USER MANUAL - Schulz Electronic GmbH
Contents
1. a INTERLOCK Pin 3 the Interlock must be grounded via Pins 4 9 or 15 in order for the output to deliver current b PULSE CONTROL Pin 8 the PULSE CONTROL pin must be a TTL HIGH in order for the output to deliver current The PULSE CONTROL function is used when the user wants to pulse the output Because the default for PULSE CONTROL is TTL LOW OFF for CW operation the PULSE CONTROL must be set to a TTL high Refer to Section 7 for more information on pulsing c ENABLE Pin 1 the ENABLE signal is a 5V to 24V signal used to turn the output section on The ENABLE circuitry incorporates a soft start function which ensures rise times of approximately 15 to 20msec Tek Run CH 1 Tout 20A div 4 H i Chi Rise 17 37ms CH 2 ENABLE Pee Aha Se aCe AL CE ER 12 40 Response of Iout to ENABLE signal 11 Apr 2006 09 02 03 d Iprogram Pin7 A 0 10V signal results in 0 to Ioutmax as long as the rated compliance voltage of the driver is not exceeded 4 Operating the LDD a AC INPUT POWER CONNECTION Connect AC power connections to power supply input power terminals as follows refer to Figure 3 e Neutral wire 16AWG connected to the right contact of the AC input terminal labeled N e Line wire 16AWG connected to the left contact of the AC terminal block e Ground wire shall be crimped to a 8 ring lug and connected to the ground stud IMPORTANT APPLICATON NOTE REGARING AC INPUT POWER AC Input wir2. INTERLOCK 3 RUN Connect to GND Interlock OK GND A Pulse Control TTL S es GND 4 om 9 0 to 10V D lout mox _PROGRAM_ 7 OVERTEMP_WARNING PULSE V_MONITOR_OUT _MONITOR_OUT CROWBAR_STATUS 5V 15V 15V 15V GND Figure 2 LDY Interface lout Monitor LM324M 1K 1K TTL High Temp Warning 11 10K Default Laser Diode OFF PULSE OFF 0 PULSE ON TTL HIGH Default is OFF No output unless Pin amp is TTL High one Internal Programmable Current Limit All Open lout Max 110 All Closed lout Max 56 0 to 10V 0 Vout max 0 to 10V 0 lout max 5V CROWBAR OUTPUT SHORTED 5V 15V 15V 0 5A max output 10 OUTPUT_CROWBAR_STATUS 0 5A max output 13 0 54 max output 14 15 GND INSTALLATION AND OPERATION OF LDY Diode Drivers IMPORTANT INSTALLATION NOTES e LDY diode drivers are air cooled by internal fans Do not restrict air flow near the input or output air vents of the power supply If the unit overheats due to restricted air flow it will shut down and remain off until the unit has cooled to a safe operating temperature e LDY units should be mounted in systems using 8 32 or M4 bolts to secure the mounting flanges to mounting plate SAFETY WARNING Because LDY units are designed for OEM applications the user must connect AC input power to the power supply Any input AC voltage must be considered
3. ZVS Inverter The ZVS inverter and the output transformer are used to step the 400VDC bus down to the appropriate output value The ZVS inverter is the most modern high frequency low loss low noise topology utilized in power electronics today Instead of running the inverter in a traditional PWM mode the inverter is run in a phase shift mode With the appropriate output inductor and the appropriate capacitance across each switching device in this case MOSFETS there are virtually no switching losses in the inverter The only losses in the devices are I R losses associated with the Drain Source resistance of the MOSFETS Therefore the ZVS inverter also contributes to reduced losses reduce EMI noise and a reduction in overall system heatsink requirements Output Circuit The output filter is a two stage RC filter designed to keep ripple and output noise very low For lower power units such as the LDY 250 a single stage filter is used Control Circuit The control circuit handles all the responsibilities associated with safe operation of the laser diode Controlled rise and fall times as well as tight current regulation overvoltage and over power protection are controlled and monitored in the control circuit Auxiliary Power All internal power supply requirements as well as the external 15V and 5V power supplies are derived from the power factor control boost inductor All auxiliary power supplies are regulated by standard linear reg
4. Temp When temperature of main heat sink exceeds 65 Deg C Pin 11 the TTL Low Temp OK Over Temp Warning will go to a TTL High to indicate unit is in 11 a danger of shutting down due to over temperature condition When temperature of main heat sink exceeds 75 Deg C unit will shut down 15V 0 5A Auxiliary 15V power supply for user Up to 0 5A output current output available 13 14 15V 0 5A Auxiliary 15V power supply for user Up to 0 5A output current output available 4 9 15 GND Interface return TABLE 1 LDY Interface Schulz W Electronic Professional Power Supplies FIGURE 1 LDY Laser Diode Power Supply Soft Switching SEN Power Factor Correction Zero Voltage Switching Boost Inverter Inverter Output AC Input Power 400VDC geg ne 200kHz Output Filter Crowbar 7x Input Mee Line Out AC Filter 5 Out Boost Ipfe Vpte Drive Sense Sense Control 7 Aux Power Input ss Gate Drive Isense Auxiliary Control Ckt coe Crowbor Power Supplies PFC Control ENABLE DC out INTLCK User Interface IPROGRAM gt IMON VMON gt GND gt 15V gt 15V a AEN OUT ser PART HBV Iprog O 10V has Imon O 10V INTERNAL_PS_ENABLE Vmon 0 10V if Voutmax gt 10V 100k tox 11K Vmon 0 Vout if Voutmax lt 10V Enable 5V to 15V 2N3904 Vmon Vout if Voutmax lt 10V ENABLE 1 2N3904 Enable 5V to 15V
