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Sorensen DCR-B 10-80B Instruction Manual

1000-watt power supplies
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Sorensen
SORENSEN
Division of Elgar
9250 Brown Dee
San Diego, CA
1-800-525-20
Tel: (858)
Fax: (85
Email:
©1986 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.
June 1986
DCR-B SERIES
1000-Watt
Power Supplies
Instruction Man
Manual Covers
80-12B
150-6B
300-3B
600-1.5B
Document No. 588734 Rev E

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Summary of Contents for Sorensen DCR-B 10-80B

  • Page 1 ©1986 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. June 1986...
  • Page 2 Buyer returns the defective product in the original, 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;...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Page INTRODUCTION SECTION 1 INTRODUCTION .. . • • . • ..• ..• . . • ..• ... DESCRIPTION . . · ........General ..•........1.2.1 Automatic Crossover ......1.2.2 Remote Sensin g ......
  • Page 4 TABLE OF CONTENTS (Cont'd) OPERATION SECTION 3 Pag e CURRENT MODE OPERATION ••.•••••••••••••••.•••••••• 3- 8 Resistance Programming ••••••••••••••••••••••• 3- 9 3.3.1 Signal . P rogramming ......3-10 3.3.2 Alternate Current Programming Method ••••••••...
  • Page 5 TABLE OF CONTENTS (Cont'd) Page SECT ION 5 MAINTENANCE 5. 1 GENERAL ..........PERIODIC SERVICING ....•...•... 5. 2 TROUBLESHOOTING ........CALIBRATION ..........5.4.1 Current Mode Section, Limit Settings ••••.•.••. 5- 3 PERFORMANCE TESTING ••.••••••...•..•...••••.•• 5.5.1 Voltage Mode Regulation and Rip ple....
  • Page 6 LIST OF ILLUSTRATIONS Title Figure Page DCR-B Controls and Indicators ••••..••..•••••.•••.••.•••••••. 3- 3 Control PCB Barrier Strip Connections ••..•.•• .••••••••..•. Remote Sensing Connections ........3- 6 Illustration of Load Lead Resistance (Remote Sensing) ••••••.• 3- 4 3- 7 Voltage Mode Programming Connections •.••••••••••...
  • Page 7 LIST OF TABLES Table Title Page S p ecifications ..........Front Panel Controls and Indicators •••..••..••..

  • Page 8: Introduction

    . The system output is taken ac· r oss a terminal pair at rear terminal strip TB2. A variety of Sorensen power supply application notes are available through your Sorensen Service Representative. These notes detail many hook-up configurations and special usages available to meet most power supply applications.

  • Page 9: Remote Sensing

    rent mode, the voltage varies, and current is held constant. The automatic crossover feature enables the unit to switch operating modes as a function of load requirement s. If, for example, load current attempts to increase above a preset current limit, the unit will switch operation automatically from the voltage to the current mode.

  • Page 10: Optional Modifications

    components are protected by the unit circuil break er . Control circuitry is pro­ tected by a fuse on the rear. In the event of an overvoltage condition at the output, such as a failure in the power supply or an externally induced condition, an overvoltage electronic crow­ bar is actuated by an integral OVP sensing circuit.
  • Page 11 Table 1-1 Specific,,tions INPUT POWER Constant Constanl OUTPUT OUTPUT POWER Voltage Current Voltage Current IMPEDANCE Ripple n:MPCO RWOTE SIGNAL Ripple Range Po'W'er (T yp ical) PROGRAMMI NG (Volt In/ Efficiency (Vac) Voltage Current (Ade) (PARD) (PARD) (Aac) Factor 120Hz !kHz lOkHz Model (Vdc)

  • Page 12: Installation

    If it is determined that the unit is damaged, the carrier should be notified immediately. Repair problems should be directed to the nearest Sorensen representative, or to the factory. INITIAL INSPECTION 2. 2 Proceed as follows to inspect for damage incurred during shipment: Inspect panel and chassis for scratches, dents and chips.

  • Page 13: Electrical Check

    CAUTION During installation, if two or more supplies are to be rack mounted or otherwise stacked, the operating ambient of the· upper units should not exceed 71 C/160 Output current must ° ° be derated according to specifications for am­ bients above 40 °...

  • Page 14: Operation

    SECTION 3 OPERATION GENERAL This section provides basic operating instructions, and details the methods by which DCR-B power supplies may be adapted to their more common applications including remote sensing, remote programming, and series and parallel operation. Table identifies the operating controls shown in Figure and describes 3-1, their functions.

