to the schematic diagram in Section 6 for the fol
17. 3 Configuration for Resistive Programming of the Output Voltage J3 sense line OVP and current control jumpers shown set for local operation To program the output current limit set switches SW1 1 and SW1 2 open default factory setting and remove the jumpers connecting pins 10 to 11 and 22 to 23 on connector J3 Connect pins 10 and 22 to the counterclockwise end of the 5k potentiometer and connect the tap and clockwise end of the potentiometer to pin 12 Adjusting the tapped resistance from 0 5k will vary the current limit from 0 100 of the rated output SWITCH SW1 OPEN 1312 CONNECTOR J3 10 i 5 Switch SW1 SWI 1 Off Open SWI 2 Off Open SWI 3 Off Open SWI 4 On Closed SWI 5 Off Open SWI 6 Off Open SWI 7 Off Open SWI 8 On Closed 1 NS Ii un d 2 14 22 Gow 5k OHMS Switch SW1 and Connector J3 Configuration for Resistive Programming of the Output Current Limit J3 sense line OVP and voltage control jumpers shown set for local operation 2 19 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL 2 11 3 Programming With an External Current Source The output voltage and current limit can be programmed using an external 0 1 current source To program the output voltage set the front panel voltage control to maximum set switch SW1 3 open default factory setting and remove the jumper between pins 20 and 21 of connector J3 Connect the external current sour
18. 6255 Ferris Square San Diego CA 92121 2294 Sales Tel 1 800 525 2024 Fax 858 458 0267 Customer Service Tel 1 800 458 4258 Fax 858 677 9453 When ordering parts please include the model number and serial number of the unit with your order 5 3 Parts Lists Table 5 1 provides a listing of Fuse Ratings Table 5 2 provides a listing of the Parts Lists included in this section and Table 5 3 provides a Parts List by Model Number matrix Table 5 1 DCS 1kW Fuse Rating Reference Designator Fast Acting 3AB 20A 250V 1 4 x 1 1 4 Time Lag 0 5A 250V 1 4 x 1 1 4 10 250V 13 32 x 1 1 2 5 1 PARTS LISTS SORENSEN DCS SERIES MANUAL Table 5 2 DCS 1 kW Parts Lists Table 5 3 DCS 1 kW Parts Lists By Model Number Assembl Assembl PCB Assembl Assembl Assembl Model DCS20 50E E DCS33 33E a DCS40 25E Model DCSS0 20E 5360800 10 5360802 01 5360801 02 1066830 01 5360726 02 Model 5360800 05 5360802 01 5360801 02 1066830 01 5360726 03 DCS60 18E Model 5360800 06 5360802 01 5360801 02 1066830 080 5360726 04 DCS80 13E Model DCS150 7E 5360800 07 5360802 02 5360801 01 Model DCS300 3 5E 5360800 08 5360802 02 5360801 01 Model DCS600 1 7E 5360800 09 5360802 02 5360801 01 5 2 SORENSEN DCS SERIES MANUAL DRAWINGS and SCHEMATICS SECTION 6 DRAWINGS AND SCHEMATICS 6 1 General This section contains drawings and schematic diagrams for the DCS 1 kW power supply The schematic diagrams should be u
19. 63 Hz Maximum Voltage Differential from output to safety ground 600 Vdc Additional Characteristics Stability Voltage 4mV 10mV 16 5mV 20mV 25mV 30mV 40 mV 75 mV 150 mV 300 mV Current 62 5mA 25mA 16 5mA 12 5mA 10mV 9mA 6 5 mA 3 5 mA 1 75 mA 0 85 mA Temperature Coefficient Voltage 1 6 mV 4mV 6 6 mV 8mV 10mV 12mV 16 mV 30 mV 60 mV 120 mV Current 37 5mA 15 mA 9 9 mA 7 5 mA 6mA 5 4 mA 3 9 mA 2 1 mA 1 05 mA 0 51 mA Maximum Remote Sense Line Drop Compensation 0 1V 1V 1V IV 1V 1V 1V 1V 1V line Maximum drift over 8 hours with constant line load and temperature after 20 minute warm up 1 2 Change in output per C change in ambient temperature with constant line and load 1 2 SORENSEN DCS SERIES MANUAL FEATURES and SPECIFICATIONS Altitude 2000M 6562 Ft Storage Temperature Range 55 to 85 C Humidity Range 0 to 80 Non condensing Time Delay from power on until output stable 3 seconds maximum Voltage Mode Transient Response Time 1mS recovery to 1 band for 30 step load change from 70 to 100 or 100 to 7096 Remote Start Stop and Interlock TTL compatible input Contact Closure 12 250 Vac or 12 130 Vdc Switching Frequency Nominal 70 kHz 140 kHz output ripple Analog Programming Linearity Typical error is less than 0 596 setting Maximum error is 1 of rated output Agency Approvals CE Pollution Degree 2 UL pending Remote Analog Programming Full Scale Input Scales are selectable via an inte
20. ECTION 4 3 BEFORE PROCEEDING AND PERFORM THE PRELIMINARY CHECKS IN SECTION 4 3 1 SWITCH SW1 TURN THE POWER SWITCH OFF CONNECTOR J3 DISCONNECT THE UNIT FROM THE AC SOURCE 1234756798 DICCONNECT THE LOAD FROM THE OUTPUT TERMINALS 13 1 OFF OPEN DISCONNECT ANY PROGRAMMING OR MONITOR LINES 0 0000p00 CLOSED CONFIGURE SWITCH SW1 AND CONNECTOR J3 FOR LOCAL CONTROL SEE DIAGRAMS AT LEFT AND RIGHT FOR SETTINGS AND CONNECTIONS of 99 SO 000800 SET VOLTAGE AND CURRENT CONTROLS FULLY CLOCKWIS 14 CONNECT THE UNIT TO THE AC SOURCE THROUGH AN ISOLATION TRANSFORMER CONNECTIONS FOR LOCAL TURN UNIT ON CONTROL AND SENSING Y QUTPUT CHECK OUTPUT VOLTAGE VOLTAGE VISUALLY CHECK FRONT DISPLAYS OK WITH VOLTMETER gt PANEL DISPLAYS DC VOLTS OK TPUT NGOLTAGE NO DISPLAYS CHECK INPUT VOLTAGE SELECTOR F2 BLOWN P1 FOR CORRECT VOLTAGE Lug CHECK FUSE F2 CHECK AND REPLACE F2 FUSE RIBBON CABLE JT BETWEEN A1 AND A2 eK P1 5 FOR 6 2VDC REFERENCE 1 U1 U2 051 8 ON A1 ASSY NO VISUALLY CHECK FRONT By F1 GROS AND lx tends v INPUT V CTOR P1 DISPLAYS PANEL DISPLAYS DISPLAYS OK PERFORM FUNCTION TEST AS CHECK F3 BLOWN DESCRIBED IN SECTION 2 4 13 16 C69 R11 1 113 ll K FUSE F3 BEFORE REPLACING FUSE E F3 OK TEST NOT OK TES
21. L INSTALLATION and OPERATION 2 5 Controls Connectors and Indicators Refer to Figure 2 1 and the descriptions below 2 5 1 10 11 12 13 2 5 2 14 15 16 17 18 19 Front Panel AC Power Switch AC Input Circuit Breaker OVP Adjust Potentiometer Manual adjustment for OVP trip level OVP LED Indicates that the OVP circuit has been activated when illuminated Shutdown LED Indicates activation of the remote shutdown circuit when illuminated Remote Programming LED Indicates operation by remote programming when illuminated Over Temperature LED Indicates that the power supply is shut down due to an internal over temperature condition when illuminated Voltage Mode LED Indicates operation in voltage mode when illuminated Output Voltage Control Multi turn potentiometer used to adjust the output voltage in local mode Current Mode LED Indicates operation in current mode when illuminated Output Current Control Multi turn potentiometer used to adjust the output current limit in local mode Digital Voltmeter Digital Ammeter Rear Panel Positive Output for 8 20 33 40 50 60 and 80 Volt Models Output and Sense Connector for 150 300 and 600 Volt Models Negative Output for 8 20 33 40 50 60 and 80 Volt Models Programming Sense and Monitor Connector J3 Input connector for programming signals Also provides access to sense connections and monitoring points See Table 2 1 for individual pin descriptio
22. NS SORENSEN DCS SERIES MANUAL e External indicator signals for remote monitoring of OVP status local remote programming status thermal shutdown and output voltage and current e Optional IEEE 488 interface for complete remote programming and readback capability 1 4 Specifications 1 4 1 Electrical Specifications Output Ratings Output Voltage Output Current Output Power Line Regulation Voltage 8mV 20mV 33mV 40 mV 50mV 60 mV 80 mV 150mV 300mV 600mV Current 125 mA 50mA 33mA 25 mA 20 mA 18 mA 13 mA 7 mA 35mA 17mA Load Regulation Voltage 8mV 20mV 33mV 40 mV 50mV 60mV 80 mV 150mV 300mV 600mV Current 125 mA 50mA 33mA 25 mA 20 mA 18 mA 13 mA 7 mA 35mA 1 7mA Meter Accuracy Voltage 0 09V 0 3V 0 43V 0 5V 0 6V 0 7V 0 9V 1 6V 4 0V 7 0V Current 1 35A 0 6A 0 43A 0 35A 0 30A 0 28A 0 23A 0 08A 0 045A 0 018 Output Noise and Ripple V rms 10 mV 10 mV 10 mV 10 mV 20mV 20mV 20mV 30mV 40 mV 100 mV 100 100 100 100 100 100 100 200 200 500 20Hz 20MHz Specifications are warranted over a temperature range of 0 50 C with default local sensing From 50 70 C derate output 2 per C For input voltage variation over the AC input voltage range with constant rated load For 0 100 load variation with constant nominal line voltage I Typical P P noise and ripple is 50 mV AC Input 200 250 Vac at 10 A rms or 100 130 Vac at 20 A rms 47
