1. Manuals
  2. Brands
  3. Elgar Manuals
  4. Power Supply
  5. Sorensen DCS 3kW Series
  6. Operation manual

Elgar Sorensen DCS 3kW Series Operation Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
.
Power Supplies
Elgar Electronics Corporation
9250 Brown Deer Road
San Diego, CA 92121-2294
1-800-73ELGAR (1-800-733-5427)
Tel: (858) 450-0085
Fax: (858) 458-0267
Email: sales@elgar.com
www.elgar.com
This document contains information proprietary to Elgar Electronics Corporation. The information contained herein is not
to be duplicated or transferred in any manner without prior written permission from Elgar Electronics Corporation.
September 13, 2002
DCS 3kW Series
DC Power Supplies
Operation Manual
This manual covers models:
DCS8-350
DCS12-250
DCS20-150
DCS40-75
©2002 by Elgar Electronics Corporation
DCS55-55
DCS60-50
DCS80-37
DCS150-20
Document No. 1065787 Rev V

Advertisement

Table of Contents
loading

Related Manuals for Elgar Sorensen DCS 3kW Series

Summary of Contents for Elgar Sorensen DCS 3kW Series

  • Page 1 ©2002 by Elgar Electronics Corporation This document contains information proprietary to Elgar Electronics Corporation. The information contained herein is not to be duplicated or transferred in any manner without prior written permission from Elgar Electronics Corporation. September 13, 2002 Document No. 1065787 Rev V...
  • Page 2 All the safety instructions and advice notes are to be followed. Neither Elgar Electronics Corporation, San Diego, California, USA, nor any of the subsidiary sales organizations can accept any responsibility for personal, material or consequential injury, loss or damage...
  • Page 3 SAFETY SYMBOLS CAUTION CAUTION Risk of Electrical Shock Refer to Accompanying Documents Off (Supply) Direct Current (DC) Standby (Supply) Alternating Current (AC) On (Supply) Three–Phase Alternating Current Protective Conductor Terminal Earth (Ground) Terminal Fuse Chassis Ground...
  • Page 4 Elgar 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 Elgar prior to scheduling. •...
  • Page 5 Section 6 Servicing the 3000 Watt System Supply covers maintenance, calibration, and repairs and features parts lists. Section 7 contains a link to the Elgar website to access the schematics for the supply's component assemblies and an interconnection diagram. Note that you must have a password to access these drawings.

