Ametek Sorensen DCS-E Series Operation Manual
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Ametek Sorensen DCS-E Series Operation Manual

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DCS-E 1kW Series & DCS-E
1.2kW Series DC Power
DCS8-125E
DCS8-140E
DCS10-100E
DCS10-120E
DCS20-50E
DCS20-60E
M362500-01 Rev K
Supplies
Operation Manual
This manual covers models:
DCS33-33E
DCS60-18E
DCS33-36E
DCS60-20E
DCS40-25E
DCS80-13E
DCS40-30E
DCS80-15E
DCS50-20E
DCS100-10E
DCS50-24E
DCS100-12E
DCS150-7E
DCS150-8E
DCS300-3.5E
DCS300-4E
DCS600-1.7E
DCS600-2E
www.programmablepower.com

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Summary of Contents for Ametek Sorensen DCS-E Series

  • Page 1 DCS-E 1kW Series & DCS-E 1.2kW Series DC Power Supplies Operation Manual This manual covers models: DCS8-125E DCS33-33E DCS60-18E DCS150-7E DCS8-140E DCS33-36E DCS60-20E DCS150-8E DCS10-100E DCS40-25E DCS80-13E DCS300-3.5E DCS10-120E DCS40-30E DCS80-15E DCS300-4E DCS20-50E DCS50-20E DCS100-10E DCS600-1.7E DCS20-60E DCS50-24E DCS100-12E DCS600-2E M362500-01 Rev K www.programmablepower.com...
  • Page 5 About AMETEK AMETEK Programmable Power, Inc., a Division of AMETEK, Inc., is a global leader in the design and manufacture of precision, programmable power supplies for R&D, test and measurement, process control, power bus simulation and power conditioning applications across diverse industrial segments. From bench top supplies to rack-mounted industrial power subsystems, AMETEK Programmable Power is the proud manufacturer of Elgar, Sorensen, California Instruments and Power Ten brand power supplies.
  • Page 6 Contents Sorensen DCS Series 1kW and 1.2kW Supplies Email: sales.ppd@ametek.com service.ppd@ametek.com Web: www.programmablepower.com viii M362500-01 Rev K...
  • Page 7 Sorensen DCS Series 1kW and 1.2kW Supplies Contents Important Safety Instructions Before applying power to the system, verify that your product is configured properly for your particular application. SECTION 1 Hazardous voltages may be present when covers are removed. Qualified personnel must use extreme caution when servicing this equipment.
  • Page 8 Neither AMETEK Programmable Power Inc., San Diego, California, USA, nor any of the subsidiary sales organizations can accept any responsibility for personnel, material or inconsequential injury, loss or damage that results from improper use of the equipment and accessories.
  • Page 9 Sorensen DCS Series 1kW and 1.2kW Supplies Contents This page intentionally left blank. M362500-01 Rev K...
  • Page 10 AMETEK will, at its expense, deliver the repaired or replaced Product or parts to the Buyer. Any warranty of AMETEK will not apply if the Buyer is in default under the Purchase Order Agreement or where the Product or any part thereof: is damaged by misuse, accident, negligence or failure to maintain the same as •...
  • Page 11 Sorensen DCS Series 1kW and 1.2kW Supplies Contents This page intentionally left blank. M362500-01 Rev K xiii...