23. PEN 1312 9 1 25 14 CLOSED rasyevns t 0 Switch SW1 SWI 1 Off Open SWI 2 Off Open SWI 3 Off Open SWI 4 On Closed SWI 5 Off Open SWI 6 Off Open SWI 7 Off Open SWI 8 On Closed Switch SW1 and Connector J3 Configuration for 0 5V Programming of the Output Voltage J3 sense line OVP and current control jumpers shown set for local operation For programming with a 0 10Vdc source close switch SW1 3 and replace the 0 5V source with a 0 10V source SWITCH SW1 CONNECTOR J3 OPEN 1312 9 1 25 14 CLOSED R t 0 10 Switch SW1 SWI 1 Off Open SWI 2 Off Open SWI 3 On Closed SWI 4 On Closed SWI 5 Off Open SWI 6 Off Open SWI 7 Off Open SWI1 8 On Closed Switch SW1 and Connector J3 Configuration for 0 10V Programming of the Output Voltage J3 sense line OVP and current control jumpers shown set for local operation The output current limit can be programmed using a 0 5 Vdc or 0 10Vdc external voltage source Selection of the programming voltage is done using switches SW1 1 and SW1 2 as indicated below 2 17 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL SWI 1 SW1 PROGRAMMING VOLTAGE OPEN OPEN 0 5Vdc and Local Mode CLOSED CLOSED Not Used CLOSED OPEN 0 10Vdc OPEN CLOSED 0 100mV To remotely program the output current limit set switches SW1 1 and SW1 2 as show
24. R 150 300 CONNECTOR J3 SCREW AND 600V MODELS MATING CONNECTOR AND SOCKET PINS SUPPLIED WITH EACH UNIT J3 CONNECTIONS FOR LOCAL OPERATIONS 13 1 SWITCH SW1 3 0 Eee io Op poo PROGRAMMING RANGE SELECTOR 6665 dao MOUNTED INTERNALLY ON MAIN PCB 6 5 25 14 SWITCHES SHOWN SET FOR LOCAL OPERATION 1 POSITIVE SENSE T2094 9 B7 9 2 amp 3 POSITIVE OUTPUT 4 NEGATIVE SENSE FRONT VIEW g 5 amp 6 NEGATIVE OUTPUT 7 OVER TEMPERATURE LED 6 REMOTE PROGRAM LED 8 10 5 SHUTDOWN LED VOLTAGE CURRENT 4 OVP LED MODE MODE LED LED 39 ADJUST TENTIOMENTER 1 2 9 11 13 ac POWER ac Nour output OUTPUT DIGITAL SWITCH BREAKER VOLTAGE CURRENT VOLTMETER AMMETER CONTROL CONTROL Figure 2 1 IVANVIWN SAMAS SOA 5 NOLLV IHdO pu NOLLV T IV LSNI INSTALLATION and OPERATION 2 4 Before connecting the unit to an AC outlet make sure that the power switch is in the OFF position and that the voltage and current controls are turned fully counter clockwise Check that the J3 mating connector on the rear of the unit is in place with jumpers connected for local operation as shown below This is the default configuration Connect the unit to a 230Vac grounded outlet 115Vac outlet if previously configured for 115Vac operation as per instructions in section 2 3 1 and switch the unit on After a short power as shipped from the factory Initial Functional Tests on delay the front panel meters should ligh
25. T OK CHECK NO HIGH CHECK FOR HIGH VOLTAGE UTOR Ex Asics al CR35 2 C72 A B C VOLTAGE DC APPROX 360VDC RECHECK LOAD AND PROGRAMMING CONNECTIONS AND CIRCUITS RRORS HIGH VOLTAGE DC OK CHECK 5 5 12 18 6 2 AUX SUPPLIES AUXILARY SUPPLIES pem d CHECK d CHECK FOR 12V ON U12 amp U13 NOT OK U9 11 CRI AUX SUPPLIES OK T To Figure 4 1B Figure 4 1A IVANVIWN SHISIHS SOG 5 rt From Figure 4 1A AUX SUPPLIES CAUTION OK MAKE OSCILLOSCOPE CONNECTIONS WITH THE UNIT SHUT OFF ENSURE THAT THE UNIT IS ISOLATED FROM USE OSCILLOSCOPE TO CHECK WAVES PRESENT CHECK THE AC LINE OR DAMAGE TO THE UNIT FOR SQUARE WAVES ON THE OUTPUT RECTIFIERS L3 AND OR TEST EQUIPMENT MAY RESULT PRIMARY OF T1 P301 304 C51 53 C301 C302 APPROX 720V pp 70KHz OUTPUT BUS BAR ASSY T1 NO WAVEFORMS PRESENT USE OSCILLOSCOPE TO CHECK WAVES PRESENT CHECK FOR SQUARE WAVES ON THE Hm 107 110 Q13 16 APPROX 12V pp 70KHz R107A 110 CR51 58 NO WAVES PRESENT CHECK U6 11 AND U6 14 WAVES PRESENT CHECK FOR 12V PEAK 70KHz oo DRIVE FETS SQUARE WAVES Q7 12 18 AND 19 NO WAVES PRESENT HIGH HIGH Y OVP SHUTDOWN CHECK U3 2 CHECK ANODE 24 CHECK DC
26. WM which limits the swing of the error amplifier output placing an upper limit on the primary current in transformer T1 Output Rectifier Circuit and Output Filter The DCS series uses two different configurations for the output rectifier The 8V to 80V models use a full wave center tap configuration while the 150 to 600V models employ a full wave bridge On 8V and 20V models the output rectifiers are one piece power tap units mounted on the rectifier heatsink with the secondary snubber components connected directly to the rectifier input terminals The 33V to 600V models have their rectifier and snubber components on a separate printed circuit board which is mounted on a rectifier heatsink Capacitors C51 C53 power inductor L3 and common mode inductor L4 form the main output filter on all models On 8V to 80V models the secondary filter capacitors C401 C407 are on a separate PCB which is mounted on the output bus bar assembly On 150V to 600V models the secondary filter capacitors C50 C50A C50B C50C C48 C48A C48B C49 C49A and C49B are mounted directly on the A2 PCB Resistor R90 is an output pre load which allows the unit to operate under no load or light load conditions Models DCS 8 125 and DCS 20 50 On these models diodes CR301 and CR302 rectify the output of power transformer 1 Resistors R301 R304 and capacitors C301 and C302 form snubbers on the secondary of T1 to limit switching transients while resistors R305 R305A R306 and R306A
27. age which is supplied to the power FETs Q13 Q16 on the primary of power transformer Resistor R116 and relay K1 form an input surge current limiter which reduces the inrush current to the filter capacitors C32 A B C and C72 A B C during power up The power FETs and the primary winding of T1 form a bridge which is driven at 70 kHz by pulse width modulator PWM U6 through FETs Q7 Q12 Q18 and Q19 and drive transformer T2 A current sense transformer T3 in the primary of the power transformer provides a feedback signal to the PWM which is compared to a limited error signal derived from the output current and voltage control circuits The output of the comparator controls the on time of the PWM output drive waveforms on a cycle by cycle basis thereby controling the primary current and the output of the power transformer Diodes CR301 and CR302 CR301 CR304 on models DCS 150 7 and 300 3 5 and CR300 CR307 on model DCS 600 1 7 rectify the output of power transformer T1 and inductor L3 and capacitors C51 C52 and C53 filter the rectified signal to provide the DC output 3 1 ct T4 AUXILIARY TRANSFORMER REGULATORS U9 U13 1 gt gt POWER SWITCH SIMPLIFIED FULL BRIDGE CONVERTER SURGE LIMITER K1 R116 DRIVE FETS 07 012 6 2 VOLT 018 019 REFERENCE CRA CR2 PULSE WIDTH MODULATOR 12V is 5V 18V EXTERNAL PROGRAMMING INPUTS V PGM RTN
28. and capacitors C303 and C304 are used to provide additional rectifier snubbing on some models Models DCS 33 33 DCS 40 25 DCS 50 20 DCS 60 18 and DCS 80 13 On these models diodes D1 and D2 rectify the output of power transformer T1 Resistors R2 and R3 and capacitors C3 and C4 form snubbers on the secondary of 1 to limit switching transients Resistors R1 and capacitors C2 and C5 are used to provide additional rectifier snubbing 3 4 SORENSEN DCS SERIES MANUAL THEORY OF OPERATION Models DCS 150 7 DCS 300 3 5 and DCS 600 1 7 On DCS 150 7 and DCS 300 3 5 diodes CR301 CR304 form the rectifier bridge with resistors R301 R304 and capacitors C301 C304 providing snubbing for the diodes Resistor R305 and capacitor C305 form the snubber on the secondary of transformer T1 Capacitor C306 provides bypassing on the output of the bridge On DCS 600 1 7 diodes CR300 CR307 form the rectifier bridge with resistors R302 R305 and capacitors C1 2 4 13 providing snubbing for the diodes Resistor R300 and R301 and capacitor C303 form the snubber on the secondary of transformer T1 Capacitor C300 provides bypassing on the output of the bridge Voltage Control Circuit The output voltage is monitored by the voltage control op amp 05 at pin 3 via the positive sense line pin 13 of connector J3 on 8V to 80V models and the resistor divider formed by R21 R22 R53 R85 and R147 This feedback voltage is compared with a 0 5V reference voltage gated from the f
29. between pins 3 and 16 of connector J3 is in place Using a small flat bladed screwdriver through the OVP ADJUST hole in the front panel turn the adjusting screw fully clockwise until audible clicking is heard or 20 turns maximum Turn the unit on and adjust the output to the desired trip voltage Slowly turn the adjusting screw counterclockwise until the red OVP indicator lamp lights and the power supply output shuts off Turn the POWER switch to OFF Turn the voltage control knob to minimum Turn the POWER switch back ON and increase the voltage to check that the power supply shuts off the output at the desired voltage Remote Programming of OVP With External Voltage Sources To remotely program the OVP trip level using a 0 5V or 0 10V DC voltage source use the following procedure 1 With the unit off and disconnected from its AC source remove the cover and set switch SW1 4 closed default factory setting for 0 5V programming or open for 0 10V programming Also check that switch SWI 8 is closed default factory setting Set the front panel OVP adjusting potentiometer fully clockwise until audible clicking is heard or 20 turns maximum Remove the default jumper connecting pins 16 and 3 of connector J3 and connect the voltage source between pins 3 positive and 12 negative Set the programming source voltage to maximum Turn the unit on and adjust the output to the desired trip voltage Slowly reduce the programming volta