  • Page 15: Front Panel Controls And Indicators •••..••....••.... •.•.•..••

    Table 3-1 Front Panel Controls and Indicators CONTROL/INDICATOR FUNCTION POWER switch A 125-volt, 50 ampere circuit breaker used to (CBl) connect disconnect input line voltage. POWER indicator A white light connected across the primary of (DS1) input transformer T2. Illuminates when the unit POWER switch is...

  • Page 16: Control Pcb Barrier Strip Connections

    Sink 1 mA to Regulator Common. - - --- - - - - - Remote Shutdown: Internal Current Shunt, Positive. -- -- - - -- - - - - - - - -- - - } Approx. 0.4V for ® rated output.

  • Page 17: Voltage Mode Operation

    VOLTAGE MODE OPERATION Local Sensing 3.2.1 OCR-B series units are shipped ready for use in the local sensing configuration, that is, with unit regulation occurring at the output terminals. Local sensing is usually acceptable for applications where the load current is nearly constant (or when large output conductors are used).
  • Page 18 For this reason, it is recommended that remote sensing be a voided, or damage. that the external line drop not exceed 1 volt per load line on the 150 to 600 Vdc models. Note that a heavy pulse load can act the same as a momentary load short, and may damage the amplifier under remote sense conditions.

  • Page 19: Resistance Pro G Rammin G

    + SENSE .01 sn - --- -----;•A + OUT WIRE RESISTANCE .,,,..-- -, .15V LOST LOAD = 10A OUTP UT ___ _ .,,,, DCR-B R = Sn 50.3V VOL TS A TO B = 50 .__,. 10A / .01sn ___ .,,,, -OUT WIRE RESISTANCE .15V LOST...

  • Page 20: Voltage Mode Programming Connections

    abrupt changes in programming resistance, make before break switching should be used. Figure 3-5 Voltage Mode Programming Connections unit to resistance programming operation, proceed as follows: To adapt Set unit power to OFF. Remove link between terminals 5 and 6, and connect a programming re­ sistor between terminals 4 and 5 (Figure 3-5).

  • Page 21: Si G Nal Pro G Rammin G

    NOTE Panel controls are disabled when unit is con­ nected in this way. Signal Programming Voltage Mode 3.2.4 A fixed or variable voltage signal may be fed into the voltage mode amplifier circuit to provide a fixed or variable voltage output. The selected signal source output should be floating, unless the positive output of the supply is grounded.

  • Page 23: Alternate Current Programming Method

    CAUTION If resistance programming is to be discontinued, set POWER switch to OFF, remove programming device, and reconnect link between terminals 7 and 8. 3.3.2 Signal Programming Current Mode The procedure for adapting a DCR-B unit to current mode signal programming is identical to that for current mode resistance programming except that the signal source, ( 488 OAP or equivalent) rather than a programming resistor, is connected across terminals 8 and 9.

  • Page 24: Dcr-B Interconnections ( Current Programming) •••••••.•••.••

    488 OAP CONTROLLER OR EQUIVALENT + OUT - OUT 3900 SIGNAL SOURCE DCR-B (488 OAP OR EQUIVALENT) 1000 RI = 3900 , l /4W, 2%, I 00 PPM R2 = 00 0 , /2W, TR MP0T, CERMET, 00 _PPM OR BETTER CRJ = JN6263 SCHOTTKY DIODE figure 3-7 DCR-B Interconnections (Current Programming) Calibration Procedure...

  • Page 25: Parallel Operation

    Reconnect the signal source connections removed in step 7. Turn the signal source and the DCR-B power ON. Set the signal source for 400 mV output. Vary the signal source output slightly until the rated full scale de out­ put current of the DCR-B is obtained. (e.g. , DCR40-25B may require 385 mV for 40A output).

  • Page 26: Master/ Slave Paralleling

    will be supplied by the second unit up to its current limit setting. Regulation, therefore, will be the sum of the regulations of the units plus the difference in the voltage settings. UNIT 2 UNIT 1 LOAD For remote sensing, connect both unit + and - terminals directly to the load instead of output terminal board.