  • Page 6: Table Of Contents

    CONTENTS SECTION 1 INTRODUCING THE DCS SERIES SYSTEM SUPPLY..1-1 Description....................... 1-1 Features......................1-1 Specifications....................1-2 1.3.1 Electrical Specifications ............... 1-2 1.3.2 Mechanical Specifications..............1-3 SECTION 2 INSTALLATION ...............2-1 Introduction ...................... 2-1 Safety....................... 2-1 2.2.1 High Energy/High Voltage Warning ............. 2-1 2.2.2 AC Source Grounding................
  • Page 7 Contents Sorensen DCS Series 3kW Supplies AC Input Power Connection................2-4 2.5.1 AC Input Power Requirements .............2-4 2.5.2 AC Input Connector Assembly .............2-5 2.5.3 Strain Relief Assembly .................2-6 Initial Functional Tests ..................2-8 2.6.1 Power-on Check...................2-8 2.6.2 Voltage Mode Operation Check ............2-8 2.6.3 Current Mode Operation Check ............2-9 2.6.4...
  • Page 8 Sorensen DCS Series 3kW Supplies Contents Remote Programming: Output Voltage and Current Limit ......... 4-6 4.3.1 Programming Output Voltage and Current Limit with the REM/LOC Switch..............4-8 4.3.2 Programming Output Voltage .............. 4-9 4.3.3 Programming Output Current Limit ............ 4-11 Using Over Voltage Protection (OVP) ............
  • Page 9 Contents Sorensen DCS Series 3kW Supplies 5.2.5 Output Current Shunt, Shunt Amplifier, and Down Programmer (A4 PCB) ....................5-2 5.2.6 Control, Programming, OVP, Shutdown, Monitoring, and Auxiliary Supply Circuits (A2 PCB)............5-3 5.2.7 Front Panel Displays and Local Operating Mode Controls (A1 PCB) ..5-4 Detailed Circuit Descriptions ................5-4 5.3.1 AC Input and RFI Filter Circuit (A5 PCB) ..........5-5...
  • Page 10 Sorensen DCS Series 3kW Supplies Contents SECTION 7 DRAWINGS AND SCHEMATICS ........7-1 SECTION 8 APPLICATION NOTES .............8-1 Battery Charging....................8-1 LIST OF FIGURES Figure 1-1 DCS Series (3kW) Supply Front Panel Controls and Indicators ....1-4 Figure 1-2 DCS Series (3kW) Supply Rear Panel Connectors and Terminals (including optional internal GPIB Interface) ..........
  • Page 11 Contents Sorensen DCS Series 3kW Supplies Figure 4-6 Programming Output Voltage with a 0-1 mA Source.......4-10 Figure 4-7 Programming Output Voltage with a 5k ohm Resistance ......4-10 Figure 4-8 Programming Output Current Limit with a 0-5 Vdc Source .....4-11 Figure 4-9 Programming Output Current Limit with a 0-10 Vdc Source ....4-11 Figure 4-10 Programming Output Current Limit with a 0-1 mA Source ....4-12 Figure 4-11 Programming Output Current Limit with a 5k ohm Resistance....4-12 Figure 4-12 Remote Programming of OVP with a 0-5 Vdc External...

  • Page 12: Section 1 Introducing The Dcs Series System Supply

    SECTION 1 INTRODUCING THE DCS SERIES SYSTEM SUPPLY Description The DCS Series System Supplies are 3000 watt 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 13: Specifications

    Introduction Sorensen DCS Series 3kW Supplies • Remote Sensing to compensate for losses in power leads up to 1V per lead. • Adjustable Over Voltage Protection (OVP). • External Shutdown using AC, DC, or TTL compatible signals (positive or negative logic). •...

  • Page 14: Mechanical Specifications

    Sorensen DCS Series 3kW Supplies Introduction Additional Characteristics Models DCS8-350 DCS12-250 DCS20-150 DCS40-75 DCS55-55 DCS60-50 DCS80-37 DCS150-20 Stability Voltage 4 mV 6 mV 10 mV 20 mV 27.5 mV 30 mV 40 mV 75 mV Current 175 mA 125 mA 75 mA 37.5 mA 27.5 mA...

  • Page 15: Figure 1-1 Dcs Series (3Kw) Supply Front Panel Controls And Indicators

    Introduction Sorensen DCS Series 3kW Supplies Figure 1-1 DCS Series (3kW) Supply Front Panel Controls and Indicators Operation Manual...

  • Page 16: Figure 1-2 Dcs Series (3Kw) Supply Rear Panel Connectors And Terminals (Including Optional Internal Gpib Interface)

    Sorensen DCS Series 3kW Supplies Introduction Figure 1-2 DCS Series (3kW) Supply Rear Panel Connectors and Terminals (including optional internal GPIB Interface) Operation Manual...

  • Page 17: Section 2 Installation

    SECTION 2 INSTALLATION Introduction This section provides recommendations and procedures for inspecting, testing, and installing the DCS Series power supply. 1. Read and follow safety recommendations (Section 2.2) 2. Perform an initial physical inspection of the supply (Section 2.3) 3. Install the supply (bench or rack mount), ensuring adequate ventilation (Section 2.4) 4.

  • Page 18: Ac Source Grounding

    Installation Sorensen DCS Series 3kW Supplies 2.2.2 AC Source Grounding Ensure the power supply is connected to an appropriately rated AC outlet with the recommended AC input connector as set out in Section 2.5 AC Input Power Connection. There is a shock hazard if the power supply chassis and cover are not connected to an electrical ground via the safety ground in the AC input connector.