30. ce between pins 8 positive and 12 return of connector J3 Varying the current source from 0 1mA will vary the output voltage from 0 100 of the rated output SWITCH SW1 CONNECTOR J3 OPEN 1312 8 1 x mn EVI 25 14 i CLOSED SE LO OEEO Ce OSA 0000000 m Switch SW1 and Connector J3 Configuration for 0 1mA Current Programming of the Output Voltage J3 sense line OVP and current control jumpers shown set for local operation To program the output current limit set the current control to maximum set switches SW1 1 and SW1 2 open factory setting and remove the jumper between pins 22 and 23 of connector J3 Connect the external current source between pins 11 positive and 12 return Varying the current source from 0 1mA causes the current limit to vary from 0 100 of rated maximum SWITCH SW1 CONNECTOR J3 OPEN 131211 1 NU icut NE aS 25 14 i SW1 1 swt swt swt swt swt swt swt o 3 gt Switch SW1 and Connector J3 Configuration for 0 1mA Current Programming of the Output Current Limit J3 sense line OVP and voltage control jumpers shown set for local operation 2 20 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION 2 12 Remote Monitoring and Status Indicators Readback signals for remote monitoring of the output voltage and current are available at connector J3 on the rear of the unit A 0 5V uncalibra
31. ce voltage at pin 6 of U3 2 is provided directly by the external voltage source Switch SW1 4 is used to select the programming range 0 5V with the switch closed or 0 10V with the switch open For current programming the internal 1mA current source is replaced with a 0 1mA external source to provide the required 0 5V reference signal For resistive programming switch SW1 8 is opened to disconnect the front panel adjusting potentiometer and the internal current source is connected to the external 0 5k ohm potentiometer to provide the 0 5V reference Remote ON OFF Circuit A TTL high signal applied between pins 14 positive and 2 negative of connector J3 activates opto coupler U1 which turns on transistor switch Q3 by pulling its base low This applies 12V through diode CR11 to the shutdown pin of the PWM thereby shutting down the power supply output A 12 250Vac or 12 130Vdc signal applied between pins 1 positive and 2 negative of connector J3 will also activate U1 and disable the power supply output Diode 14 rectifies ac inputs while resistors R37 and R38 limit the current through the opto coupler Diode CR13 provides protection against reverse polarity TTL signals 3 6 SORENSEN DCS SERIES MANUAL THEORY OF OPERATION Remote Programming of the Output Voltage During remote programming of the output voltage with an external voltage source 0 5V or 0 10V the local operation jumpers connecting J3 pins 8 to 9 and 20 to 21 are remove
32. d and the external source is connected between pins 9 positive and 12 negative of connector J3 The input signal at J3 pin 9 is buffered via U14 2 to provide noise immunity When using a 0 5V source the reference at pin 2 of U5 voltage control op amp is provided directly by the external source When using a 0 10V source switch SW1 3 is closed to provide the necessary voltage divider to scale the reference voltage to 0 5V For remote programming with an external 5k resistance the jumpers connecting J3 pins 8 to 9 and 20 to 21 are removed pins 9 and 21 are connected to the counterclockwise end of the external 5k ohm potentiometer and the tap and clockwise end are connected to pin 12 The internal 1mA current source at pin 21 develops a 0 5V potential across the potentiometer depending on the potentiometer setting which is fed to pin 2 of US During remote programming of the output voltage with an external 0 1mA current source the jumper connecting J3 pins 20 and 21 is removed the front panel voltage control is set fully clockwise and the external current source is connected between pins 8 positive and 12 return Varying the current source from 0 1mA causes 0 5V to develop at the reference pin of the voltage control circuit The front panel remote programming indicator is controlled by op amp U8 4 Resistors R55 and R56 form a voltage divider with the 6 2V reference which develops a nominal 0 3V at pin 12 the non inverting input of the op amp
33. d current controls These current sources are also used for remote resistive programming of the output voltage and current limit Over Voltage Protection Circuit Op amp U3 1 transistor Q4 and related components provide a 1mA current source which is fed to the front panel OVP adjusting pot via the external jumper connecting pins 3 and 16 of connector J3 switch SW1 8 and pin 17 of connector J1 This current source and the OVP adjusting pot provide a 0 5V reference at pin 6 of U3 2 the OVP control op amp The power supply output voltage is monitored at pin 5 of U3 2 through the resistor divider formed by R80 R89 and R148 When the output voltage increases such that the voltage at pin 5 becomes higher than that at pin 6 the output of U3 2 goes high activating MOSFET Q17 via drive FET Q2A which clamps the power supply output off through resistor R93 Diode CR25 latches U3 2 on while diodes CR23 and CR24 gate the high signal to the shutdown pin of the PWM The OVP indicator on the front panel is biased on via pin 15 of connector J1 when the OVP is activated The OVP may be reset by cycling the power switch off and then back on to release the latch provided by CR25 or by momentarily activating the remote shutdown circuit which causes pin 6 to be pulled high through diode CR10 During remote voltage programming of the OVP trip level the internal 1mA current source is disconnected by removing the jumper connecting pin 3 and 16 of connector J3 and the referen
34. dels the positive sense connection is available at pin 13 of connector J3 and the return sense connection is available at pin 12 For local sensing regulation at the power supply output terminals the sense pins are connected to pins 25 positive output and 24 return of connector J3 For remote sensing the local operation jumpers are removed and pins 13 and 12 are connected directly to the positive and negative terminals of the load On 150 300 and 600V models the sense connections are available through the output connector See Figure 2 1 for the exact pin out On these models no sense line jumpers are required for local operation Sense wires can be any size 24AWG or larger but in high noise environments or when the lowest possible power supply ripple is required sense wires must be twisted and or shielded On 8 80V models the sense leads must always be connected either for remote or local sensing Operation of the supply with the sense leads disconnected will cause the output to fall to zero or to be unregulated NEVER use the sense connections without the normal power lead connections to the output terminals Avoid reversing positive and negative sense lead connections 2 6 5 Negative Output Operation Operation of the unit as a negative output supply may be accomplished by referencing the positive output terminal to the power supply chassis or some other common system ground This mode of operation is limited to 8 150V models only du
35. e 5 1 SECTION 6 DRAWINGS AND SCHEMAT ICS eeeeeeeee eene eene nennen eee ee eee sees esee esee ssepe eese eese esee esee 6 1 OL GENERAIESS 4 6 1 6 2 DRAWINGS AND SCHEMATICS sssssccccccccccssssscccccsccesesececcssseuuseeccccssseeeeeeecccssssuuessescccsssseuuesescsesssseueuseeesecsseauenenss 6 1 vi SORENSEN DCS SERIES MANUAL FEATURES and SPECIFICATIONS SECTION 1 FEATURES AND SPECIFICATIONS 1 1 Description DCS Series power supplies are 1000W supplies designed to provide highly stable continuously variable output voltage and current for a broad range of development system and burn in applications The series consists of ten models designated by the DCS prefix followed by the output voltage and current ratings For example the model number DCS 60 18E indicates that the unit is rated at 0 60 Vdc and 0 18 Amps while a model DCS 20 50E is rated at 0 20 Vdc and 0 50 Amps The DCS Series employs high frequency switching regulator technology to achieve high power density and small package size 1 2 Operating Modes The DCS Series supply has two basic operating modes Constant Voltage and Constant Current In constant voltage mode the output voltage is regulated at the selected value while the output current varies with the load requirements In constant current mode the output current is regulated at the selected value while output the voltage varies with the load requirements An automatic crosso