  • Page 12: Table Of Contents

    Contents Sorensen DCS Series 1kW and 1.2kW Supplies CONTENTS SECTION 1 FEATURES AND SPECIFICATIONS ........ 1-1 Description ....................... 1-1 Operating Modes ....................1-1 Power Supply Features ..................1-1 Specifications ....................1-3 1.4.1 Electrical Specifications for 1kW Models ........... 1-3 1.4.2 Electrical Specifications for 1.2kW Models ........
  • Page 13 Sorensen DCS Series 1kW and 1.2kW Supplies Contents Single Supply Operation (Local Mode) ............2-11 Multiple Supplies .................... 2-12 2.8.1 Series Operation ................2-12 2.8.2 Parallel Operation ................2-12 2.8.3 Split Supply Operation ..............2-13 Over Voltage Protection (OVP) ..............2-13 2.9.1 Front Panel OVP Operation .............
  • Page 14 Contents Sorensen DCS Series 1kW and 1.2kW Supplies SECTION 5 PARTS LISTS ..............5-1 General ......................5-1 Parts Ordering ....................5-1 Parts Lists ......................5-2 M362500-01 Rev K...
  • Page 15 Sorensen DCS Series 1kW and 1.2kW Supplies Contents LIST OF FIGURES Figure 2-1 DCS Series Power Supply ................2-4 Figure 2-2. Diode Connection ..................2-9 Figure 3-1 Simplified Full Bridge Converter ..............3-2 M362500-01 Rev K xvii...
  • Page 16 Contents Sorensen DCS Series 1kW and 1.2kW Supplies Figure 4-1 Trimpot Locations ..................4-4 xviii M362500-01 Rev K...
  • Page 17 Sorensen DCS Series 1kW and 1.2kW Supplies Contents LIST OF TABLES Table 2–1 Wire Size and Length .................. 2-8 Table 4–1 Troubleshooting Guide ................4-2 Table 5–1 DCS 1kW and 1.2kW Fuse Ratings ............5-2 Table 5–2 DCS 1kW Parts Lists by Model Number ............5-2 Table 5–3 DCS 1kW Parts Lists ...................

  • Page 19: Section 1 Features And Specifications

    SECTION 1 FEATURES AND SPECIFICATIONS Description DCS Series power supplies are 1000W and 1200W supplies designed to provide highly stable, continuously variable output voltage and current for a broad range of development, system, and burn-in applications. The DCS Series employs high frequency switching regulator technology to achieve high power density and small package size.
  • Page 20 Features and Specifications Sorensen DCS Series 1kW and 1.2kW Supplies Automatic mode crossover into current or voltage mode. • Ten turn potentiometer voltage and current controls permit high resolution setting of • the output voltage and current from zero to the rated output. Flexible output configuration: multiple units can be connected in parallel or series to •...

  • Page 21: Specifications

    Sorensen DCS Series 1kW and 1.2kW Supplies Features and Specifications Specifications 1.4.1 Electrical Specifications for 1kW Models Specifications are warranted over a temperature range of 0-50°C with default local sensing. From temperatures of 50-70°C, derate output 2% per °C. Models 8-125 10-100 20-50 33-33 40-25 50-20 60-18 80-13 100-10 150-7 300-3.5 600-1.7...

  • Page 22: Electrical Specifications For 1.2Kw Models

    Features and Specifications Sorensen DCS Series 1kW and 1.2kW Supplies 1.4.2 Electrical Specifications for 1.2kW Models Specifications are warranted over a temperature range of 0-50°C with default local sensing. From temperatures of 50-70°C, derate output 2% per °C. Models 8-140 10-120 20-60 33-36 40-30 50-24 60-20 80-15 100-12 150-8 300-4 600-2...

  • Page 23: Physical Specifications

    Sorensen DCS Series 1kW and 1.2kW Supplies Features and Specifications 1.4.3 Physical 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: 500µS recovery to 1% band for 30% step load change from 70% to 100% or 100% to 70% Remote Start/Stop and Interlock: TTL compatible input, Contact Closure, 12-250 Vac or...

  • Page 24: Mechanical Specifications

    Features and Specifications Sorensen DCS Series 1kW and 1.2kW Supplies 1.4.4 Mechanical Specifications Size: 44mm H x 482.6mm W x 508mm D (1.75” H x 19” W x 20” D) Weight: 8.2 kg (18 lbs) UTPUT ONNECTOR Models DCS-E 8V through DCS 100V Connector type: Nickel plated copper bus bars.

  • Page 25: Section 2 Installation And Operation

    SECTION 2 INSTALLATION AND OPERATION 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 the carrier immediately. Direct repair problems to the Customer Service Department at 1-800-733-5427. Initial Inspection The equipment should be inspected for damage as follows: Inspect for obvious signs of physical damage.

