AE Techron 7548 Operator's Manual
Single-channel industrial amplifiers for demanding, high-power systems
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- Page 1 7548/7794/7796/7796HC Operator’s Manual Single-Channel Industrial Amplifiers for Demanding, High-Power Systems APPLIES TO UNITS WITH MAINBOARD PART NUMBER 65-7796135-3 574.295.9495 | www.aetechron.com 2507 Warren Street, Elkhart, IN 46516...
- Page 3 This includes any damage to ITEMS EXCLUDED FROM WARRANTY another product or products resulting from such a This AE Techron Warranty is in effect only for failure defect. of a new AE Techron product which occurred within the Warranty Period.
- Page 4 574-295-9495 Elkhart, IN 46516 lshank@aetechron.com This Declaration of Conformity is issued under the sole responsibility of AE Techron, Inc., and belongs to the following product: Equipment Type: Industrial Power Amplifiers Model Name: 7548 EMC Standards: EN 61326-1: 2013 – Electrical equipment for measurement, control and laboratory use —...
- Page 5 574-295-9495 Elkhart, IN 46516 lshank@aetechron.com This Declaration of Conformity is issued under the sole responsibility of AE Techron, Inc., and belongs to the following product: Equipment Type: Industrial Power Amplifiers Model Name: 7794 EMC Standards: EN 61326-1: 2013 – Electrical equipment for measurement, control and laboratory use —...
- Page 6 574-295-9495 Elkhart, IN 46516 lshank@aetechron.com This Declaration of Conformity is issued under the sole responsibility of AE Techron, Inc., and belongs to the following product: Equipment Type: Industrial Power Amplifiers Model Name: 7796 EMC Standards: EN 61326-1: 2013 – Electrical equipment for measurement, control and laboratory use —...
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Page 7: Table Of Contents
Contents 1 Introduction ............................7 1.1 Features ..........................7 2 Amplifier Unpacking and Installation ....................8 2.1 Safety First ..........................8 2.2 Unpacking ..........................8 2.3 Installation ..........................8 2.4 Connecting the Load ......................9 2.5 Connecting the Input Signal ....................10 2.6 Connecting the AC Supply ....................2.7 Start-up Procedure ......................3 Amplifier Operation ........................12 3.1 Front-Panel Controls & Display ...................12 3.2 Front-Panel Indicators ......................13... - Page 8 List of Figures Figure 1.1 – 7548 Front Panel .....................7 Figure 2.1 – Connecting the Load ..................9 Figure 2.2 – Close-up of the Output Terminal Resistor ............9 Figure 2.3 – Close-up of SIM card..................10 Figure 2.4 – Wiring for Unbalanced or Balanced Input Connector ........10 Figure 2.5 – 208V 3-Phase AC Mains Wiring ..............11 Figure 2.6 – 380/400/415V 3-Phase AC Mains Wiring ............11 Figure 3.1 – Front Panel Controls and Display..............12 Figure 3.2 – Front Panel Indicators ...................13 Figure 3.3 – Main Status Indicators for Stand-Alone Amplifiers ........13 Figure 3.4 – Fault Status Indicators for Stand-Alone Amplifiers ........14 Figure 3.5 – Main Status Indicators for Multi-Amplifier Systems ........15 Figure 3.6 – Fault Status Indicators for Multi-Amplifier Systems ........16 Figure 3.7 – Back Panel Controls and Connectors ............17 Figure 4.1 – Master or Follower Setting ................19 Figure 4.2 – Gain Trim Control ..................19 Figure 4.3 – Controlled-Voltage or Controlled-Current Mode Setting ........19 Figure 4.4 – Compensation Setting ...................20 Figure 4.5 – Ready/Run Mode or Standby Mode on Power-Up Setting ......20 Figure 4.6 – Standby Mode on Overload Setting ..............20...