  • Page 27: Series Operation

    Set master unit POWER switch to ON, and then set the slave unit POW­ ER switch to on. Adjust control R53 (on Control PCB) to balance the output currents be­ tween the paralleled units. Note that the units should be ad j usted for equal output currents using the heaviest load (i.e.
  • Page 28 With no load connected, set each unit to its desired output voltage level, and appropriate current limiting value. Set the POWER switch of each unit to OFF. Interconnect units as shown in Figure 3-10. CAUTION Rectifiers (and heat sinks where required) must be c onnected across the output terminals of each unit as shown in the figure.

  • Page 29: Master/ Slave Connections

    Master/Slave Connectio_ n s (Figure 3-11) 3.5.2 The voltage range of a DCR-B power supply system can be increased by series -connecting units . up to a total rated output of 200 Vdc (150/300/600 volt models, two in series) in a master/slave configuration. Two 40 volt supplies thus connected provide volt range capability with voltage programming neces­...

  • Page 30: Ra/Rb Values--Two Identical Dcr-B Units Series Connected

    145K 295K *For 10 volt units, terminal 3 of the slave unit is connected directly to the plus sense terminal of the master unit. Table 3-3 Recommended Rectifiers, Series Operation Sorensen Heats inkid; Model Mfr.-Tiee Part No. Dim. Inches (mm)

  • Page 31: Unit Shutdown Circuit

    With POWER switches OFF, connect each unit to an appropriate input power source (115/208/220/230 Vac). All units in the system can be connected through common ac line OFF /ON switch. Proceed as follows: Set the COARSE and FINE CURRENT controls of each unit fully clock­ wise.
  • Page 32 Adjust R3 slowly counterclockwise until the OVP trips. Leave R3 in this position. Set unit power to OFF, and turn front panel voltage control counter­ clockwise away from the trip point. Apply unit power and adjust the supply output voltage to the desired operating level.

  • Page 33: Theory Of Operation

    SECTION 4 THEORY OF OPERATION 4 .1 INTRODUCTION This section provides a basic discussion of unit operating principles, which may be used in conjunction with the troubleshooting chart provided in Section 5, to enable the . l ogical and . rapid isolation of unit faults. A brief description of the phase control principle is given first, followed by a block diagram analysis of ·...

  • Page 34: Dcr-B Functional Block Diagram

    r--------------- ------------------ ----- 7 +l6V VARIABLE REFERENCE r--+-1 -6. 2V REFERENCE SUPPLY •12.4V I C3 I CI /QI ( ETC. ) -I 6V RESET RAMP C. V. ERROR eIRCUIT GEN ERATOR AMPLI Fl ER Q3/Rl3 R l5/C6 I C2 C. V. MODE TURN-ON I NOi CA TOR CIRCUIT...

  • Page 35: Block Diagram Analysis

    BLOCK DIAGRAM ANALYSIS (Figure 4-2) The ac input voltage is first applied to CR7 (SCR), which is in series with power transformer Tl. CR7 functions with the control circuits to form a feedback loop which prevents a change in output voltage when either the line or load changes. To accomplish this, the control circuits issue a phase adjusted firing pulse to CR7 once during each half cycle of the input ac voltage.
  • Page 36 ABSORBED INPUT VOLTAGE VOLTAGE ---� � -�--, ,-�-�- PASSING STAGE ---, CONTROL Figure 4-3 Passing Stage Principle To illustrate circuit operation, assume an increase in the T2 (Figure 6-4) supply output. Pin 2 of ICl will become more negative, and the output at pin 6 more positive, tending to turn Ql off.

  • Page 37: Current· L\1Ode Section

    Pin 4 of IC2 is at virtual de ground since pin The main error amplifier is IC2. 5 is at ground (+sense). Thus the current through R25 can be varied from 0 to 1 milliampere. This current, through R26, programs the supply to the desired output.

  • Page 38: Blocking Oscillator Q2

    The comparator consists of Q4/Q5, CRl0, R16, and· Rl 7. Comparator Q4/ Q5 com­ pares the de signal from either the voltage or current mode amplifier (applied to Q5) with the ramp generator voltage. The varying output of Q4 (across R17) establishes the conduction angle of blocking oscillator Q2.

  • Page 39: Indicator Lamps

    A reference voltage (+12V) is generated by zener CR3 and R4. This reference voltage is compared to the output voltage in a bridge circuit, by the ratio of Rl to R2 plus R3 (adjust pot). The bridge output is applied to ICl, pins 3 and 4. Assume that the resistor ratio is set (by adjust pot R3) to produce a balanced bridge at a specified output voltage.