  • Page 19: Physical Check

    Sorensen DCS Series 3kW Supplies Installation 2.3.1 Physical Check After unpacking, perform an initial inspection to ensure the unit and parts shipped with it have not been damaged in transit. The package should contain the power supply, a manual, one (1) AC input connector, and five (5) contact pins.

  • Page 20: Ventilation

    Installation Sorensen DCS Series 3kW Supplies 2.4.3 Ventilation The DCS system supply is fan-cooled, so it requires space on the sides for the ventilation inlets and space at the rear for the ventilation exhaust. The following temperature ranges apply for the best results when operating or storing the unit.

  • Page 21: Ac Input Connector Assembly

    Sorensen DCS Series 3kW Supplies Installation 2.5.2 AC Input Connector Assembly Each unit is shipped with a connector and contacts which mate with the chassis-mounted AC connector located on the rear panel. See Figure 2-1 AC Connector and Contacts. Parts Supplied •...

  • Page 22: Strain Relief Assembly

    Installation Sorensen DCS Series 3kW Supplies Contact Installation 5. Insert contact with attached wire into the connector until lock snaps into place. See Figure 2-3 and Figure 2-4 to complete the connector for either single or three phase input. Figure 2-3 Contact Orientation Figure 2-4 AC Wire Locations 2.5.3 Strain Relief Assembly...

  • Page 23: Figure 2-5 Strain Relief, As Supplied

    Sorensen DCS Series 3kW Supplies Installation Figure 2-5 Strain Relief, as Supplied 3. Insert strain relief tab A into AC input connector slot B. Insert second strain relief tab A into AC input connector slot C. See Figure 2-6. 4. Install screws in holes provided on outside of strain relief pieces. Thread through to screw standoff inside opposite piece.

  • Page 24: Initial Functional Tests

    Installation Sorensen DCS Series 3kW Supplies Initial Functional Tests The initial functional test procedure includes power-on and front panel function checks as well as voltage or current mode operation checks. See Figure 1-1 and Figure 1-2 for front and rear panel diagrams.

  • Page 25: Current Mode Operation Check

    Sorensen DCS Series 3kW Supplies Installation 2.6.3 Current Mode Operation Check 1. Ensure the front panel AC power switch is set to OFF. 2. Turn the voltage and current controls on the front panel fully counter-clockwise. 3. Turn the VOLTAGE control one (1) or two (2) turns clockwise. 4.

  • Page 26: Load Connection

    Installation Sorensen DCS Series 3kW Supplies Load Connection This section provides recommendations for load wiring and connecting as they apply to both single and multiple load configurations. 2.7.1 Load Wiring When connecting load wiring to the power supply, you must consider the following factors: •...

  • Page 27: Making The Connections

    Sorensen DCS Series 3kW Supplies Installation Figure 2-8 Maximum Load Wire Length Noise and Impedance Effects To minimize noise pickup or radiation, load wires should be shielded-twisted pair wiring of as short a length as possible. Connect the shield to the chassis via a rear panel mounting screw. Where shielding is impossible or impractical, simply twisting the wires together will offer some noise immunity.

  • Page 28: Connecting Single Loads

    Installation Sorensen DCS Series 3kW Supplies 2.7.3 Connecting Single Loads Figure 2-9 and Figure 2-10 show recommended load and sensing connections for single loads. Local sense lines shown are default J3 connections. Refer to Section 3.3.1 Connecting Remote Sense Lines for more information about the sense line shield. Figure 2-9 Single Load with Local Sensing (Default) Figure 2-10 Single Load with Remote Sensing 2.7.4...

  • Page 29: Figure 2-11 Multiple Loads With Local Sensing

    Sorensen DCS Series 3kW Supplies Installation Radial Distribution Method With this method, power is connected to each load individually from a single pair of terminals designated as the positive and negative distribution terminals. These terminals may be the power supply output terminals, the terminals of one of the loads, or a distinct set of terminals especially established for distribution use.