36. e carrier immediately Direct repair problems to the Service Department Sorensen Company Customer Service Inquiries 1 800 458 4258 2 2 Initial Inspection The equipment should be inspected for damage as follows e Inspect for obvious signs of physical damage e Turn front panel controls from stop to stop Rotation should be smooth Test the action of the power switch Switching action should be positive e If internal damage is suspected remove the cover and check for printed circuit board and or component damage Reinstall cover 2 3 Installation 2 3 1 Input Voltage Selection Before using the DCS power supply the correct AC input voltage must be selected and an appropriate line cord and plug attached or hook up wire sized for input current based on NEC or local electrical code The frequency of the AC input voltage must be maintained between 47 and 63 Hz units are shipped in a configuration requiring a 200 250Vac 10 Amp input The unit can also be converted for use with a 100 130Vac 20A input WARNING Attempted operation of the DCS power supply with the incorrect input voltage may result in internal damage to the unit For use with a 200 250Vac input connect a 250Vac 10Amp plug and cord to the rear panel AC connector and the safety ground screw Note that the NEUT and LINE designations above the AC connector do not apply to 200 250V operation To convert the unit for use with a 100 130Vac 20A input perform the following steps
37. e front panel power switch Both input lines are switched with one line the neutral line of a 115Vac input returning to the A2 PCB and the input rectifier CR35 via fuse F1 The other input line the hot line of a 115Vac input is connected to the remaining input of rectifier CR35 via front panel circuit breaker CB1 fuse F2 and the inrush limiter formed by resistor R116 and relay K1 Resistor R116 limits the power on inrush current to the main filter capacitors C32 A B C and C72 A B C until it is shorted by K1 relay contacts The time delay for K1 contact closure is determined by the time constant formed by capacitor C12 resistor R118 and the gate threshold of FET Q6 Diode CR38 discharges C12 when the 12V auxiliary supply collapses and CR39 provides an inductive kickback path for the relay coil During the inrush period diode CR33 holds the PWM shutdown line high disabling the power supply output until Q6 turns on Resistors R114 and R115 are bleeder resistors for the main filter capacitors The rectified high voltage dc from CR35 is supplied to the main switching FETs Q13 Q16 on the primary of the power transformer T1 via fuse F3 3 3 THEORY OF OPERATION SORENSEN DCS SERIES MANUAL For 230Vac operation rectifier CR35 and filter capacitors C32 A B C and C72 A B C are configured as a full wave bridge For 115Vac operation the input voltage selector P1 is switched so that CR35 C32 A B C and C72 A B C form a voltage doubler In addition to determi
38. e the following procedure 2 14 1 8 With the unit off and disconnected from its AC source remove the cover and set switches SW1 4 and SW1 8 closed default factory setting Using a small flat bladed screwdriver through the OVP ADJUST hole in the front panel turn the adjusting screw fully clockwise until audible clicking is heard or 20 turns maximum Remove the default jumper connecting pins 16 and 3 of connector J3 and connect the current source between pins 3 positive and 12 negative Set the programming source to 1mA Turn the unit on and adjust the output to the desired trip voltage Slowly reduce the programming current until the red OVP indicator lamp lights and the power supply shuts down Turn the POWER switch to OFF Turn the voltage control knob to minimum Turn the POWER switch back ON and increase the voltage to check that the power supply shuts off the output at the desired voltage SWITCH SW1 CONNECTOR J3 OPEN 1312 3 1 MN e 25 14 No LO 2 be n Switch SW1 SWI 1 Off Open SWI 2 Off Open SWI 3 Off Open SWI 4 On Closed SWI 5 Off Open SWI 6 Off Open SWI 7 Off Open SW1 8 On Closed Switch SW1 and Connector J3 Configuration for 0 1mA Current Source OVP Programming J3 sense line voltage control and current control jumpers shown set for local operation SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION 2 9 5 Remote OVP Sens
39. e to the metal shell 25 pin D connector supplied with the unit which mates to J3 WARNING Operation of the 300V or 600V models in the negative output mode is in violation of the European Community s Low Voltage Directive NOTE If a 300V or 600V supply is required please contact the Sorensen Sales Department or Customer Service for availability 2 8 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION 2 7 Single Supply Operation Local Mode A To operate the DCS power supply in local mode first install the unit and connect the load following the instructions in Sections 2 1 to 2 6 Check that switch SW1 mounted internally on the main printed circuit board is set for local operation and that the J3 mating connector on the rear of the unit is in place with jumpers connected for local operation Note This is the default configuration as shipped from the factory See the diagram below Set both the current and voltage controls fully counterclockwise SWITCH SW1 CONNECTOR J3 OPEN 13 1 25 14 CLOSED TURP LEHR SESS 25585 WN Switch SW1 SWI 1 Off Open SWI 2 Off Open SWI 3 Off Open SWI 4 On Closed SWI 5 Off Open SWI 6 Off Open SWI 7 Off Open SWI 8 On Closed Switch SW1 and Connector J3 Configuration for Local Operation Default factory settings For voltage mode operation turn the current control fully clockwise and then adjust the voltage control t
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41. for repair Sorensen will repair the unit and return it by ground freight pre paid Normal warranty service is performed at Sorensen during the weekday hours of 7 30 am to 4 30 pm Pacific time Warranty repair work requested to be accomplished outside of normal working hours will be subject to Sorensen non warranty service rates Warranty field service is available on an emergency basis Travel expenses travel time per diem expense and related air fare are the responsibility of the Buyer A Buyer purchase order is required by Sorensen prior to scheduling A returned product found upon inspection by Sorensen to be in specification is subject to an inspection fee and applicable freight charges Equipment purchased in the United States carries only a United States warranty for which repair must be accomplished at the Sorensen factory Committed to Quality Striving for Excellence SAFETY NOTICE Before applying power to the system verify that the DCS Series unit is configured properly for the user s particular application WARNING HAZARDOUS VOLTAGES IN EXCESS OF 280 VRMS 600V PEAK MAY BE PRESENT WHEN COVERS ARE REMOVED QUALIFIED PERSONNEL MUST USE EXTREME CAUTION WHEN SERVICING THIS EQUIPMENT CIRCUIT BOARDS TEST POINTS AND OUTPUT VOLTAGES MAY BE FLOATING ABOVE BELOW CHASSIS GROUND Installation and service must be performed by qualified personnel who are aware of dealing with attendant hazards This includes such s
42. ge until the red OVP indicator lamp lights and the power supply shuts down Turn the POWER switch to OFF Turn the voltage control knob to minimum Turn the POWER switch back ON and increase the voltage to check that the power supply shuts off the output at the desired voltage 2 11 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL SWITCH SW1 CONNECTOR J3 OPEN 1312 3 1 25 14 CLOSED T Q o0 O00 0 5V Switch SW1 SWI 1 Off Open SWI 2 Off Open SWI 3 Off Open SWI 4 On Closed SWI 5 Off Open SWI 6 Off Open SWI 7 Off Open SW1 8 On Closed Switch SW1 and Connector J3 Configuration for 0 5Vdc OVP Programming J3 sense line voltage control and current control jumpers shown set for local operation SWITCH SW1 CONNECTOR J3 OPEN 1312 3 1 25 14 CLOSED S eyes i pots T zZzzzzzzzz P 0 0 10 Switch SW1 SWI 1 Off Open SWI 2 Off Open SWI 3 Off Open SWI 4 Off Open SWI 5 Off Open SWI 6 Off Open SWI 7 Off Open SWI 8 On Closed Switch SW1 and Connector J3 Configuration for 0 10Vdc OVP Programming J3 sense line voltage control and current control jumpers shown set for local operation 2 12 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION 2 9 3 Remote Programming of OVP with an External Resistance To remotely program the OVP trip level using a 5k ohm external p
