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Ulvac DPG-30R Instruction Manual

30 kw dc power supply controller
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30 kW DC Power Supply
Controller
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Controller
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Store this manual carefully so that it can be used at anytime.
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DPG-30R
DPG-MC60R
DPG-MC120R
DPG-MC240R
* Read this manual before using the system.
DC0043E-05
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5th Edition: July 14, 2023
ULVAC Inc.
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Summary of Contents for Ulvac DPG-30R

  • Page 1 DC0043E-05 30 kW DC Power Supply Controller Model DC power supply DPG-30R Controller DPG-MC60R DPG-MC120R DPG-MC240R 5th Edition: July 14, 2023 ULVAC Inc. * Read this manual before using the system. Store this manual carefully so that it can be used at anytime.
  • Page 2 The content of this manual may differ from the system being used due to system improvements.  If you have any questions and items of concern, contact your exclusive ULVAC dealer.  Please operate the system safely and administer it correctly.

  • Page 3: Safety Precautions

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] Introduction 1. Safety precautions Most accidents are attributed to carelessness during operation, inspection, maintenance, or repair. Failure to comply with the safety precautions or neglecting to anticipate danger causes accidents to happen more easily.

  • Page 4: Safety Symbols

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] Introduction 2. Safety symbols Safety symbols are used throughout this manual and labeled on the system to call the operator's attention to safety. The terminology used in safety symbols is classified below.
  • Page 5 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] Introduction 1) Power supply unit safety symbols The safety symbols below are used on the power supply unit. Power supply unit safety symbol list Power supply unit safety Description symbol Warning: Be careful of heavy item handling ・There is a risk of injury...

  • Page 6: About This System

    2. If an on-site response is required, consult separately with ULVAC or the nearest sales office or dealer. 2) For direct export transactions ULVAC will send a replacement system, or you will return the system to ULVAC or the nearest ULVAC service center where it will be repaired. Return shipping expenses are borne by the customer.

  • Page 7: If You Notice A Problem With The System

    If you have determined there is a malfunction or if you have any questions, contact to ULVAC. When contacting ULVAC, please inform us of the names or model numbers of the products, the serial numbers, and the symptoms of the problem in as much detail as possible.

  • Page 8: Rohs Compliance

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] Introduction 7. RoHS compliance 1) European Union RoHS EU RoHS non-compliant parts list Hazardous substance or element Hexavalent Polybrominated Part name Lead Mercury Cadmium Polybrominated chromium diphenyl (Pb) (Hg) (Cd) biphenyls (PBB)

  • Page 9: Table Of Contents

    3-4. W ....................29 IRING AND CONNECTIONS 3-4-1. Cables to connect to the DPG-30R and DPG-MC60R ........29 3-4-2. Cables to connect to the DPG-30R and DPG-MC120R ........30 3-4-2. Cables to connect to the DPG-30R and DPG-MC240R ........31 3-4-3.
  • Page 10 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] Contents 4-1. DPG-30R DPG-MC60R/120R/240R ............. 33 OPERATIONS 4-1-1. Operations ....................... 33 4-1-2. Controller configuration ..................33 4-1-3. System power each power setting ..............34 4-1-4. Timing chart for power supply system control ........... 34 4-1-5.

  • Page 11: For Safe Operation

    Danger This power supply handles high voltages. Internal power supply inspections and repair are handled by ULVAC or ULVAC Group representatives. Therefore, do not remove the power supply or controller panels under any circumstances. Danger When replacing the power supply, always turn off the upstream breaker and remove the...

  • Page 12: Warning Label/Nameplate Locations

    To order parts, ask questions about the system, and to make inquires related to system malfunctions, first verify the system information and then contact ULVAC or an exclusive dealer. Especially when you have determined the system has malfunctioned, inform us of the system information along with the system's history and symptoms in as much detail as possible.

  • Page 13: Overview

    (PLC). 2-2. Features  A single controller can control up to 2 power supplies (DPG-30R) by using the DPG-MC60R controller  A single controller can control up to 4 power supplies (DPG-30R) by using the DPG-MC120R controller ...