  • Page 26: Input Line Impedance

    Installation and Operation Sorensen DCS Series 1kW and 1.2kW Supplies To convert the unit for use with a 100-130 Vac input, perform the following steps: 1. Ensure that the unit is switched off and disconnected from any power source. 2. Remove the Phillips head screws that secure the cover and then remove the cover. 3.

  • Page 27: Rack Mounting

    Sorensen DCS Series 1kW and 1.2kW Supplies Installation and Operation 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.

  • Page 28: Figure 2-1 Dcs Series Power Supply

    Installation and Operation Sorensen DCS Series 1kW and 1.2kW Supplies Figure 2-1 DCS Series Power Supply M362500-01 Rev K...

  • Page 29: Controls, Connectors, And Indicators

    Sorensen DCS Series 1kW and 1.2kW Supplies Installation and Operation Controls, Connectors, and Indicators Refer to Figure 2-1 and the descriptions below. 2.4.1 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...

  • Page 30: J3 Program, Sense And Monitor Connector Description

    Installation and Operation Sorensen DCS Series 1kW and 1.2kW Supplies 2.4.3 J3 Program, Sense and Monitor Connector Description D-subminiature 25-pin female; mating connector: 25-pin Male ITT Cannon DB25P or equivalent Pin # Function AC/DC Shutdown Input (12-250 Vac or 12-130 Vdc) Return for Shutdown Input Signals OVP Programming Input (0-5V, 0-10V, or 0-1mA) Jumpered to pin 16 for local mode operation...

  • Page 31: Initial Functional Tests

    Sorensen DCS Series 1kW and 1.2kW Supplies Installation and Operation Initial Functional Tests 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.

  • Page 32: Standard Operation

    Installation and Operation Sorensen DCS Series 1kW and 1.2kW Supplies 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.

  • Page 33: Inductive Loads

    Sorensen DCS Series 1kW and 1.2kW Supplies Installation and Operation 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 terminals designated as the positive and negative distribution terminals.

  • Page 34: Remote Sensing

    Installation and Operation Sorensen DCS Series 1kW and 1.2kW Supplies 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 4V/line [0.5V/line for the DCS 8-125 and DCS 10-100 models]).

  • Page 35: Negative Output Operation

    Sorensen DCS Series 1kW and 1.2kW Supplies Installation and Operation 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 8V–150V models only due to the metal shell 25-pin “D”...

  • Page 36: Multiple Supplies

    Installation and Operation Sorensen DCS Series 1kW and 1.2kW Supplies For voltage mode operation, turn the current control fully clockwise and then adjust the voltage control to 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.

  • Page 37: Split Supply Operation

    Sorensen DCS Series 1kW and 1.2kW Supplies Installation and Operation 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.

  • Page 38: Remote Programming Of Ovp With External Voltage Sources

    Installation and Operation Sorensen DCS Series 1kW and 1.2kW Supplies 2.9.2 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.

  • Page 39: Remote Programming Of Ovp With An External Resistance

    Sorensen DCS Series 1kW and 1.2kW Supplies Installation and Operation SWITCH SW1 CONNECTOR J3 1312 OPEN CLOSED 0-10V Switch SW1 SW1-1 Off (Open) SW1-2 Off (Open) SW1-3 Off (Open) SW1-4 Off (Open) SW1-5 Off (Open) SW1-6 Off (Open) SW1-7 Off (Open) SW1-8 On (Closed) Switch SW1 and Connector J3 Configuration for 0-10 Vdc OVP Programming...

  • Page 40: Remote Programming Of Ovp With External Current Sources

    Installation and Operation Sorensen DCS Series 1kW and 1.2kW Supplies SWITCH SW1 CONNECTOR J3 1312 OPEN CLOSED 5k OHMS Switch SW1 SW1-1 Off (Open) SW1-2 Off (Open) SW1-3 Off (Open) SW1-4 On (Closed) SW1-5 Off (Open) SW1-6 Off (Open) SW1-7 Off (Open) SW1-8 Off (Open) Switch SW1 and Connector J3 Configuration for 0-5k OVP Programming...