  • Page 30: Section 3 Basic Operation

    SECTION 3 BASIC OPERATION Introduction Once the power supply installation is complete and both the AC input power and the load have been connected (see Section 2 Installation), the DCS Series power supply is in its default configuration and is ready to operate in local programming mode. This section covers Constant Voltage and Constant Current Mode operation as controlled by local programming (Section 3.2).

  • Page 31: Figure 3-1 Operating Modes

    Basic Operation Sorensen DCS Series 3kW Supplies Figure 3-1 provides a graphical representation of the relationships between these variables. Constant Voltage Mode Operation The power supply will operate in constant voltage mode whenever the load current I is less than the current limit setting I , or: I <...

  • Page 32: Local Programming Mode Operation

    Sorensen DCS Series 3kW Supplies Basic Operation 3.2.2 Local Programming Mode Operation Units are shipped from the factory configured for local programming mode operation. In local programming mode: • Output voltage and current limit settings are adjusted with the front panel controls. •...

  • Page 33: Using Remote Sensing

    Basic Operation Sorensen DCS Series 3kW Supplies Using Remote Sensing Remote sensing is used during voltage mode operation to shift the power supply's regulation point from its output terminals (default sense point) to the load or distribution terminals by using a separate pair of wires to monitor the load voltage.

  • Page 34: Figure 3-3 Connecting Remote Sense Lines

    Sorensen DCS Series 3kW Supplies Basic Operation Figure 3-3 Connecting Remote Sense Lines CAUTION Do not use remote sensing with multiple supplies connected in series or in parallel. Operation Manual...

  • Page 35: Section 4 Advanced Operation

    SECTION 4 ADVANCED OPERATION Introduction All DCS Series power supplies offer the following standard features: • Remote Programming of Output Voltage and Current Limit with 0-5V, 0-10V, 0-1 mA, and 0-5k ohms (Section 4.3) • Overvoltage Protection (OVP) with front panel controls or 0-5V and 0-10V programming (Section 4.4) •...

  • Page 36: Configuring For Remote Programming, Sensing, And Monitoring

    Advanced Operation Sorensen DCS Series 3kW Supplies Configuring for Remote Programming, Sensing, and Monitoring This section lists switch, connector, and jumper functions for the DCS Series (3kW) supply. Subsequently, it provides a location diagram (Section 4.2.2), in addition to procedures for resetting the internal jumpers and switches (Section 4.2.3), and for reconfiguring or making connections to the J3 connector (Section 4.2.4).

  • Page 37: Figure 4-1 Connector J3 Pin Descriptions (For Remote Programming, Remote Monitoring, And Sense Connections)

    Sorensen DCS Series 3kW Supplies Advanced Operation Figure 4-1 Connector J3 Pin Descriptions (for Remote Programming, Remote Monitoring, and Sense Connections) Operation Manual...

  • Page 38: Locating Jumpers, Switch, And Connector

    Advanced Operation Sorensen DCS Series 3kW Supplies Internal Switch and Jumpers If you should need to change any of the standard configurations of the supply, internal jumpers JMP1 and JMP2, and switch SW1 enable you to select: voltage and current programming scale factor, over voltage protection (OVP) programming mode and scale, voltage and current monitor range, and shutdown circuit logic.

  • Page 39: Resetting Jumpers And Switch

    Sorensen DCS Series 3kW Supplies Advanced Operation 4.2.3 Resetting Jumpers and Switch Most applications will use the default factory settings of the internal jumpers, JMP1 and JMP2, or of the internal 8-position DIP switch, SW1. If the jumpers and switch should require resetting, read Section 2.2 Safety, and follow the procedures in this section.

  • Page 40: Making J3 Connections

    Advanced Operation Sorensen DCS Series 3kW Supplies Replacing the Option Board (when required) 12. Place the option board into its original location over the A2 circuit board. 13. Reinstall the mounting screws into the standoffs. Reattach any cables. 14. Reinstall the jackscrews with the nut driver. 15.
  • Page 41 Sorensen DCS Series 3kW Supplies Advanced Operation sources. As a programming source is varied, the power supply's output varies proportionally over its output range. The analog programming signals are connected to the rear panel J3 connector. To provide the lowest noise performance, shielded-twisted pair wiring is recommended for making connections from external circuits to the J3 connector.