43. imple tasks as fuse verification Ensure that the AC power line ground is connected properly to the DCS Series unit input connector or chassis Similarly other power ground lines including those to application and maintenance equipment must be grounded properly for both personnel and equipment safety Always ensure that facility AC input power is de energized prior to connecting or disconnecting the input output power cables During normal operation the operator does not have access to hazardous voltages within the chassis However depending on the user s application configuration HIGH VOLTAGES HAZARDOUS TO HUMAN SAFETY may be generated normally on the output terminals Ensure that the output power lines are labeled properly as to the safety hazards and that any inadvertent contact with hazardous voltages is eliminated To guard against risk of electrical shock during open cover checks do not touch any portion of the electrical circuits Even when the power if off capacitors can retain an electrical charge Use safety glasses during open cover checks to avoid personal injury by any sudden failure of a component Due to filtering the unit has high leakage current to the chassis Therefore it is essential to operate this unit with a safety ground Some circuits are live even with the front panel switch turned off Service fuse verification and connection of wiring to the chassis must be accomplished at least five minutes after power has
44. ing The default configuration for the OVP circuit senses the output voltage at the power supply output terminals For applications using remote sensing where there is a need to accurately monitor the actual load voltage the following procedure allows the OVP sense point to be shifted from the power supply output to the sense line connection points 1 Shut the unit off and disconnect it from its power source Remove the cover from the unit 2 Using a sharp Exacto knife cut the component side trace connecting the right hand side of resistor R89 to the via marked OVP LOC 3 Install an piece of insulated 22 AWG wire from the via marked C near the trace cut just made to the via marked C1 near capacitor C51 4 Reinstall the cover and reconnect the unit to its power source To return to local OVP sensing remove the jumper installed in step 3 above and install a jumper across the trace cut made in step 2 2 10 Remote ON OFF This feature is useful in test applications requiring remote ON OFF control of the output The remote ON OFF control circuit uses either a TTL compatible or a 12 250Vac or 12 130Vdc input to remotely control disable or enable the power supply output For TTL operation a logic level signal between pins 14 positive and 2 return of connector J3 determines the output conditions TTL LOW OUTPUT ON TTL HIGH OUTPUT OFF For AC or DC operation an input of 12 250Vac or 12 130Vdc between pins 1 positive for
45. lowing discussion 3 2 1 Voltmeter U2 is a 3 1 2 digit analog to digital converter which converts the analog input from the A2 board voltage control circuit to a digital display on seven segment displays DS5 DS8 maximum display is 1999 The 6 2V reference from pin 5 of connector J1 is divided down by resistors R16 and R17 and potentiometer R18 to provide the reference for the converter The analog input from the voltage control circuit via pin 6 of connector J1 is filtered by resistor R9 and capacitor C14 before it is input to pin 31 of the converter Capacitor C12 and resistor R7 set the conversion frequency to approximately 3 times per second Resistors R8 R11 and R12 are used to select the appropriate decimal point position depending on the model of the power supply 3 2 2 Current Meter The current meter circuit operates in the same manner as the voltage meter circuit with U1 performing the conversion for display on DS1 DS4 Capacitors C4 and C6 provide additional filtering on the meter analog input Resistors R2 R5 and R6 are used to select the appropriate decimal point 3 8 SORENSEN DCS SERIES MANUAL MAINTENANCE SECTION 4 MAINTENANCE TROUBLESHOOTING AND CALIBRATION 4 1 General This section provides periodic maintenance calibration and troubleshooting information 4 2 Periodic Service No routine service except for periodic cleaning is required Whenever a unit is removed from service it should be cleaned using denat
46. ls designated as the positive and negative distribution terminals The pair of terminals may be the power supply output terminals the terminals of one of the loads or a distinct set of terminals specially established for distribution Connecting the sense leads to these terminals will compensate for losses and minimize the effect of one load upon another 2 6 3 Inductive Loads To prevent damage to the power supply from inductive kickback connect a diode rated at greater than or equal to the supply s output voltage and current across the output Connect the cathode to the positive output and the anode to return Where positive load transients such as back EMF from a motor may occur connect a transorb or a varistor across the output to protect the power supply 2 7 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL 2 6 4 Remote Sensing The use of remote sensing permits the regulation point of the power supply to be shifted from the output terminals to the load or other distribution terminals thereby automatically compensating for the voltage losses in the leads supplying the load provided these losses do not exceed 1V line 0 5V line for the DCS 8 125 model For example with the voltmeter reading 10 0 volts and the sense lines connected directly to the load the load voltage will remain regulated at 10 0 volts regardless of the voltage drops in the power leads and variations in the load current On 8V 20V 33V 40V 50V 60V and 80V mo
47. n above remove the jumpers connecting pins 10 to 11 and 22 to 23 of connector J3 and connect the external voltage source between pins 10 positive and 12 return Varying the voltage source from 0 100 causes the current limit to vary from 0 100 of the rated maximum CONNECTOR J3 1312 10 1 NN Mn T 25 14 ira 0 100mV 0 5V or 0 10V Connector J3 Configuration for Remote Programming of the Output Current Limit J3 sense line OVP and voltage control jumpers shown set for local operation 2 11 2 Programming With an External Resistance The output voltage and current limit can be programmed using a 5k ohm external potentiometer To program the output voltage set switch SW1 3 open default factory setting and remove the jumpers connecting pins 8 to 9 and 20 to 21 on connector J3 Connect pins 9 and 21 to the counterclockwise end of the 5k potentiometer and connect the tap and clockwise end of the potentiometer to pin 12 Adjusting the tapped resistance from 0 5k will vary the output voltage from 0 100 of the rated output SWITCH SW1 CONNECTOR J3 OPEN 1312 9 m TTL M co UE e d o 25 21 14 CLOSED xU soup ore nii 60000000 5k OHMS 2 18 SORENSEN DCS SERIES MANUAL Switch SW1 SWI 1 Off Open SWI 2 Off Open SWI 3 Off Open SWI 4 On Closed SWI 5 Off Open SWI 6 Off Open SWI 7 Off Open SWI 8 On Closed INSTALLATION and OPERATION Switch SW1 and Connector J
48. ning the input rectifier configuration P1 also switches the connections to the primary of auxiliary transformer T4 Pulse Width Modulator Pulse width modulator U6 is a current mode controller which drives the main switching FETs Q13 Q16 through drive FETs Q7 Q12 Q18 and Q19 and drive transformer T2 Capacitor C69 and resistors R111 R113 form a snubber on the primary of transformer 1 limiting switching transients Transformer 3 is used to monitor 1 primary current and provide a feedback signal for the current sense amplifier of U6 Diodes CR29 and CR30 rectify T3 output while resistors R66 and R95 R97 and capacitors C60 C62 and C64A scale and condition the signal before it is input to the PWM An internal PWM comparator compares the output of the current sense amplifier with a limited error signal derived from the output voltage and current control circuits The output of the PWM comparator controls the pulse duration of the drive signals from pins 11 and 14 of the PWM thereby controlling the primary current in 1 and the output power Resistor R100 and capacitor C63 set the internal oscillator of U6 to approximately 140kHz resulting in a 70kHz output switching frequency A 5 1V reference developed at pin 2 of the PWM is divided down by resistors R64 and R67 to provide a reference at the non inverting input of the PWM error amplifier pin 5 The 5 1V reference voltage is also divided by resistors R65 and R68 to provide a reference at pin 1 of the P