  • Page 41: 2.10 Remote On/Off

    Sorensen DCS Series 1kW and 1.2kW Supplies Installation and Operation SWITCH SW1 CONNECTOR J3 1312 OPEN CLOSED 0-1mA Switch SW1 SW1-1 Off (Open) SW1-2 Off (Open) SW1-3 Off (Open) SW1-4 On (Closed) SW1-5 Off (Open) SW1-6 Off (Open) SW1-7 Off (Open) SW1-8 On (Closed) Switch SW1 and Connector J3 Configuration for 0-1mA Current Source OVP Programming...

  • Page 42: Remote Programming Of Output Voltage And Current Limit

    Installation and Operation Sorensen DCS Series 1kW and 1.2kW Supplies 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.
  • Page 43 Sorensen DCS Series 1kW and 1.2kW Supplies Installation and Operation SW1-1 Off (Open) SW1-5 Off (Open) SW1-2 Off (Open) SW1-6 Off (Open) SW1-3 Off (Open) SW1-7 Off (Open) SW1-4 On (Closed) SW1-8 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 0-10 Vdc source, close switch SW1-3 and replace the 0-5V source with...

  • Page 44: Programming With An External Resistance

    Installation and Operation Sorensen DCS Series 1kW and 1.2kW Supplies CONNECTOR J3 1312 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.

  • Page 45: Programming With An External Current Source

    Sorensen DCS Series 1kW and 1.2kW Supplies Installation and Operation 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.
  • Page 46 Installation and Operation Sorensen DCS Series 1kW and 1.2kW Supplies 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.

  • Page 47: 2.12 Remote Monitoring And Status Indicators

    Sorensen DCS Series 1kW and 1.2kW Supplies 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 (uncalibrated) signal between pins 19 (positive) and 12 (negative) represents 0-100% of the rated output voltage.

  • Page 49: Section 3 Theory Of Operation

    SECTION 3 THEORY OF OPERATION 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.

  • Page 50: Figure 3-1 Simplified Full Bridge Converter

    Theory of Operation Sorensen DCS Series 1kW and 1.2kW Supplies Figure 3-1 Simplified Full Bridge Converter M362500-01 Rev K...

  • Page 51: Simplified Full Bridge Converter Theory

    Sorensen DCS Series 1kW and 1.2kW Supplies Theory of Operation 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 voltage which is supplied to the power FETs, Q13-Q16, on the primary of power transformer T1.
  • Page 52 Theory of Operation Sorensen DCS Series 1kW and 1.2kW Supplies NPUT ECTIFIER AND NRUSH IMITING Input AC power passes from the rear panel AC connector (TB1) through an RFI filter consisting of C1-6, R122, and common mode filter inductors L1, and L2 to the 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 bridge rectifier CR35 via fuse F1.
  • Page 53 Sorensen DCS Series 1kW and 1.2kW Supplies Theory of Operation UTPUT ECTIFIER IRCUIT AND UTPUT ILTER The DCS series uses two different configurations for the output rectifier. The 8V to 100V models use a full wave center tap configuration while the 150 to 600V models employ a full wave bridge.
  • Page 54 Theory of Operation Sorensen DCS Series 1kW and 1.2kW Supplies OLTAGE ONTROL IRCUIT The output voltage feedback is monitored by the voltage control op amp U5 pin 3 via the positive sense line (pin 13 of connector J3 on 8V to 100V models and on pin 1 of the Amp high voltage connector) and the resistor divider formed by R21, R22, R53, R85 and R147.
  • Page 55 Sorensen DCS Series 1kW and 1.2kW Supplies Theory of Operation PERATING NDICATOR IRCUIT Op amp U8-2 monitors the polarity of the voltage across diode CR18. CR18 is forward biased during voltage mode and reverse biased during current mode to provide a mode indication signal at U8 pin 7.
  • Page 56 Theory of Operation Sorensen DCS Series 1kW and 1.2kW Supplies During remote voltage programming of the OVP trip level the internal 1mA current source is disconnected by removing the jumper that connects pin 3 and 16 of J3. The reference voltage at pin 6 of U3-2 is then provided directly by the external voltage source.