  • Page 42: Programming Output Voltage And Current Limit With The Rem/Loc Switch

    Advanced Operation Sorensen DCS Series 3kW Supplies 4.3.1 Programming Output Voltage and Current Limit with the REM/LOC Switch The front panel REM/LOC (Remote/Local Programming) switch will allow you to switch back and forth between remote and local operation when programming output voltage and current limit with external voltage and/or current sources.

  • Page 43: Programming Output Voltage

    Sorensen DCS Series 3kW Supplies Advanced Operation 4.3.2 Programming Output Voltage Programming Output Voltage with a 0-5 Vdc Source 1. Remove the jumpers connecting pins 8 to 9 and 20 to 21 on connector J3. 2. Connect the external programming source between pins 9 (voltage programming input/positive) and 12 (return).
  • Page 44 Advanced Operation Sorensen DCS Series 3kW Supplies WARNING Exercise caution when resetting internal jumpers. Review Section 2.2 Safety and follow procedures for removing the cover and resetting jumpers in Section 4.2.3. Programming Output Voltage with a 0-1 mA Source 1. Remove the jumper between pins 20 and 21 of connector J3. 2.

  • Page 45: Programming Output Current Limit

    Sorensen DCS Series 3kW Supplies Advanced Operation 4.3.3 Programming Output Current Limit Programming Output Current Limit with a 0-5 Vdc Source 1. Remove the jumpers connecting pins 10 to 11 and 22 to 23 on connector J3. 2. Connect the external programming source between pins 10 (current limit programming input/positive) and 12 (return).
  • Page 46 Advanced Operation Sorensen DCS Series 3kW Supplies WARNING Exercise caution when resetting internal jumpers. Review Section 2.2 Safety and follow procedures for removing the cover and resetting jumpers in Section 4.2.3. Programming Output Current Limit with a 0-1 mA Source 1.

  • Page 47: Using Over Voltage Protection (Ovp)

    Sorensen DCS Series 3kW Supplies Advanced Operation Using Over Voltage Protection (OVP) The OVP circuit allows for protection of the load in the event of a remote programming error, an incorrect voltage control adjustment, or a power supply failure. The protection circuit monitors the output voltage and will reduce the output current and voltage to zero whenever a preset voltage limit is exceeded.

  • Page 48: Programming Ovp With An External Voltage Source

    Advanced Operation Sorensen DCS Series 3kW Supplies 4.4.3 Programming OVP with an External Voltage Source To set the OVP trip level with a 0-5 Vdc or a 0-10 Vdc external voltage source: 1. Ensure the power supply is turned OFF and that both the AC power source and the load are disconnected.

  • Page 49: Using The Shutdown Function

    Sorensen DCS Series 3kW Supplies Advanced Operation Figure 4-13 Remote Programming of OVP with a 0 –10 Vdc External Voltage Source Using the Shutdown Function The Shutdown function is used to disable or enable the supply's output voltage and current. It can be used to allow adjustments to be made to either the load or the power supply without shutting off the entire supply.
  • Page 50 Advanced Operation Sorensen DCS Series 3kW Supplies 2. Connect the TTL signal source to pin 14 (TTL Shutdown Input/positive) and pin 2 (Return for Shutdown Input) on the J3 connector on the rear panel. See Figure 4-14 and Figure 4-15. 3.
  • Page 51 Sorensen DCS Series 3kW Supplies Advanced Operation AC/DC Shutdown To activate the Shutdown function using a 12-250 Vac input or a 12-130 Vdc input: 1. Turn off the power supply and disconnect the AC power source. Allow five (5) minutes to elapse to dissipate stored energy before making connections or resetting switches.