49. ns Note The positive output and positive sense are not available at connector J3 on 150 300 and 600 volt models AC Input Safety Ground Screw AC Input Connector 2 5 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL PIN NUMBER jode 14 Deuce 15 TP 16 4 17 B esf 18 19 20 21 22 TOs cutee 23 Pies 24 25 Table 2 1 J3 Program Sense and Monitor Connector Description D subminiature 25 Pin Female FUNCTION AC DC Shutdown Input 12 250Vac or 12 130Vdc TTL Shutdown Input Return for Shutdown Input Signals 12Vdc Output 1k ohm source impedance OVP Programming Input 0 5V 0 10V or 0 1mA Jumpered to pin 16 for local mode operation ImA Current Source for Local OVP Control or Remote Resistive OVP Programming Remote Programming Indicator High Remote Programming Low Local Control OVP Status High OVP Circuit Activated Operating Mode Indicator High Voltage Mode Low Current Mode Thermal Shutdown Indicator High Shutdown Ground Output Voltage Monitor Uncalibrated 0 5V 0 100 Output Current Monitor Calibrated 0 5V 0 100 Front Panel Voltage Control Local Mode Jumpered to pin 21 for local operation Front Panel Voltage Control Remote Programming Input for 0 1 mA remote programming signal Jumpered to pin 9 for local operation and remote current source programming ImA Current Source for Local Operation or Remote Resistive Programming of O
50. o obtain the desired output voltage For current mode operation turn the voltage control 1 2 turn clockwise the current control fully counterclockwise and connect an appropriately sized shorting jumper across the output terminals Turn the current control clockwise until the desired output current is obtained Turn the power supply off remove the shorting jumper turn the voltage control fully clockwise and turn the power supply on Note that for a short period less than 2 seconds after power on the power supply output is disabled and the current mode LED is illuminated while the main filter capacitors charge through the inrush limiter 2 8 Multiple Supplies DCS Series power supplies of the SAME MODEL may be operated with outputs in series or parallel to obtain increased load voltage or current Split supply operation allows two positive or a positive and negative output to be obtained 2 9 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL 2 8 1 Series Operation Series operation is used to obtain a higher voltage single output supply using two or more single units Connect the negative terminal of one supply to the positive terminal of the next supply of the same model The total voltage available is the sum of the maximum voltages of each supply add voltmeter readings Notes 1 The maximum allowable sum of the output voltages is 300V This is limited by the creepage clearance distances internal to the construction of
51. on signal at pin 7 This output is used to drive the back to back mode LEDs on the front panel through pin 1 of connector J1 In voltage mode U8 2 pin 7 is high and the green voltage mode led is illuminated In current mode pin 7 is low and the red current mode led is illuminated 3 5 THEORY OF OPERATION SORENSEN DCS SERIES MANUAL Auxiliary Supply and 6 2V Reference Circuit Transformer T4 rectifier CR42 and capacitors C9 and C10 provide the raw dc supply voltages from which the 12V and 5V auxiliary supplies are derived by three terminal regulators U10 and U11 respectively Two additional regulators U12 and U13 provide the 12V feed to drive FETs Q7 Q12 Q18 and Q19 on the primary of T2 and the 12V feed to PWM U6 Diodes CR40 and CR41 with capacitors C7 and C11 provide the negative input to three terminal regulator U9 which supplies the 5V auxiliary output Resistor R2 and Zener diode 1 are used to derive a stable 6 2V reference from the 12V auxiliary supply for use on the front panel meters via pin 5 of connector J1 and the A2 PCB Transistor Q5 diode CR32 resistors R60 62 and Zener diode CR20 form a low voltage lock out which disables the power supply output by shutting down the PWM should the auxiliary raw supply fall below the threshold set by CR20 Voltage and Current Control Current Sources Op amps 02 1 and U2 2 transistors Q1 and Q2 and related components are used to provide 1mA current sources for the front panel voltage an
52. otentiometer use the following procedure 1 With the unit off and disconnected from its AC source remove the cover set switch SW1 8 open and check that switch SW 1 4 is closed default factory setting for switch SW1 4 Connect the counterclockwise end of the 5k potentiometer to pins 3 and 16 of connector J3 Connect the tap and the clockwise end of the potentiometer to pin 12 Set the potentiometer fully clockwise Turn the unit on and adjust the output to the desired trip voltage Slowly turn the potentiometer counterclockwise until the red OVP indicator lamp lights and the power supply shuts down Turn the POWER switch to OFF Turn the voltage control knob to minimum Turn the POWER switch back ON and increase the voltage to check that the power supply shuts off the output at the desired voltage SWITCH SW1 CONNECTOR J3 25 22 16 14 CLOSED Vou 65000000 5k OHMS Switch SW1 SWI 1 Off Open SWI 2 Off Open SWI 3 Off Open SWI 4 On Closed SWI 5 Off Open SWI 6 Off Open SWI 7 Off Open SWI 8 Off Open Switch SW1 and Connector J3 Configuration for 0 5k OVP Programming J3 sense line voltage control and current control jumpers shown set for local operation 2 13 INSTALLATION and OPERATION 2 9 4 SORENSEN DCS SERIES MANUAL Remote Programming of OVP with External Current Sources To remotely program the OVP trip level using 0 1mA current source us
53. put line voltage to high voltage DC by diode rectification and then chops the DC at a high frequency This high frequency waveform is applied to the primary of a power transformer which provides a step up or step down in voltage and electrical isolation on its secondary The secondary waveform is rectified and filtered giving a smooth DC output voltage Feedback from the secondary circuit is applied to a pulse width modulator PWM control circuit which controls the on time of the primary circuit switching waveform This increases or decreases the voltage on the secondary of the power transformer so that output regulation is obtained The use of high frequency transformers in switching power supplies has the advantage of requiring less volume less weight and dissipating less heat than the lower frequency transformers in conventional linear power supplies CAUTION Potentially LETHAL VOLTAGES exist on the A2 circuit board on the primary side of the isolation barrier Troubleshoot with care preferably with power off and recognizing that filter capacitors store potentially LETHAL and DESTRUCTIVE ENERGY even for some time AFTER POWER is REMOVED Always use an isolation transformer connected ONLY to the power supply input when making test measurements on the primary side circuits 3 1 2 Simplified Full Bridge Converter Theory See Figure 3 1 The input AC line voltage is rectified and filtered by CR35 C32 A B C and C72 A B C to a raw DC volt
54. rnally mounted switch PARAMETER RESISTANCE VOLTAGE CURRENT Voltage 5V 10V Current 100 mV 5V 10V OVP 5V 10V 1 4 2 Mechanical Specifications HEIGHT WIDTH DEPTH WEIGHT Single Unit 44 mm 482 6 mm 508 mm 8 2 kg 1 75 in 19 in 20 in 18 Ibs e Models DCS 8 125 through DCS 80 13 Output Connector Connector type Nickel plated copper bus bars Approximate dimensions 1 365 x 0 8 x 0 125 Distance between positive and negative bus bar centers 2 2 Load wiring mounting holes Two 0 257 diameter holes on 0 5 centers 1 4 hardware Two 0 191 diameter holes on 0 4 centers 10 hardware e Models DCS 150 7 through DCS 600 1 7 Connector type Six pin Amp Universal Mate N Lok connector Chassis mounted parts Housing Amp part number 1 480705 0 Pins Amp part number 350547 1 Mating connector parts Housing Amp part number 1 480704 0 Socket pins Amp part number 350550 1 Note Eight Socket pins and one mating connector housing are supplied with each 150V through 600V unit Input Connector 2 position terminal block plus safety ground screw Note Input power cord not supplied SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 1 3 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION SECTION 2 INSTALLATION and OPERATING INSTRUCTIONS 21 General After unpacking perform an initial inspection and function test to ensure that the unit is in good working order If the unit was damaged in shipment notify th