  • Page 40: Maintenance

    In addition, Figures 6-2 and 6-3 physically locate the components referred to in the text. Any questions per­ taining to repair should be directed to the nearest Sorensen representative* or to the factory. Include the model and serial numbers in any correspondence.

  • Page 41: Current Mode Section, Limit Settings

    Current Mode Section, Limit Settings 5.4.1 Set unit POWER switch to OFF. Short output terminals and set CUR­ RENT control to 100% and VOLTAGE control to 50%. Set potentiometer R54 on the PCB to about 20% rotation. Set POWER switch to ON and adjust R54 to the limit stated in specifications Table 5-3, upper limit set point.

  • Page 42: Performance Testing

    OSCILLOSCOPE DC OUTPUT VOLTAGE OUTPUT ::, Ill CURRENT ::z:: a: Figure Performance Test Setup 5. 5 PERFORMANCE TESTING Sensitive instruments like the DCR-B require rigorous testing methods if a true performance evaluation is to be made. Wherever possible, twisted leads should be used with test equipment to reduce stray pickup.

  • Page 43: Current Mode Regulation

    Use an autotransformer with a current rating that exceeds the maximum unit input current called out in the unit specifications. NOTE Input devices such as autotransformers or line regulators can distort the input wave suffi­ ciently to adversely affect performance measure­ ments.

  • Page 44: Hi-Pot Test Procedure

    Set unit POWER switch to ON. Adjust COARSE VOLT AGE control for rated output, and COARSE CURRENT control fully clockwise. Apply half load, and then abruptly apply full load ( or switch from full load to half load). Return to steady state operation should occur with­ in 50 milliseconds (typical).
  • Page 45 1f it is essential to use the high potential test method, please contact the factory for information on special precautions that should be taken. CAUTION Sorensen cannot be held liable for any malfunctions resulting from the application of a high potential test {greater than 1 00V). See Sorensen Warranty.
  • Page 47 !'"ROM �� OUTPUT flLT(R ------------------ - --, TO Ti jcOMPARATORI (!11uP G£N [PULSE GEnl �2i "" "° ., . "" ' .015 56()() '"" cu .. r - - !'"ROM CKT 8RKR --td.--1 -€.21/ ..' • �----V « -------a3-e NOTE$: -12,41/�...
  • Page 48 Table 6-1 Replaceable Parts List DCR-B PCB Assembly Circu- i t CirCuit ' P'srt Nulllber Descrlpt'ton Symbol Sorensen SymbOI DesCription Circuit Sorensen ·-sorensen sYriibol Resistors (ohms, 1/2 watt !10% unte;;s noted) Part Nun1bcr Description Part Humber Diodes Capaclton unless noted>...
  • Page 49 sue ..ssv Pt-! see,1·1',-9 REv _/_ 58G955-I RE.Y R ASSY PtJSB8176-_R Ev _ /_ Figure 6-2 PCB Component Location Diagram Rev C (5/85)

  • Page 50: Component Layout, Typical Assembly

    � � '-."C ,,.. '-"C ,,.. ,,.. l()c :::, a::::, ..� � �- � ..l­ Figure 6-3 Component Layout, Typical Assembly Rev C (5/85}...
  • Page 51 P.3-l ---- £1; DC R "S" P.C.S. '- - ----- - -- ------------------� ��--J P2·4 \OOAt,,tP S�Ut-lT 12.-SW Cl'-9 IH.4'5,87 zoov ''°' ., .., r ,;t.l. "'' �I 15'1 S££ FIG. R� + C5 + C7 :,OW ,,o,ooo 600VDC -.:- (-)I L...J 1,-cc...

  • Page 52: Dcr 20-50B Schematic Diagram

    � � 6 5 1 6 � · � · , 1 1 , I.SK T� - (t)ouf (•)OUT P 2 - 7 ---- P.!1-1 P4-,i; � , r •l >< .sG ' 1s e P 3 · 4 <· '<'-'--"-----------�...

  • Page 53: Dcr 40-25B Schematic Diagram

    /.SI< ��5 PN HT, "'tL .,J;: l " . ----------- P�-7 ____,,, ___,v.: _ P3• \ -Jh" ·so SC!-11.M'"-"TIC G,,:50 '=:ti DCR''B'" P.C.B. L__ _________ ______ ______ __ __ E.·588300 P Z - 3 P2· 4 2'/lo A. - - - -- - i#JPI..Jr ?OWt: .
  • Page 54 - - � L � ' '" - - - � - - '"' � <5 �� ' " O� � r< - J ,. , :.__ • (•1; , � r (-i} o u r >- {v ) '( _l: , £...