  • Page 52: Shutdown Application - Contact Closure

    Advanced Operation Sorensen DCS Series 3kW Supplies 4.5.3 Shutdown Application - Contact Closure An external relay, whether normally open or normally closed, may be used to activate the Shutdown circuit. Either positive or negative logic may be used. To activate the Shutdown function using an external relay: 1.
  • Page 53 Sorensen DCS Series 3kW Supplies Advanced Operation Figure 4-19 Using Shutdown with Contact Closure of a Normally OPEN Relay (Negative Logic) Figure 4-20 Using Shutdown with Contact Closure of a Normally CLOSED Relay (Positive Logic) Figure 4-21 Using Shutdown with Contact Closure of a Normally CLOSED Relay (Negative Logic) Operation Manual 4-19...

  • Page 54: Remote Monitoring Of Readback Signals And Status Indicators

    Advanced Operation Sorensen DCS Series 3kW Supplies Remote Monitoring of Readback Signals and Status Indicators 4.6.1 Readback Signals Calibrated readback signals for remote monitoring of the output voltage and current are available via connections at the J3 connector on the rear panel. Internal switch SW1 settings allow you to select either a 0-5 Vdc or a 0-10 Vdc range for the output.

  • Page 55: Using Multiple Supplies

    Sorensen DCS Series 3kW Supplies Advanced Operation Using Multiple Supplies DCS Series power supplies of the SAME MODEL may be operated with outputs in series or in parallel to obtain increased load voltage or increased current. Split supply operation allows two positive or a positive and a negative output to be obtained.

  • Page 56: Configuring Multiple Supplies For Parallel Operation

    Advanced Operation Sorensen DCS Series 3kW Supplies 4.7.2 Configuring Multiple Supplies for Parallel Operation Parallel operation is used to obtain a higher current through a single output using two or more supplies. Set all of the outputs to the same voltage before connecting the positive (+) output terminals and negative (-) output terminals in parallel.

  • Page 57: Configuring Multiple Supplies For Split Supply Operation

    Sorensen DCS Series 3kW Supplies Advanced Operation 4.7.3 Configuring Multiple Supplies for Split Supply Operation Split supply operation uses two power supplies to obtain two positive voltages with a common ground, or to obtain a positive-negative supply. To obtain two positive voltages, connect the negative output terminals of both supplies together.

  • Page 58: Output Voltage Biasing

    Advanced Operation Sorensen DCS Series 3kW Supplies Figure 4-25 Split Supply Operation of Multiple Supplies (Positive-Negative Supply) (Local sense lines shown are default J3 connections.) Output Voltage Biasing The power supply output may be biased up to a maximum of 400 Vdc with respect to the chassis.

  • Page 59: Section 5 Theory Of Operation

    SECTION 5 THEORY OF OPERATION Introduction This section describes the internal operation of the DCS (3kW) Series power supply. Section 5.2 Basic Functional Blocks provides an explanation of the main functions within each functional block of the supply. Section 5.3 Detailed Circuit Descriptions contains more in-depth descriptions of the supply's circuitry, including remote programming and monitoring circuits not covered in Section 5.2.

  • Page 60: Ac Input And Rfi Filter (A5 Pcb)

    Theory of Operation Sorensen DCS Series 3kW Supplies 5.2.1 AC Input and RFI Filter (A5 PCB) The AC input, either single or three phase, is connected to the power supply via a four-pole connector on the rear panel and passes through an RFI filter before going to the front panel circuit breaker.

  • Page 61: Control, Programming, Ovp, Shutdown, Monitoring, And Auxiliary Supply Circuits (A2 Pcb)

    Sorensen DCS Series 3kW Supplies Theory of Operation regulate the output under no load or lightly loaded conditions. The down programming circuit is also used to discharge the output capacitors whenever the control circuit signal goes negative or when any of the shutdown circuits are activated. 5.2.6 Control, Programming, OVP, Shutdown, Monitoring, and Auxiliary Supply Circuits (A2 PCB)

  • Page 62: Front Panel Displays And Local Operating Mode Controls (A1 Pcb)

    • Remote/local programming selection Detailed Circuit Descriptions Refer to Section 7 Assembly Schematics for links to the Elgar website to access illustrations of the following assemblies: 1. AC Input and RFI Filter Circuit (A5 PCB) 2. Input Rectifier and Inrush Limiting Circuit (A6 PCB) 3.