55. ront panel voltage control to pin 2 of U5 by U7 2 to provide an error signal for the PWM If the output voltage tries to rise above the selected level the voltage at pin 3 rises and the output of U5 becomes more positive This increase is applied to the inverting input of the PWM error amplifier through diode CR18 and resistor R69 causing the amplifier output to decrease This reduces the PWM output drive waveform pulse width lowering the output voltage and regulating the output at the desired level Similarly if the output voltage tries to fall below the selected level the voltage at pin 3 decreases U5 output decreases the output from the PWM error amplifier increases and the drive waveform pulse width increases which raises the output voltage to the desired level During voltage mode operation the output of the current control circuit at U4 1 pin 1 remains low Resistor R70 and capacitor C54 provide compensation for the op amp and diode CR21A limits saturation Capacitor C20 resistor R54 and CMOS gate U7 3 provide a soft start for the power supply during initial startup and recovery from shut down conditions by delaying the voltage rise at pin 2 of U5 Resistor R21 supplies the front panel voltmeter with a voltage proportional to the output voltage through pin 6 of the J1 connector while a buffered 0 5V signal uncalibrated for remote monitoring of the output voltage is provided at pin 19 of connector J3 Potentiometer R53 is used to adjust the full scale
56. sed to understand the theory of operation and also be used as an aid in troubleshooting the unit 6 2 Drawings and Schematics Table 6 1 provides a listing of the Drawings and Schematics included in this section and Table 6 2 provides a Drawings Schematics by Model Number matrix Table 6 1 DCS 1 kW Drawings Schematics 6 1 DRAWINGS and SCHEMATICS SORENSEN DCS SERIES MANUAL Table 6 2 DCS 1 kW Drawings Schematics By Model Number Final Mother Mother Front Panel Front Panel Output Rectifier Rectifier Assembly PCB PCB PCB PCB PCB PCB PCB Drawing Assembly Schematic Assembly Schematic Assembly Assembly Schematic Drawing Drawing Drawing Drawing Model 5360800 5360802 6360802 5360801 6360801 1066830 N A N A DCS8 125E Model 5360800 5360802 6360802 5360801 6360801 1066830 N A N A DCS20 50E Model 5360800 5360802 6360802 5360801 6360801 1066830 5360726 6360726 DCS33 33E Model 5360800 5360802 6360802 5360801 6360801 1066830 5360726 6360726 DCS40 25E Model 5360800 5360802 6360802 5360801 6360801 1066830 5360726 6360726 DCS50 20E Model 5360800 5360802 6360802 5360801 6360801 1066830 5360726 6360726 DCS60 18E Model 5360800 5360802 6360802 5360801 6360801 1066830 5360726 6360726 DCS80 13E Model 5360800 5360802 6360802 5360801 6360801 1066830 1066832 N A DCS150 7E Model 5360800 5360802 6360802 5360801 6360801 1066830 1066832 N A DCS300 3 5E Model 5360800 5360802 6360802 5360801 6360801 1066830 1068573 N A DCS600 1 7E 6 2
57. t limits can be set independently The maximum current available in split operation is equal to the rated output of the supplies used A Refer to paragraph 2 6 4 for additional information pertaining to negative output configured supplies 2 9 Over Voltage Protection OVP The OVP circuit allows for protection of the load in the event of a remote programming error incorrect voltage control adjustment or power supply failure The protection circuit monitors the output and reduces the output voltage and current to zero whenever a preset voltage limit is exceeded A red LED on the front panel indicates when the OVP circuit has been activated Resetting the OVP circuit after activation requires removal of the over voltage condition and powering the unit OFF and back ON or momentarily activating the remote shut down circuit See Section 2 10 for information on shut down circuit operation The OVP trip level can be set using either the front panel potentiometer or by using one of three remote programming methods voltage resistance or current through the J3 connector at the rear of the unit 2 10 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION 2 9 1 Front Panel OVP Operation To set the trip level from the front panel use the following procedure 1 2 9 2 With the unit off and disconnected from its AC source remove the cover and check that switches SW1 4 and SW1 8 are closed factory default setting Also check that the jumper
58. t up with both displays reading zero CONNECTOR J3 13 1 oue V 25 14 Connector J3 Configuration for Local Operation To check voltage mode operation proceed as follows Connect a DVM rated better than 0 5 accuracy to the rear output terminals observing correct polarity Rotate the CURRENT control 1 2 turn clockwise Slowly rotate the VOLTAGE control clockwise and observe both the internal and external meters Minimum control range should be from zero to the maximum rated output Compare the test meter reading with the front panel voltmeter reading Check that the green voltage mode indicator led is ON Set the POWER switch to OFF To check current mode operation proceed as follows 2 4 Rotate the VOLTAGE and CURRENT controls fully counterclockwise Rotate the VOLTAGE control 1 2 turn clockwise Connect a high current DC ammeter across the rear output terminals observing correct polarity Select leads of sufficient current carrying capacity and an ammeter range compatible with the unit s rated current output The ammeter should have an accuracy of better than 0 596 Set the POWER switch to ON Rotate the CURRENT control slowly clockwise The control range should be from zero to the maximum rated output Compare the test meter reading with the reading on the front panel ammeter Check that the red current mode indicator led is ON Set the POWER switch to OFF SORENSEN DCS SERIES MANUAL SORENSEN DCS SERIES MANUA
59. ted signal between pins 19 positive and 12 negative represents 0 100 of the rated output voltage A 0 5V calibrated signal between pins 7 positive and 12 negative represents 0 100 of the rated output current The offset and gain of the current readback signal may be adjusted through holes in the cover of the unit See Section 4 4 Calibration for location of adjusting holes Status indicators for thermal shutdown OVP operation remote programming and operating mode are also available through the J3 connector The table below lists the various signals the J3 connector pins where they are available the approximate magnitude of the signal measured with respect to pin 6 of connector J3 and the source impedance through which the signal is fed INDICATOR SIGNAL J3 CONNECTOR PIN SIGNAL VOLTAGE SOURCE IMPEDANCE Thermal Shutdown OVP Circuit Activated Remote Programming Voltage Mode Operation Current Mode Operation 2 21 SORENSEN DCS SERIES MANUAL THEORY OF OPERATION SECTION 3 THEORY OF OPERATION 3 1 Power Circuit A2 Assembly This section describes the operation of the A2 assembly switching regulator power circuit Three subsections cover basic switching regulator theory a simplified description of the Sorensen full bridge converter and a more detailed circuit description intended for troubleshooting purposes 3 1 1 Basic Off Line Switching Regulator Theory An off line switching power supply first converts the AC in
60. th internal troubleshooting as described below 4 1 MAINTENANCE SORENSEN DCS SERIES MANUAL 4 3 2 Internal Troubleshooting After reading the caution in Section 4 3 and completing the preliminary checks described in Section 4 3 1 remove the cover and proceed with internal troubleshooting using the information contained in Figure 4 1 as a guide to isolate the problem to a specific area of the circuit Refer to the schematics in Section 6 and the theory of operation in Section 3 for additional information 4 4 Calibration Calibration on both the A1 and A2 assemblies is accomplished using multiturn trimpots The list below gives the circuit designation of the trimpot and the parameter affected by that part Calibration is performed at the factory during testing and recalibration should be unnecessary unless major repairs are required Calibration should be done with the cover on through the access holes in the cover See Figure 4 2 below CIRCUIT DESIGNATION ASSEMBLY PARAMETER AFFECTED A2 Output Current Monitor Calibration A2 Output Current Monitor Offset A2 Current Control Circuit Offset A2 Output Current Range A2 Voltage Control Circuit Offset A2 Output Voltage Range Al Front Panel Voltmeter Calibration Al Front Panel Ammeter Calibration M15 Option Board Program Range Adjust M15 Option Board Program Offset Adjust NOTE Consult the factory for full calibration requirements 4 2 t TROUBLESHOOTING GUIDE CAUTION READ S