5. The power supply is likely to shut down if the cause of the warning is not addressed Current Limit Dip Switches A bank of 4 DIP switches is provided to limit the output current to 16 settings between 110 and 56 of maximum output This is a useful feature in the event the diode driver is to be used for multiple applications with some applications requiring less than the maximum rated current of the LDY LDY power supplies utilize a proprietary low loss high frequency power factor correction circuit which keeps power factor above 0 98 Power factor corrected power supplies use up to 30 less input current and meet stringent IEC harmonic requirements The output inverter is a state of the art zero voltage switching ZVS inverter which permits very high frequency power conversion with minimum losses and electromagnetic noise LDY Diode Drivers Theory of Operation Refer to Figure 1 The LDY laser diode drivers were designed specifically for the OEM high power CW laser diode systems OEM power supplies for the laser diode industry have the following requirements Safe laser diode operation Broad range of control of output current Safe rise fall times Small size Power factor correction to conform with CE requirements Low conducted electromagnetic emissions Low leakage for medical applications Referring to the LDY Laser Diode Power Supply block diagram the following is a brief description of operation AC Input Power Circ
6. Class A Emissions EN55011 1998 Group 1 Class A Emissions EN61000 3 2 Limits for harmonic current emissions EN 610000303 Flicker EN60601 1 2 2001 Electromagnetic emissions and immunity for medical equipment LDY 600 1000 1500 I nterface Connector Type 15 pin D sub Female Refer to Figure 2 LDY Interface Schematic Pin LDY Pin Name Functional Voltage Level Description High RUN 5V to 15V The Enable function turns the output section of the power supply ON Low OFF OV and OFF When the power supply is enabled current is delivered to Enable load as programmed via Iprogram Pin 7 if the Pulse Control 1 input Pin 8 is High and the Interlock pin 3 is connected to interface GND Rise times resulting from Enable are approximately 25msec For pulsing the Enable function should be set to ON and the Pulsing Control Pin 8 should be used The Crowbar Status reports the status of the shorting crowbar clamp across the output The crowbar will short the output under two conditions 1 When the output is not ENABLED via Pin 1 or 2 if the output is ENABLED via pin 1 but the control circuitry has detected a no load condition or a voltage requirement on the output that exceeds the maximum voltage rating of the unit A TTL 5V signal on Pin 2 reports that the crowbar is shorting the output To turn the crowbar off an appropriate load must be connected to the LDD and the output must be turned off and on via Pin 1 ENABLE The
7. IP switch settings and resulting output current OFF For example if an LDY is configured for a maximum output current rating of 60A and the user would like to limit the maximum output current in a particular application to 37A the DIP switch array should be set as follows st s ss a marout This will limit the current to 68 of 60A which is 40 8A When the unit is programmed with a 0 10V signal the output will follow the program until the program voltage reaches 6 8V at which point the output current will not rise any further Units are shipped with all switches in the OFF position which results in the ability to program the unit to 110 of its maximum rated output current 7 PULSED OPERATION The LDY family of CW drivers are intended for CW applications However due the fast response achievable with very high frequency switchmode power supplies it is possible to pulse diode lasers at sub QCW speeds The typical rise and fall times of the LDY units are between 800usec and Imsec Therefore a rep rate of 200Hz to 400Hz is possible Pulsing can be accomplished via the PULSE CONTROL function on Pin 8 A TTL HIGH must be applied to pulse the output on The user may configure the pulse train as desired Typical performance is shown below Typical LDY Rise Fall Time CH 1 Tout 20A div Ch1 Rise A 600 24s i 1 Ch1 Fall 972 0us CH2 ENABLE 4 4 4 20 20 08 31 00 S It is possible to configu