  • Page 63: Ac Input And Rfi Filter Circuit (A5 Pcb)

    Sorensen DCS Series 3kW Supplies Theory of Operation 5.3.1 AC Input and RFI Filter Circuit (A5 PCB) The AC input is connected to the power supply via a four-pole connector in the rear panel. For three phase operation, three (3) phase lines, X, Y, and Z (190-250 Vac at 14A), and a safety ground line are required.

  • Page 64: Power Transformer, Output Rectifiers, Output Filter Inductor And Capacitor, And Down Programmer Circuit (A4 Pcb, A7 Pcb, A8 Pcb, And Power Stage Assembly)

    Theory of Operation Sorensen DCS Series 3kW Supplies The current sense amplifier monitors the current in the primary winding of the power transformer using transformer T2 and provides the signal to the non-inverting input of the PWM comparator. Diodes CR14 and CR15 rectify the output from T2 and resistors R3 and R11-3 scale the signal before it is input to the positive input of the current sense amplifier at pin 4 of U1.

  • Page 65: Auxiliary Supply, Ovp, Control, Programming, Monitor Circuit (A2 Pcb)

    Sorensen DCS Series 3kW Supplies Theory of Operation RC snubbers across each rectifier (also across the entire secondary of the transformer on some models) and tape-wound toroids on each transformer secondary lead are used to suppress transients. The rectifier output is filtered by capacitors C701-711 on the A7 PCB, capacitors C801-803 on the A8 PCB, and the output inductor to provide the DC output.
  • Page 66 Theory of Operation Sorensen DCS Series 3kW Supplies PWM control its output pulse width, thereby regulating the auxiliary output voltages. Current feedback to the PWM is provided by shunt resistor R114 which monitors current in the transformer primary winding. Resistors R115, R122, and capacitor C60 scale and condition the signal before inputting it to the PWM current sense comparator at pin 3.
  • Page 67 Sorensen DCS Series 3kW Supplies Theory of Operation through resistor R78. Resistor R10 and capacitors C7 and C8 are compensation components for U3-D. The current control circuit consists of op amp U3-C and its related components. Operation of the current control circuit is similar to that of the voltage control circuit. The 0-5V output current feedback signal from the A4 shunt amplifier is monitored at the inverting input of U3-C (pin 9).
  • Page 68 Theory of Operation Sorensen DCS Series 3kW Supplies Remote/Local Programming Select Circuits These circuits select the source of the voltage and current control circuit reference signals. The reference signals are provided by one of three sources: • Front panel controls (local programming mode) •...
  • Page 69 Sorensen DCS Series 3kW Supplies Theory of Operation Selection of IEEE-488 programming occurs when the IEEE card pulls pin 13 of U5-D and pin 2 of U5-A low through connector P2, pin 4. This causes the output of both U5-D and U5-A to go high and switch OFF both U4-C and U4-B.
  • Page 70 Theory of Operation Sorensen DCS Series 3kW Supplies Over Voltage Protection (OVP) Circuit The OVP circuit protects the load connected to the power supply from over-voltage conditions arising from programming errors, incorrect voltage control adjustments, or power supply failure. The OVP circuit monitors the output voltage and activates the internal shutdown circuit of the supply whenever the output exceeds a selected trip limit.
  • Page 71 Sorensen DCS Series 3kW Supplies Theory of Operation Output Voltage and Current Readback Circuits These circuits provide calibrated, switch-selectable 0-5V or 0-10V analog readback signals for remote monitoring of the output voltage and current. The output voltage readback signal is available at pin 19 of the rear panel J3 connector and the current readback signal is available at pin 7.