61. the metal shell 25 pin D connector mated to J3 If a higher output voltage range is required contact the Sorensen Sales Department or Customer Service for availability 2 The maximum allowable current for a series string of power supplies is the rated output current of a single supply in the string 3 Remote sensing should not be used during series operation 2 8 2 Parallel Operation Parallel operation is used to obtain a higher current single output supply using two or more single units Set all of the outputs to the same voltage before connecting the positive terminals and negative terminals in parallel The total current available is the sum of the maximum currents of each supply Caution To prevent internal damage ensure that the OVP trip level of all supplies is set to maximum 2 8 3 Split Supply Operation Split supply operation is used to obtain two positive voltages with a common ground or a positive negative supply To obtain two positive voltages connect the negative terminals of both supplies together The positive terminals will supply the required voltages with respect to the common connection To obtain a positive negative supply connect the negative terminal of one supply to the positive terminal of the second supply The positive terminal of the first supply then provides a positive voltage relative to the common connection while the negative terminal of the second supply provides a negative voltage The curren
62. ts on each side of the unit and for the fan exhaust air to exit from the rear of the unit 2 3 4 Output Voltage Biasing A If the output voltage is to be biased relative to safety ground the power supply outputs may be biased up to a maximum of 150Vdc with respect to the chassis 2 3 5 Rack Mounting The DCS power supply is designed to fit in a standard 19 equipment rack When installing the unit in a rack be sure to provide adequate support for the rear of the unit while not obstructing the ventilation inlet on the sides of the unit Use adjustable support angles such as Hammond RASA22WH2 or a support bar such as Hammond RASBI9WH2 2 2 c REAR VIEW OFF OPEN ON CLOSED 14 16 POSITIVE NEGATIVE 18 OUTPUT OUTPUT AC INPUT 8 80V MODELS 8 80V MODELS CONNECTOR 115 230 VOLT SELECTABLE 1 47 83 HZ Wem 5 13 1 COOLING FAN EXHAUST e AREA DO NOT OBSTRUCT OOOOO OOOOO 25 14 ALLOW ADEQUATE CLEARANCE 17 18 ALLOW ADEQUATE CLEARANCE ON SIDE FOR VENTILATION OUTPUT AND PROGRAM SENSE AC INPUT ON SIDE FOR VENTILATION SENSE CONNECTOR AND MONITOR SAFETY GROUND FO
63. ured or isopropyl alcohol or an equivalent solvent on the metal surfaces and a weak solution of soap and water for the front panel Low pressure compressed air may be used to blow dust from in and around components on the printed circuit boards 4 3 Troubleshooting Units requiring repair during their warranty period should be returned to Sorensen for service Unauthorized repairs performed by anyone other than Sorensen Company during the warranty period may void the warranty Any questions regarding repair should be directed to the Service Department Sorensen Company Division of Elgar Company CAUTION POTENTIALLY LETHAL VOLTAGES EXIST IN THE POWER CIRCUIT AND THE OUTPUT OF HIGH VOLTAGE MODELS Filter capacitors store potentially dangerous energy for some time after power is removed Repairs should be attempted by experienced technical personnel only Be sure to isolate the power supply from the input line with an isolation transformer when using grounded test equipment such as an oscilloscope in the power circuit 4 3 1 Preliminary Checks If the power supply displays any unusual or erratic operation shut the power supply off immediately and disconnect it from the AC power source Check all load programming and monitoring connections and circuits Check the AC input for correct voltage and frequency Correct any problems found and retest the system If no problems are found or the unit fails to operate correctly upon retesting proceed wi
64. utput Voltage Jumpered to pin 20 for local operation Remote Voltage Programming Input 0 5V or 0 10V Jumpered to pin 8 for local operation and remote current source programming ImA Current Source for Local Operation or Remote Resistive Programming of Output Current Limit Jumpered to pin 23 for local operation Remote Current Programming Input 0 100mV 0 5V or 0 10V Jumpered to pin 11 for local operation and remote current source programming Front Panel Current Control Local Mode Jumpered to pin 22 for local operation Front Panel Current Control Remote Programming Input for 0 1 external programming signal Jumpered to pin 10 for local operation and remote current source programming Return for local sense connections only Return Sense Return for Remote Programming Inputs Positive Output for local sense connections only Positive Sense Note Pins 25 and 13 not connected on 150 300 and 600V models Mating connector 25 pin male ITT Cannon DB25P or equivalent 2 6 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION 2 6 Standard Operation Reliable performance of the DCS power supply can be obtained if certain basic precautions are taken when connecting it for use on the lab bench or installing it in a system To obtain a stable low noise output careful attention should be paid to factors such as conductor ratings system grounding techniques and the way in which the load and remote sensing connections are made 2 6
65. ver system enables the unit to switch operating modes in response to varying load requirements If for example the unit is operating in voltage mode and the load current attempts to increase above the setting of the current control the unit will switch automatically from voltage mode to current mode If the load current is subsequently reduced below the setting of the current control the unit will return to voltage mode automatically 1 3 Power Supply Features e Ten models with voltage ranges from 0 8 Vdc to 0 600 Vdc and current outputs from 1 7A to 125A e 115 230 Vac selectable input voltage 50 60 Hz single phase Installation Category For Indoor Use e Simultaneous digital display of both voltage and current e turn potentiometer voltage and current controls permit high resolution setting of the output voltage and current from zero to the rated output e Automatic mode crossover into current or voltage mode e Flexible output configuration multiple units can be connected in parallel or series to provide increased current or voltage e High frequency switching technology allows high power density providing increased power output in a small light package e Remote sensing to compensate for losses in power leads e Adjustable Over Voltage Protection OVP e External TTL AC or DC shutdown e Remote voltage resistive current limit and OVP programming with selectable programming constants 1 1 FEATURES and SPECIFICATIO
66. y an E after the model designator e g DCS 40 25E would indicate that the model is certified when configured for 230 VAC input only Since the goal of the Low Voltage Directive is to ensure the safety of the equipment operator universal graphic symbols see below have been used both on the unit itself and in this manual to warn the operator of potentially hazardous situations TABLE OF CONTENTS SECTION 1 FEATURES AND SPECTFICATIONS cssssssssssssscsssscsssssssscccssssssssccssssssssssssssssssssssssssssssssssssses 1 1 T AIDES GRIR TION saen erns a vec opes coca REOS a 1 1 T27OPER ATING MODBES tuper owed vetera er viret Rd OE RS 1 1 1 3 POWER SUPPLY EEATURES t D E NP e MS E 1 1 1644S PECIEICA TIONS 2 e dont estet oe ed nean SRM ess 1 2 T4 LElectrical Specifications ie d Ee ee e Ee e EE RU E ERES 1 2 142 Mechanical Specifications t e HR ER teats ERE ERR SRI ERU ER 1 3 SECTION 2 INSTALLATION AND OPERATING INSTRUCTIONS eese ee eee ee eee enne oues eese e sensa oe esee 2 1 22 GIENERATS Est RASEN SR Ay tate tt cone pana tae Me Lun ELI Lens 2 1 2 2 INITTAT INSPECTION erster E 2 1 PAE M INSTAEBATION tette Te aie e e ute Ae Ea Vibes aeos eii SSA NGS SLL BETTE Ge T A 2 1 2 341 Input Voltage Selection i ied d Ff E s 2 1 2 3 2 Input Line Impedan e i uis t UU BEER DR B HUE 2 2

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