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Page 9: Introduction
Full protection tems. The 7548, 7794, 7796 and 7796HC ampli- includes: fiers are built and tested to the most stringent • Over-Voltage quality standards for long life and outstanding • Over-Temperature performance. The AE Techron brand is known • Temperature monitor of heat-sinks, trans- throughout the world for its robust precision ampli- formers and output transistors fiers as well as its product service and support. • Immediate protection and fast recovery in the event of overheating. ... -
Page 10: Amplifier Unpacking And Installation
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 2 2 Amplifier Unpacking and Along with any additional accessories purchased by the customer, all 7548/7794/7796/7796HC Installation amplifiers ship with the following: The 7548, 7794, 7796 and 7796HC amplifiers are • Toolkit (contains one 1/8-inch Allen driver and precision instruments that can be dangerous if not three 2.7-ohm resistors) handled properly. Lethal voltages are present in both • NEMA connector for Power Cord the AC input supply and the output of these ampli- • Operator’s Manual USB drive and Quick Start fiers. For this reason, safety should be your primary sheet concern when you setup and operate this amplifier. WARNING 2.1 Safety First Throughout this manual special emphasis is Never attempt to lift the amplifier with- out assistance. -
Page 11: Connecting The Load
NOT be removed. WARNING: Removing this re- Output potentials can be lethal. Make connections only with AC Power OFF sistor can cause dangerous output and/or damage and input signals removed. to the load unless configuring multiple amplifiers in series. See the AE Techron Multi-Amplifier Con- 2.4 Connecting the Load figuration Guide for more information on these Before connecting the amplifier, make sure the AC advanced configurations. power cord is unplugged. ... -
Page 12: Connecting The Input Signal
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 2 2.4.1 Connecting the Outputs The four-position terminal barrier block accepts up to #4 AWG wire. Always use the appropriate wire size and insulation for the maximum current and voltage expected at the output. Never connect the output of the amplifier to any other model amplifier, power supply, signal source, or other inappropriate Figure 2.3 – Close-up of SIM card load; fire can result. on the amplifier back panel (see Figure 2.3). The 1. Connect the negative terminal of the load to standard SIM card includes both an Unbalanced the SAMPLED COMMON terminal. Input BNC jack and a Balanced Input “WECO” ter- NOTE: Alternately, the COMMON terminal minal block connector, an Input Select switch, and may be used when operating in Controlled- an Interlock – I/O Connector. See the Applica- Voltage mode; however, the integrated tions section for information on using the Interlock current monitor will not function if the COM- – I/O Connector. ... -
Page 13: Connecting The Ac Supply
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 2 Connect your input signal to the amplifier’s unbal- The amplifier includes a NEMA style locking AC connector as standard equipment. Connect the anced or balanced input connector as shown in Figure 2.4. Use cables that are high quality and amplifier to the proper 3-phase AC mains with this shielded to minimize noise and to guard against connector. See Figures 2.5 and 2.6 for proper AC possible feedback. Mains wiring. The connector then plugs into the amplifier. 2.7 Start-up Procedure DANGER 1. Turn down the level of your signal source. 2. Check to make sure the AC Mains Switch/ The risk of lethal ELECTRICAL SHOCK Circuit Breaker is in the off position ... -
Page 14: Amplifier Operation
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 3 3 Amplifier Operation 3.1 Front-Panel Controls & Display Stop – For stand-alone amplifiers, Stop will place This section provides an overview of Front- the amplifier in Stop mode (both Standby and Stop Panel controls and display screen found on the LEDs will be lit). When the amplifier is part of a 7548/7794/7796/7796HC amplifier. Please refer to multi-amp system, pressing the Stop button on any Figure 3.1 for item locations. amplifier in the system will place that amplifier in Stop mode and all other amplifiers in the system 3.1.1 Input Buttons in Standby mode. When an amplifier is in Stop or ... -
Page 15: Front-Panel Indicators
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 3 3.1.2 Multi-Function LCD Display The multi-function LCD display provides vari- ous displays of peak and RMS values for voltage and current measured directly from the amplifier output. The amplifier’s model name is displayed on the model display screen in the display rotation. If the amplifier experiences a fault condition, the LCD display will automatically change to display details of the fault condition and prescribed correc- Figure 3.2 – Front Panel Indicators tive actions. NOTE: The Enter button has been provided for On startup, the LCD Display will provide readings future expansion and has no function at this time. for all four measurements: Volts peak, Volts RMS, 3.2 Front-Panel Indicators Current peak, and Current RMS. Use the Naviga- tion buttons to scoll to other available displays, This section provides an overview of Front-Panel indi- such as model name, peak voltage and peak ... -