  • Page 57: Meter Circuit (A1 Assembly)

    Sorensen DCS Series 1kW and 1.2kW Supplies Theory of Operation 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.

  • Page 58: Voltmeter

    Theory of Operation Sorensen DCS Series 1kW and 1.2kW Supplies 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).

  • Page 59: Section 4 Maintenance, Troubleshooting, And Calibration

    Units requiring repair during their warranty period should be returned to AMETEK Programmable Power for service. Unauthorized repairs performed by anyone other than AMETEK during the warranty period may void the warranty. Any questions regarding repair should be directed to the Service Department of AMETEK Programmable Power, Inc.

  • Page 60: Preliminary Checks

    Maintenance and Troubleshooting Sorensen DCS Series 1kW and 1.2kW Supplies 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.

  • Page 61: Calibration

    Sorensen DCS Series 1kW and 1.2kW Supplies Maintenance and Troubleshooting Symptom Check Further Checks and Corrections Output voltage Is unit at current limit? See Section 2.5. fluctuating or Is input voltage within Measure voltage on input terminals. regulation poor specified range? See Section 1.4.
  • Page 62 Maintenance and Troubleshooting Sorensen DCS Series 1kW and 1.2kW Supplies ure 4-1 Trimpot Locations Refer to the Safety Notice at the beginning of this manual for an explanation of these symbols. M362500-01 Rev K...

  • Page 63: Section 5 Parts Lists

    Do not substitute parts without first checking with Customer Service Department. Sorensen parts may be ordered from the factory with the information in the following sections. Order parts from: AMETEK Programmable Power Tel: 800 733 5427 (Toll Free North America)

  • Page 64: Table 5-1 Dcs 1Kw And 1.2Kw Fuse Ratings

    Parts Lists Sorensen DCS Series 1kW and 1.2kW Supplies Parts Lists Table 5–1 provides fuse ratings for the DCS 1kW and DCS 1.2kW power supplies. Table 5–2 provides a matrix of parts lists according to model numbers for the DCS 1kW power supplies, and Table 5–3 provides a listing of the parts lists.

  • Page 65: Table 5-3 Dcs 1Kw Parts Lists

    Sorensen DCS Series 1kW and 1.2kW Supplies Parts Lists Number Assembly 1066830-008 Output PCB Assembly 1066830-01 Output PCB Assembly 1066830-020 Output PCB Assembly 1066830-080 Output PCB Assembly 1066830-100 Output PCB Assembly 5360726-01 Rectifier PCB Assembly 5360726-02 Rectifier PCB Assembly 5360726-03 Rectifier PCB Assembly 5360726-04 Rectifier PCB Assembly...

  • Page 66: Table 5-4 Dcs 1.2Kw Parts Lists By Model Number

    Parts Lists Sorensen DCS Series 1kW and 1.2kW Supplies Front Panel Rectifier Final Mother PCB Output PCB Model Assembly Assembly Assembly Assembly Assembly 5362500-008 5362462-008 5360801-01 1066830-008 DCS8-140E 5362500-010 5362462-010 5360801-01 1066830-008 DCS10-120E 5362500-020 5362462-020 5360801-02 1066830-020 DCS20-60E 5362500-033 5362462-033 5360801-02 1066830-01 5360726-01...

  • Page 67: Table 5-5 Dcs 1.2Kw Parts Lists

    Sorensen DCS Series 1kW and 1.2kW Supplies Parts Lists Number Assembly 1066830-008 Output PCB Assembly 1066830-01 Output PCB Assembly 1066830-020 Output PCB Assembly 1066830-080 Output PCB Assembly 1066830-100 Output PCB Assembly 5360726-01 Rectifier PCB Assembly 5360726-02 Rectifier PCB Assembly 5360726-03 Rectifier PCB Assembly 5360726-04 Rectifier PCB Assembly...

This manual is also suitable for:

Sorensen dcs8-125eSorensen dcs33-33eSorensen dcs60-18eSorensen dcs150-7eSorensen dcs8-140eSorensen dcs33-36e ... Show all

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