8. Interlock function must be connected to GND in order for output 3 EES Sg RUN current to be delivered It can beused for external interlock functions H such as door or overtemp switches Crowbar Status High Crowbar ON 5V output Low Crowbar OFF DN The output voltage of the supply can be monitored by Vout Monitor Vout Monitor 0 10V 0 Voutmax For LDY s with a maximum rated output voltage less than 10V Vout output Monitor Vout For output voltages greater than or equal to 10V 0 10V 0 Voutmax geg Monitor The output current of the supply can be monitored by lout Monitor put en The power supply output current is set by applying a 0 10V analog input 0 10V 0 loutmax signal to Iprogram The output may be pulsed by applying a TTL signal to Pulse Control pin 8 The amplitude of the output current pulse is determined by the voltage programmed via Pin 7 Iprogram Rise fall times of lt imsec are typical Rise fall times of 500usec can be achieved with 8 Pulse Control Le ge SH special order When using the LDY as a CW diode driver pin 8 input Default Off the Pulse Control must be set to TTL High in order for output current to be delivered Pin 10 5V would be a convenient connection point for this No output current will be delivered with pin 8 left unconnected 10 5V 0 5A Auxiliary 5V power supply for user Up to 0 5A output current output capability TTL High High
9. Monitor A 0 10V signal will represent the output voltage from 0 maximum rated output voltage c Crowbar Status The status of the output crowbar circuit can be monitored on Pin 2 the Crowbar Status The crowbar will short the output under two circumstances i The ENABLE is OFF or ii The power supply has detected an open circuit In this case it is probable that no load has been connected to the power supply OR the load exceeds the maximum rated compliance voltage of the device In this case it is required to clear the Crowbar fault by turning the ENABLE off connecting a proper load and reapplying the ENABLE signal d Over Temp Warning The Over Temp Warning signal monitors internal heat sink temperature and warns the user of an impending power supply shutdown This switch is a 65DegC switch When the internal heat sink temperature reaches 65 Deg C a TTL High will be transmitted When the internal heat sink temperature reaches 75Deg C the unit will shut down 6 Programmable Current Limit DIP Switches The LDY includes an internal DIP switch array which may be set to limit the maximum current This is useful when an OEM customer would like to use a single model for a variety of systems but has a laser diode system which does not require the maximum output current In this type of situation it is important to protect the laser diode from an over program error which could damage the laser diode The following table shows the various D
10. Wy A Gmina Power INC IN USER MANUAL LDY CW Diode Driver Power Supplies The LDY family of CW diode laser drivers is Lumina Power s second generation of high power laser diode drivers As a laser diode driver the LDY power supply acts as a programmable current source and delivers constant current based on the input program signal Iprogram which is normally 0 10V All units are configured with a maximum current and maximum voltage capability depending on the user s requirements LDY power supplies will deliver current as programmed into any load providing the voltage requirements of that load do not exceed the maximum rated voltage of the unit When the required compliance voltage is higher then the maximum rated output voltage of the unit the unit will limit output current Schulz W Electronic Professional Power Supplies The new LDY family includes the following additional features Pulse Control The user can pulse the output of the LDY via a TTL Signal Previously all analog control of the output had to be controlled via the Iprogram signal The Pulse Control signal simplifies pulsing of the output Crowbar A high power transistor removes energy from the output of the power supply whenever the output is off A Crowbar Monitor signal is provided to monitor the status of the Crowbar Temperature Warning A TTL signal warns the user that an over temperature condition has developed in the power supply circuitry
11. es should be at least 16 AWG rated for at least 300V and 105DegC IMPORTANT SYSTEM NOTE ON AC INPUT POWER LDY units are fused on both input lines It does not matter which of the two AC inputs are designated Line or Neutral AC input power requirements for LDY models are as follows Table 2 LDY AC Input Power Requirements b INTERFACE SETTINGS Make sure INTERLOCK Pin 3 is connected to GND and PULSE CONTROL Pin 8 is set to TTL HIGH c APPLY INPUT AC POWER Turn ON AC power After a few seconds the power supply fans should begin to run d PROGRAMMING OUTPUT CURRENT Program LDY power supply for desired output current A 0 10V signal applied to Iprogram Pin 7 will program the LDY diode driver for 0 to maximum rated output current IMPORTANT APPLICATION NOTE When the power supply is enabled using the ENABLE signal internal soft start functions limit the rise time of the output current to approximately 20msec Once the power supply is enabled the rise fall time of the Iprogram signal is approximately 600usec e ENABLE OUTPUT Apply 5V to 15V to ENABLE Pin 1 The LDY will deliver output current as programmed 5 Monitoring LDD output and performance a Current Monitor Power supply output current can be monitored via pin 6 lout Monitor A 0 10V signal will represent the output current from 0 to maximum rated output current b Voltage Monitor Power supply output voltage can be monitored via pin 5 Vout