Page 16: Figure 3.4 - Fault Status Indicators For Stand-Alone Amplifiers
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 3 a fault condition occurs. Depending on the fault 3.3 details the operational modes indicated by the condition and the configuration of the unit, the Main Status indicators. amplifier may be placed in Standby mode when a 3.2.2 Fault Status Indicator fault condition occurs. Refer to the chart in Figure The Fault Status indicator is located on the ampli- 3.4 to determine the fault condition being indicated fier front panel. This LED monitors the internal and the action required to clear the fault condition. conditions of the amplifier and will illuminate when Figure 3.4 – Fault Status Indicators for Stand-Alone Amplifiers... -
Page 17: Figure 3.5 - Main Status Indicators For Multi-Amplifier Systems
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 3 3.2.3 Main Status Indicators for along with the statuses of other amplifiers in the Multi-amplifier Systems system, the Main Status indicators can be used to determine the system status and the action The Main Status indicators on each amplifier in required to return the system to Run mode. See a multi-amp system are used to determine the Figure 3.5. operational status of the amplifier. When evaluated Figure 3.5 – Main Status Indicators for Multi-Amplifier Systems... -
Page 18: Figure 3.6 - Fault Status Indicators For Multi-Amplifier Systems
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 3 playing the Fault status. Refer to the chart below to the action required to clear the fault condition and determine the fault condition being indicated and return the system to Run mode. Figure 3.6 – Fault Status Indicators for Multi-Amplifier Systems Indicator is lit Indicator is not lit Indicator may be lit One or More Amps in System Main Status Fault Status... -
Page 19: Back-Panel Controls And Connectors
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 3 One or More Amps in System Main Status Fault Status Indicators of Action Needed to Clear Main Status Reported on Other Amps Fault Condition and Re- Indicators LCD Display in System State of Operation turn to Run Mode Overvoltage status: This To clear an Overvoltage fault ... -
Page 20: Advanced Configuration
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 4 4 Advanced Configuration WARNING The 7548/7794/7796/7796HC amplifier was de- signed to offer exceptional power and versatility in Do not attempt to access the Main Board operation. You can choose from a range of field- while the amplifier is running. Turn the configurable options, including: amplifier off and disconnect the AC Mains before removing the amplifier • Operate as a stand-alone amplifier or as part of front panel. a multiple-amplifier system. -
Page 21: Figure 4.1 - Master Or Follower Setting
P2 by placing BOTH jumpers in the UP posi- tion (upper pair of pins). See Figure 4.1. Figure 4.1 – Master or Follower Setting For information on input and output wiring and required accessories for multi-amplifier applica- tions, please refer to the AE Techron Multi-Amp Configuration Guide available for download from the AE Techron website at www.aetechron.com. 4.3.2 Gain Trim Control The amplifier allows control of gain via a multi- turn potentiometer (R210). R232 resistor sets the coarse gain and R247 sets the range or sensitivity ... -
Page 22: Figure 4.4 - Compensation Setting
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 4 4.3.4 Compensation Setting (applies to Controlled Current operation only) When the amplifier is used in Controlled Current (CC) mode, the current control loop is tuned with one of two available RC networks: CC1 (R63 and C16) or CC2 (R82 and C25). Place Jumper J5 in the UP position to select the CC1 network (factory default). Place Jumper J5 in the DOWN position to select the CC2 network. See Figure 4.4. Figure 4.4 – Compensation Setting 4.3.5 Ready/Run Mode or Standby Mode Power-up The amplifier will bypass Standby Mode and cycle ... -
Page 23: Adjusting The Bi-Level Power
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 4 4.4 Adjusting the Bi-Level Power Supply Switch The amplifier offers three Bi-Level switch settings: Automatic, High, or Low. The user can select between settings via a switch on the Power Sup- ply Board. The Power Supply Board is a horizontal board located below the main and display boards. To access the Bi-Level Power Supply Switch, com- plete the following steps to remove the front panel and access the bi-level power supply switch. Figure 4.7 – Bi-Level Power Switch Location IMPORTANT: Before removing the Front Panel, make sure the amplifier is turned off for at least 3-5 minutes and the AC mains are disconnected. -