  • Page 14: Configuration

    The DPG-30R input cable, output cable, and control cable are sold separately. Cables are provided by ULVAC. Inform us separately of the necessary cable lengths. At 5m units than 5m, output cable length is available to 10m standard. I correspond with standard 4m With regard to the input cable.

  • Page 15: 120 Kw Power Supply System Configuration Example

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 2. Overview 2-3-2. 120 kW power supply system configuration example * The DC power supply input terminal and output terminal are both located on the back of the power supply. DC PS controller...

  • Page 16: 240 Kw Power Supply System Configuration Example

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 2. Overview 2-3-3. 240 kW power supply system configuration example AD I/F DC PS Controller DPG-MC240R 1Φ+GND Input 100-240 VAC Vacuum chamber Output DC Power Supply Anode 3Φ+GND Input 380-480 VAC Output...

  • Page 17: Dc Power Supply Unit (Dpg-30R) Specifications

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 2. Overview 2-4. DC power supply unit (DPG-30R) specifications Table 2-1 Electrical specifications (single unit specifications) Item Specification Input rated voltage 380 to 480 VAC Input voltage fluctuation range 342 to 528 VAC...

  • Page 18: Controller (Dpg-Mc60R, Dpg-Mc120R, Dpg-Mc240R) Specifications

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 2. Overview * Insert a 70 A circuit breaker in the input(Recommendation breaker manufacturer: fujielectric:BW100EAGU 3P 70A) U ser I/F D C P S C o ntro ller D P G -M C 120R 1Φ...

  • Page 19: External Control Pin Assignments

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 2. Overview 2-6. External control pin assignments 2-6-1. External control terminal (controller AD-IF connector) When performing external control, see "Table 2-7 External control signal connection equivalent circuits" and connect the external control terminal to an external control device such as a PLC.
  • Page 20 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 2. Overview changes by the number of power supplies.see Table 4-1 changes by the number of power supplies.see Table 4-1 During P control:becomes the corresponding system power for a output setting voltage level 0 to 10 V...
  • Page 21 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 2. Overview • When only the power supply is connected Table 2-6 External control terminal pin assignments when only the power supply is connected Pin No. Signal name Type Voltage level Return...

  • Page 22: External Control Terminal Supplementary Description

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 2. Overview 2-6-2. External control terminal supplementary description The external control terminal wiring carries a risk of noise interference if the wiring is long. ULVAC recommends the measures below. 1. recommends shielded twisted pair cables.
  • Page 23 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 2. Overview Signal Signal Equivalent circuit type DPG-MC60R,120R, 240R PLC side AD INTERFACE side ISO　AMP Analog output COM　A COM　A COM　A DPG-MC60R,120R, 240R AD INTERFACE side COM　L COM　L COM　L PLC side 0.01μF 2. 2 kΩ...

  • Page 24: Recommended Digital I/O Connection Circuits

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 2. Overview 2-6-3. Recommended digital I/O connection circuits DPG-MC60R,120R,240R AD INTERFACE +24 V 100Ω Digital output COM　D COMD Digital input +24 V　IN +24 V COM　D 2.2 kΩ 5mA or more COMD Figure 2-5 Recommended digital I/O connection circuits 2-6-4.

  • Page 25: Selecting The Arcdelay Mode

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 2. Overview 2-6-6. Selecting the ARCDELAY mode This section lists the signals to perform ARCDELAY ON/OFF selection via the AD I/F connector. ARCDELAY mode can be enabled by setting six pins of an AD I/F connector as Low.

  • Page 26: Setup

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup 3. Setup This chapter describes the necessary preparation from when you receive the system until it can be used and precautions about the system. 3-1. Unpacking Unpack the system and remove the components.

  • Page 27: Part Names And Functions

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup 3-2. Part names and functions 3-2-1. DC power supply front and rear panels ① ② Figure 3-2 DC power supply front panel...
  • Page 28 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup ⑨ ③ ④ ⑤ ⑥ ⑩ ⑪ ⑦ ⑧ Figure 3-3 DC power supply rear panel Table 3-1 DC power supply front and rear names and functions Name Configuration Function...