  • Page 72: Front Panel Displays And Controls (A1 Pcb)

    Theory of Operation Sorensen DCS Series 3kW Supplies 5.3.6 Front Panel Displays and Controls (A1 PCB) The A1 front panel PCB consists of: • Output voltage and current displays • Local controls for output voltage and current limit • Local control potentiometer for the OVP set point •...
  • Page 73 Sorensen DCS Series 3kW Supplies Theory of Operation Local OVP Set Point Control Potentiometer R29 (or R29A depending on the production part used) is a 20-turn trimpot which provides a 0-5V reference signal to the OVP circuit on the A2 PCB via pin 17 of connector P1. Voltage and Current (V &...

  • Page 74: Section 6 Servicing The 3000 Watt System Supply

    SECTION 6 SERVICING THE 3000 WATT SYSTEM SUPPLY Introduction This section provides general maintenance and calibration information as well as replacement parts lists for the DCS Series (3kW) supply. Units Under Warranty Units requiring repair during their warranty period should be returned to the manufacturer for service.

  • Page 75: Servicing Precautions

    Servicing Sorensen DCS Series 3kW Supplies 6.2.2 Servicing Precautions Always disconnect power, discharge circuits, and remove external voltage sources before making internal adjustments or replacing components. When performing internal adjustments or servicing the power supply, ensure another person with first aid and resuscitation certification is present.

  • Page 76: Voltage Programming Circuit Calibration

    Sorensen DCS Series 3kW Supplies Servicing 6.3.1 Voltage Programming Circuit Calibration Designation & Location Voltage Programming Recalibration Procedure (Multiturn trim pots) • Voltage Program Offset Disconnect any load. Connect a DVM rated at better than 0.5% (R93) accuracy to the power supply output. •...

  • Page 77: Replaceable Parts

    Servicing Sorensen DCS Series 3kW Supplies Replaceable Parts In this section, you will find parts lists for the following DCS Series (3kW) assemblies: • Main Assembly • Front Panel Assembly • A2 Control Circuit PCB Assembly (includes J3 connector and programming shell) •...

  • Page 78: Dcs 3Kw Parts Lists By Model Number

    Sorensen DCS Series 3kW Supplies Servicing 6.4.3 DCS 3kW Parts Lists by Model Number DCS8-350 DCS12-250 DCS20-150 DCS40-75 DCS55-55 DCS60-50 DCS80-37 DCS150-20 Main 1065807-008 1065807-012 1065807-020 1065807-040 1065807-055 1065807-060 1065807-080 1065807-150 Assembly 1065809-008 1065809-012 1065809-020 1065809-040 1065809-055 1065809-060 1065809-080 1065809-150 Front 1068768-008 1068768-012...
  • Page 79 Servicing Sorensen DCS Series 3kW Supplies 6.4.4 DCS 3kW Parts Lists Parts List Description Parts List Description 1065807-008 Final Assembly 1068584-012 A4 Shunt PCB Assembly 1065807-012 Final Assembly 1068584-020 A4 Shunt PCB Assembly 1065807-020 Final Assembly 1068584-040 A4 Shunt PCB Assembly 1065807-040 Final Assembly 1068584-055...

  • Page 80: Section 7 Drawings And Schematics

    SECTION 7 DRAWINGS AND SCHEMATICS Please click on the link below to access assembly drawings, schematics, bills of materials, and latest updates to this manual. To view these documents, you must be connected to the Internet. DRAWINGS Operation Manual...

  • Page 81: Section 8 Application Notes

    SECTION 8 APPLICATION NOTES Battery Charging When using the DCS Series (3kW) power supply to charge a battery, take the following precautions to prevent damage to the supply and/or the battery in case the overvoltage protection (OVP) circuit is activated. •...

This manual is also suitable for:

Sorensen dcs8-350Sorensen dcs12-250Sorensen dcs20-150Sorensen dcs40-75Sorensen dcs55-55Sorensen dcs60-50 ... Show all

Table of Contents