Page 24: Applications
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 5 5 Applications AE Techron 7548, 7794, 7796 and 7796HC ampli- 5.1 Remote Status and Control using fiers come with a SIM-BNC input module that also the SIM Interlock I/O Connector contains a female, 25-pin D-Sub connector. This The procedures outlined in this section assume connector can be used to provide remote control competence on the part of the reader in terms of and monitoring of the amplifier. ... -
Page 25: Figure 5.3 - Remote Status And Reset Schematic
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 5 5.1.2 Remote Amplifier Status and Reset Use a male, 25-pin D-Sub connector and high- The SIM Interlock I/O Connector can be used to quality wire to build the circuit. Figure 5.3 sche- create a circuit to monitor remotely one or more matic details the circuit and components required amplifier conditions, including Run status, Over- for all status and reset functions. temperature, Overload and Overvoltage. The cir- cuit can also be constructed to allow remote reset of the amplifier when it is forced to Standby due to ... -
Page 26: Figure 5.4 - Remote Enable/Standby
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 5 Remote Signal of Run Condition Remote Signal of OverVoltage Condition Purpose: LED, when lit, signals Run state. Purpose: LED, when lit, signals Overvoltage condition. Method: Use a 6mA series resistor of 4.02K-ohm Method: Use a 6mA series resistor of 4.02K-ohm for LED or OPTO, tie Run (PIN 12) to –24V source for LED or OPTO, tie OverVoltage Out (PIN 24) to (PIN 13). –24V source (PIN 13). Signal Type: DC Signal Type: DC Level when Asserted: –24V Level when Asserted: –24V Level when Deasserted: 0V... -
Page 27: Figure 5.5 - Remote Current Monitoring
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 5 When Interlock (PIN 4) is shorted to Digital Ground IMPORTANT: The amplifier must be configured for (PIN 17), the amplifier is placed in Standby mode. Ready mode at startup (factory default) or the Run When switch is open, the amplifier is released to button must be pressed at the amplifier front panel the Run condition. at startup. The Remote Enable/Standby circuit will Signal Type: DC not function if the Startup to Standby Latch has Level when Asserted: 0 to 8 V been activated on the amplifier. Level when Deasserted: 10 to 15 V 5.1.4 Remote Monitoring of Current Using the SIM-BNC Interlock connector located on the back panel of the amplifier, you can remotely monitor current output. -
Page 28: Controlled Current Operation
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 5 5.2 Controlled Current Operation The procedures outlined in this section assume age. If the load’s impedance changes, the amplifier competence on the part of the reader in terms of will seek to maintain this transconductance (ratio amplifier systems, electronic components, and of input voltage to output current) by increasing or good electronic safety and working practices. decreasing the voltage it produces, as long as it is within the amplifier’s ability to create the required 5.2.1 Controlled-Voltage vs. Controlled- voltage. Use this mode if you want the output cur- Current Modes of Operation rent waveform to be like the input waveform (see AE Techron 7548, 7794 and 7796 amplifiers ... -
Page 29: Figure 5.9 - Factory-Installed Default Rc Network
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 5 resistive values of the load will determine the (CV) or Controlled Current (CC) mode of opera- required compensation values. While the factory- tion. When operating the amplifier in Controlled default compensation setting will be sufficient Voltage (CV) mode, compensation is not required. for some applications, the compensation setting However, when operating in Controlled Current may also be adjusted in the field. The following (CC) mode, the amplifier load becomes an inte- section describes methods for determining and gral part of the system. In order to ensure sys- setting proper compensation when operating in tem stability and to control available bandwidth, Controlled-Current mode. compensation via an RC network is required for CC operation. The following steps will allow you 5.2.3 Controlling Compensation for to compensate your amplifier for operation in CC CC Operation mode safely and effectively. - Page 30 7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 5 STEP 3: Determine if Default or Custom Compensation is Required. If your load inductance falls outside of the mid- If your load inductance is between 200 microHen- range, or if your load resistance is greater than ries and 1 milliHenry, and your load resistance 5 ohms, then you must calculate your required is less than 5 ohms, then you can likely use the compensation. If, after calculating your required default compensation provided by the amplifier’s compensation, you determine that the default com- factory-installed RC network.