  • Page 29: Controller Front And Rear Panels

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup 3-2-2. Controller front and rear panels Front panel Figure 3-4 Controller front panel (Top: MC-60R,Middle: MC-120R, bottom: MC240R) Table 3-2 Controller front names and functions Name Configuration Function 1. LOCAL monitor LED (green) Turns on during LOCAL control.
  • Page 30 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup Name Configuration Function Turns on the HARC, MARC LEDs and displays the number of ARC occurrences in the 7-segment LEDs. When the number of ARC occurrences is over 9999, 9999 is displayed as flashing.
  • Page 31 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup Rear panel Figure 3-5 Controller rear panel (Top: MC-60R,Middle: MC-120R, bottom: MC240R) Table 3-3 Controller rear names and functions Name Configuration Function D-sub 37-pin 1. DC1 to DC8 Communicates signals with the DC power supplies.
  • Page 32 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup 10. MX LINK Connector Not used. 11. Nameplate Shows the model and serial number 12. Specification label - Indicates the model, input specification, weight, etc. *1 13. RS232C Connector Not used.

  • Page 33: Arc Link Terminal Pin Assignments

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup ・3-2-3. Arc link terminal pin assignments On the reference to "Table 2-7 external control signal equivalent circuit connection" to use the ARC LINK terminal, Connected to an external control device such as a PLC Table.3-4...

  • Page 34: Installing The Dc Power Supplies And Controller

    The actually used capacity corresponds to the number of power supplies. Power for the controller is separately required. * ULVAC recommends isolating the AC input for both the DC power supplies and the controller with isolating transformers.

  • Page 35: Mounting The Dc Power Supply And Controller

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup 3-3-3. Mounting the DC power supply and controller Always mount the DC power supply and the controller in a rack before use. See Figure 3-7 and Figure 3-8 for the positions to drill the mounting holes.

  • Page 36: Dc Power Supply And Controller Isolation Bushings

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup 3-3-4. DC power supply and controller isolation bushings When mounting the DC power supply and the controller in a rack, isolate the controller from the rack by attaching isolation bushings as shown in Figures 3-9 and 3-10. Isolate the power supply from the rack in the same manner.
  • Page 37 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup Figure 3-10 Isolation bushing attachment positions (controller) * Select a location as dust- and vibration-free as possible. Avoid installing the units in a location with an uneven floor surface.
  • Page 38 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup For ventilation, ensure that there is plenty of clearance around the DC power supply as shown in Figure 3-11. Create a structure that can adequately ventilate the rack so the temperature and humidity in the rack do not exceed the specifications.

  • Page 39: Wiring And Connections

    Do not connect the cables with the system energized under any circumstances. When connecting and disconnecting cables, ensure that the breakers for the input lines supplying the DC power supplies and the controller are turned off. 3-4-1. Cables to connect to the DPG-30R and DPG-MC60R AC in 100-240 V...

  • Page 40: Cables To Connect To The Dpg-30R And Dpg-Mc120R

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup 3-4-2. Cables to connect to the DPG-30R and DPG-MC120R AC in 100-240 V Controller DPG-MC120R AD IF Control DC output 1 AC in 380-480 V Control DC output 2 AC in...

  • Page 41: Cables To Connect To The Dpg-30R And Dpg-Mc240R

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 3. Setup 3-4-2. Cables to connect to the DPG-30R and DPG-MC240R AC in 100-240 V Controller DPG-MC240R AD IF Control DC output 1 AC in 380-480 V Control DC output 2 AC in...

  • Page 42: Differences In Cabling By Rating

    This DC power supply system has eight types of configurations from 30 kW to 240 kW. The connection for the control cable between the DPG-30R and the DPG-MC60R (120R,240R) is made by connecting the cables from 1 in order. A configuration error will occur on the controller when the power setting switch position is incorrect or the cable connection points are incorrect.

  • Page 43: Operation

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 4. Operation 4. Operation This chapter describes how to operate and use the system. 4-1. DPG-30R and DPG-MC60R/120R/240R operations 4-1-1. Operations This power supply system is connected to an external control device such as a PLC and that device controls the power supplies.

  • Page 44: System Power Each Power Setting

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 4. Operation 4-1-3. System power each power setting To match the system configuration of the power supply, rated output values for LEVEL signal (DCV, DCI, DCP) and each monitor signal will change. Please refer to the table below.