  • Page 55: Dcr 80-12B Schematic Diagram

    I.SK � l � D ' 11 � "' ,o w C•)c� (T:� 2-7 . - - - · 8 1 P.3•\ )P4-2 P•·• � JS-I � � P4-4 , ; : , c J S - 2 • I :� �- �5-3)\ :-2 �...
  • Page 57 51 6 ::� � 1� - _£_ ;,> ------6 £� _ _ e,i; "N o;-, (f-)01..1..- ( - )ovr -- 7 <!SD" <+) r-1· 1 ,, . 1�:dMe, (\- ;-,�,E I CR2 ��l it .. ! - � � ---- --- ---- P3-4 g�...
  • Page 58 /.SK� - - -=l9 r-=('_r,;��Q-�-�--� C � "t () _r - � l �)(+ > (:-, :i � ,-�, , ';-_ ';- "7" ' " (• lo•< ( - k) o v, ------ ,,_... P4•8 ,,_, ,)I.?_ P3-G. P4·3 f'4·1 P.3-1 P4·...
  • Page 59 Table 6-2 Replaceable Parts List DCR-B Main Assembly, lOOOWa tt Series v,.;¾��¼��r DCR-B Model Sorensen Circuit Part No. Descr iption Symbol Capacitors ( uF unle ss note d) ·x ·x ·24-'-2110-13 0 .1, 600V x · 24-2110-7 0.01, 600V 587193-3...
  • Page 60 Table 6-2 ( Cont'd) Replaceable Parts List DCR-B Main Assembly, 1000 Watt Series DCR-B Model /4¼ ¾¾ �� ¼¼ 1/I Sorensen Circuit cs���� :§#/ Description Part No. Symbol Capacitors (Cont'd) 587626-67 0.22, 250V Not Used 24-2110-13 0.1, 600V Not Used 24-2110-13 0.1, 600V...
  • Page 61 Table 6-2 (Cont'd) DCR-B Model li/4¾¾¾�½¼7/ Sorensen Circuit c!,����11'1 Part No. Description Symbol Diodes (Cont'd) Not Used CR15 587566-5 3Sl8 Not Used CR16 587566-5 3S18 Lamps 43-357 Voltage 1058485-1 Current Power 1058485-1 Fuse 42-1203 115V, 0.2A, SB 42-459 Fuseholder Filter Choke...
  • Page 64 Table 6-2 (Cout'd) Replaceable Parts List DCR'"".B Main Assembly, 1000 Watt Series &/ t!J ! �� �;i l ::! / DCR-B Model Sorensen Circuit / 15/ �2 Description Part No. Symbol �f?�/g�:f!�Q Panel, Front {Cont'd) 588618-6 588618-7 588617-8 *For 208/220/230V: (Ml/M2/M3...

  • Page 65: Ovp Pcb Schematic And Component Location

    R 3 � C589308-l REV F ---, ,so,, CR. .3 IM52.428 --n----G_RA __ Y __ ou-r n .. .--------------------.----- ______ E ..;_ - 7. Ce. <,, CS l!f (_ P,·' • { ,J� TA 11i.. E 2SO- "I 2. <.,-j) I O T 1 •...
  • Page 66 Table 6-3 Replaceable Parts List DCR-B OVP l� fa� ,/4/4 ftft 1 I OVP Model Sorense n C ircuit Part No. Description S ymbol Capacitors ( uF unless noted) 24-2015-13 0.1, 250V 24-2037-15 0.47m, 100V 586048-1 150, 50V Diodes 587565-2 587565-2 588101-15 1N5242B...

  • Page 67: Dcr-B Outline Drawing

    SENSE SEE OETAIL "'A"' #10Tllru 15 sir. wire OETAILB CURRENT RESISTANCE PROO PROO VOLTAGE PROO REAR P.S. SHUTOOWN SEE OETAIL "B'' FOR OCR10·80B Same as AC Input ETAIL "C" FOR OCR20-SOB terminal board OETAILA #12 lllru W I TH COVERS REMOVEO REFER TO MANUAL F OR COMPLETE OET, A ILS 118 sir.

This manual is also suitable for:

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