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Page 31: Figure 5.10 - Custom Compensation Location
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 5 STEP 7: Optimizing the Compensation Values. If a change in compensation is necessary, an ad- Once an approximate Rc and Cc have been justment to the resistor component of the Compen- computed, these values will need to be evaluated. sation circuit is probably required. To do this, install components with the required values in the main board at locations R82 and C25 If the output current waveform is ringing, the circuit as shown in Figure 5.10. -
Page 32: Multi-Amplifier Systems
The SIM-BNC-OPTOC module is required for all system setup. Parallel wiring kits are recommended Series configurations and should be used in con- for all Parallel configurations. junction with the DB9M CABLE (see below). To download the AE Techron 7000-Series Multi- DB9M CABLE – The DB9M (OPTOC) CABLE is a Amp Configuration Guide or for additional high-voltage Interlock cable that provides superior information, visit the AE Techron website at www. insulation for multi-amp series systems running aetechron.com. high-voltage applications. Information subject to change 97-7796264_09-04-2020... -
Page 33: Maintenance
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 6 6 Maintenance 6.1 Clean Amplifier Filter and Grills 6.1.1 Tools Required Simple maintenance can be performed by the The recommended equipment and supplies user to help keep the equipment operational. needed to perform the functions required for this The following routine maintenance is designed task are described below. to prevent problems before they occur. See the Troubleshooting section for recommendations for •... -
Page 34: Troubleshooting
Inspect the entire lengths of wires and ribbon cables for breaks or other physical damage. Uninsulated terminals with AC Mains 7. If there is any physical damage to the amplifier, potential are exposed when the panel is please return it to AE Techron for repair. removed. Do not proceed until AC Mains have been disconnected. Figure 7.1 – +Vcc and –Vcc Point Locations Figure 7.2 – Amplifier cover removed for inspection Information subject to change... -
Page 35: No Signal
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 7 Figure 7.3 – Fuse F1 Location 7.3 No Signal AC mains voltage to the proper level. When the Missing Output signal may be caused by one of line voltage condition is corrected, the amplifier the following: will automatically reset. If the amplifier does not 1. Master/Follower Jumpers are set to the Follower automatically reset, the amplifier’s three internal (down) position. The amplifier should only be transformers may need to be rewired. Please see configured for Follower mode if it is in a multi- the Factory Service information at the end of this amplifier system; otherwise it should be set for section. Master mode. See the Advanced Configura- tion section in this manual for more information. -
Page 36: Amplifier Overheats (Over Temp Fault Condition)
7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 7 7.7 Amplifier Overheats (Over Temp Connect across +TEMP and GND to monitor the Fault Condition) heat sinks responsible for positive voltages; con- nect across –TEMP and GND to monitor the heat There are two possible reasons why the amplifier sinks responsible for negative voltages. is overheating: 1. Excessive Power Requirements When running typical sine-type wave forms, read- 2. Inadequate Airflow ings at both monitor points should be similar. A deviation can be an indication of a DC offset that 7.7.1 Excessive Power Requirements is causing one side of the amplifier to work harder An amplifier will overheat if the required power ex- than the other. ceeds the amplifier’s capabilities. High duty cycles and low-impedance loads are especially prone to To convert the monitor point voltage readings to cause overheating. To see if excess power require- degrees Celsius:... -