  • Page 45: Controller Display

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 4. Operation 4-1-5. Controller display Operations are performed with the procedures below. Based on "Figure 3-14 Power supply and external PLC connections" in the previous section, verify the connections for the cables and connectors, and verify that the power setting is accurately configured.
  • Page 46 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 4. Operation 7. SET LED turns on for 0.2 seconds HARC MARC 8. MARC LED turns on for 0.2 seconds HARC MARC MARC 9. The CPU firmware version turns on for 1.0 second ex: Ver 00.01...
  • Page 47 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 4. Operation * The display below is shown When the power supply is not connected to the controller HARC MARC 2) Power/voltage/current/LEVEL monitor display When the startup display is finished, the display changes to the main screen.
  • Page 48 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 4. Operation 3) Change the display method By quickly pressing the DSP SW, the display changes in the following order. (Initial) kW monitor & V monitor -> A monitor & V monitor ->...
  • Page 49 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 4. Operation 4) Output value setting method (during LOCAL only) Only during LOCAL, you can set the output values by pressing and holding the DSP SW. The display changes to (Initial) kW monitor & V monitor ->...
  • Page 50 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 4. Operation Quick press △ SW 3 times HARC MARC Flashing Flashing Quick press ENT SW HARC MARC 5) Error display example When the 1st error is E303 and the second error is E321...

  • Page 51: Error Code, Warning Code Display On The Controller

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 4. Operation MARC HARC 3. Monitor display The display returns to the monitor display. MARC HARC When the error is reset, the error information for display usage between the last error reset (or from when the power was turned on) up to this error reset is discarded.
  • Page 52 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 4. Operation Table 4-4 Controller warning display Warning name Code Warning details Classification (*) V_OUT_OVER C300 Occurs when the output voltage has exceeded 1700 V Occurs when a short circuit on the load side has been...
  • Page 53 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 4. Operation 4-1-7. Behavior of more than one error occurs If multiple errors occur, and then output by switching up to a maximum of 20 error code in chronological order every 3 seconds.

  • Page 54: Maintenance

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 5. Maintenance 5. Maintenance The chapter describes necessary maintenance so the system can be used for years to come. If you neglect maintenance, the system will wear out more quickly, which may cause it to stop working.

  • Page 55: Recommended Parts For Replacement

    5. Maintenance 5-2. Recommended parts for replacement In order to use the power supply for a long period of time, ULVAC recommends a periodic overhaul. See Table 5-1 below for parts that we recommend you replace during the periodic overhaul.

  • Page 56: Troubleshooting

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 6. Troubleshooting 6. Troubleshooting This chapter explains corrective action when problems occur. 6-1. Troubleshooting When a problem occurs, please perform an initial diagnostic with the LED indicators on the front panel of the power supply and the controller display according to the method below.
  • Page 57 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 6. Troubleshooting Symptom Possible cause Action TEMP ERROR Overheating in the inverter or If there is no cause such as a drop in rectification circuit power supply cooling efficiency near the power supply's front or rear, replace the power supply.

  • Page 58: Reference Materials

    DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 7. Reference Materials 7. Reference materials The following materials on the DPG-30R and DPG-MC60R(MC120R/MC240R) are included with this manual as a reference. (1) DPG-30R external view (2) DPG-MC60R external view (3) DPG-MC120R external view...
  • Page 59 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 7. Reference Materials Figure 7-1 DPG-30R external view...
  • Page 60 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 7. Reference Materials Figure 7-2 DPG-MC60R external view...
  • Page 61 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 7. Reference Materials Figure 7-3 DPG-MC120R external view...
  • Page 62 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 7. Reference Materials Figure 7-4 DPG-MC240R external view...
  • Page 63 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 7. Reference Materials Figure 7-5 DPG-30R warning label locations...
  • Page 64 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 7. Reference Materials Figure 7-6 DPG-MC60R warning label locations...
  • Page 65 DC Power Supply [DPG-30R & DPG-MC60R, DPG-MC120R, DPG-MC240R] 7. Reference Materials Weight warning Danger high voltage Nameplate label Weight label Figure 7-6 DPG-MC120R, DPG-240R warning label locations...

This manual is also suitable for:

Dpg-mc60rDpg-mc120rDpg-mc240r

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