12. extremely dangerous and as such care must be taken to connect AC input power to the unit BS Terminals Stud Figure 3 Figure 5 LDY Input Connections LDY Output Connections 1 CONNECTING TO DIODE LASER Figure 5 shows the location of the LDY output terminals Connect diode laser load to the output terminals Although CW diode laser applications are generally free of voltage spikes associated with high speed Quasi CW applications it is still good practice to keep connections between the diode laser and power supply as short as possible to avoid I R losses in the wire 2 INTERFACE CONNECTION Connect user system to 15 pin D sub connector shown in Figure 4 Although the user interface is typically designed by the user Lumina Power can provide any assistance necessary to modify interface program and monitor levels See Table 1 and Figure 2 for description of LDY Interface and the associated simplified interface schematic IMPORTANT NOTE Make sure when connecting interface that the current program setting Iprogram is set no higher then the value required for operation When AC power is applied and system is Enabled output current will rise to this program value 3 INTERFACE INFORMATION BEFORE APPLYING AC POWER The unit may be programmed for output current via Pin 7 the Iprogram function But there are three interface control signals which must be properly set before the output will deliver current as programmed by Iprogram
13. re LDY s for rise and fall times up to 500usec which would permit pulsing up to 600Hz Consult the factory for faster rise fall times NOTE It is not possible to use Enable Pin 1 for pulsing since the ENABLE circuit includes a soft start is intended for turning on the power supply output slowly The Enable function controls several soft start features which do not permit pulsing NOTE For faster pulsing refer to the data sheet for Lumina Power s LDQCW power supplies These units have rise fall times of less than 25usec and can achieve output currents up to 200A These units can pulse at frequencies up to 5khz depending on the average power required 8 Servicing LDY Diode Drivers LDY units have no serviceable parts Do not attempt to repair or service this unit in the field For further information contact Lumina Power at 978 774 0179 Schulz W Electronic Professional Power Supplies
14. uitry AC input power is processed through a line filter to reduce the conducted EMI to an acceptable level The LDY line filter has minimum capacitance to ground to minimize leakage currents Earth Ground stud is provided near the AC input terminals and should be connected to the system ground Power Factor Correction Boost I nverter The rectified input power is next applied to power factor boost inverter This inverter boosts the input voltage to 400VDC In the process of boosting the input AC voltage the input AC current is adjusted so that is always in phase with the input AC voltage Without this power factor correction circuit the AC input current would be delivered to the power supply in high amplitude narrow spikes having a high harmonic content With power factor correction the non 50 60 Hz harmonics are reduced to near zero Since only the fundamental frequency is now used to deliver power the efficiency of the power supply is improved considerably One problem with standard input power factor correction circuits is that a high frequency switching circuit is placed across the line in the input side of the traditional input capacitor filter This results in substantial switching noise conducted to the line Lumina Power employs a proprietary soft switching boost inverter which produces minimum switching noise reduces switching losses and results in a smaller heat sink associated with the power factor circuit Zero Voltage Switching
15. ulators LDY 600 1000 1500 XX YY SPECIFICATIONS XX loutmax YY Voutmax XX YY cannot exceed Poutmax Model Pout pax Tout ax Input Voltage Size L x W x H LDY 600 XX YY 600W Can be configured 100 240VAC 9 9 x 7 2 x 2 5 k xX X Z LDY 1000 XX YY 1000W from 10A to 100A 100 240VAC 25 1 x 18 3 x 6 35 cm LDY 1500 XX YY 1500W 200 240VAC Auxiliary Outputs 5V 0 5A 15V 0 5A 15V 0 5A LDY 1500 input voltage 200 240VAC Maximum compliance voltage determined by maximum rated power RS 232 Option available Other outputs available upon request Input Voltage See table above Power Factor gt 98 Interface Connector 15 Pin D Sub Female Current Program Current Monitor Voltage Monitor 0 10V for 0 Max Current 0 10V for 0 Max Current 0 10V for 0 Max Voltage Performance Pulse Width Range 1 5msec to CW Rise Fall Time 600usec 10 to 90 Full Current Current Regulation 0 5 of Maximum output current Current Ripple lt 0 5 of maximum output current Current Overshoot Power Limit lt 1 of maximum output current Limited to maximum power with power fold back circuit Environment Operating Temp 0 to 40 C Storage 20 to 85 C Humidity 0 to 90 non condensing Cooling Forced air Regulatory Leakage Current lt 250uA Approvals Medical Safety UL60601 1 IEC 60601 1 EN 60601 1 CAN CSA C22 2 No 601 1 M90 Industrial Safety UL60950 Emissions Immunity FCC 47 CFR
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