Page 37: Fault Led Is Illuminated
Try resetting the Fault condition only once. If the Fault condi- tion does not clear after one reset, STOP. Contact AE Techron Support for further assistance. Repeated resetting can dam- age the amplifier. Information subject to change... -
Page 38: Specifications
Current Monitor: ± 1V / 20A ±1% Residual Noise, 10 Hz to 20 kHz: Less than 250 μV Reporting: System Fault, OverTemp, Over Voltage, THD, DC - 20 kHz, Overload 7548, 7794 and 7796HC: >0.25% Control: Force to Standby; Reset after a fault 7796: >0.2% 8.4 Protection Input Characteristics, Balanced with ground: Three-terminal barrier- Over/Under Voltage: ± 10% from specified supply ... - Page 39 7548/7794/7796/7796HC OPERATOR’S MANUAL – SECTION 8 AC Power: A toggle switch circuit breaker opens all Humidity: 70% or less, non-condensing legs of the AC mains on excess current demand. Cooling: Forced air-cooling from front to back 7548: Three-phase, 208V AC (±10%), 47-60 Hz, through removable filters via four (7548) or six 20A AC service (400V AC (±10%), 15A version (7794/7796/7796HC) 100 ft3/min. fans. No space is available). required between rack-mounted amplifiers. Air filters 7794 and 7796: Three-phase, 208V AC (±10%), are removable from the rear via one fastener per side 47-60 Hz, 30A AC service (400V AC (±10%), 15A and may be eliminated if cabinet filtration is provided. version available). Dimensions: 7796HC: Three-phase, 208V AC (±10%), 47-60 ...
- Page 40 (ready) I MON + Differential Current AC or 7212/7224/ Output current produced per volt- Current Monitoring: Connect a voltage meter to mon- Monitor + 7226: 5A/V age detect. itor the output current being produced by the amplifier. 7548/7794/ For unbalanced, for each 1V detected, current output is 7796/7796HC: 5A (7212/7224/7226) or 20A (7548/7794/7796/7796HC). 20A/V Not currently used. None No connection None No connection Not currently used. Blanking input Blanking control...
- Page 41 Standby of all amps in a multi-amplifier system. OEM App Input Monitor (OEM Used to monitor the input signal OEM modification only; normally no connection. only) from an OEM DAC card; this is the actual input signal. 7212/7224/ Current Monitoring: Connect a voltage meter to I MON – Differential Current AC or Inverted I MON+ (PIN 6). Output (alt.: OEM Monitor – ; 7226: 5A/V current produced per voltage monitor the output current being produced by the App) (- Input Monitor, 7548/7794/ detect. amplifier. For each 1V detected, current output is 5A OEM only) 7796/7796HC: (7212/7224/7226) or 20A (7548/7794/7796/7796HC). 20A/V...
- Page 42 Pin # Function Description Signal Level when Level when Notes Applications Type Asserted Deasserted I SUM1– Multiple Amplifier Planned for use in multiple amplifier Currently not used. Summing, Ampli- configurations - paralleled and run- fier 1 ning Controlled Current Mode I SUM2– Multiple Amplifier Planned for use in multiple amplifier Currently not used. Summing, Ampli- configurations - paralleled and run- fier 2 ning Controlled Current Mode I SUM3– Multiple Amplifier Planned for use in multiple amplifier Currently not used. Summing, Ampli- configurations - paralleled and run- fier 3...
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