Sorensen DCS-E Series Instruction Manual

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SORENSEN

Division of Elgar

9250 Brown Deer Road

San Diego, CA 92121-2294

1-800-525-2024

Tel: (858) 450-0085

Fax: (858) 458-0267

Email: sales@sorensen.com

www.sorensen.com

This document contains information proprietary to Sorensen, Elgar Electronics Corporation. The information

contained herein is not to be duplicated or transferred in any manner without prior written permission from Sorensen.

April 28, 1998

www.valuetronics.com

DCS-E SERI ES

POWER SU PPLI ES

Instruction Manual

This manual covers models:

8-125E

20-50E

33-33E

40-25E

50-20E

60-18E

80-13E

150-7E

300-3.5E

600-1.7E

Document No. M360761 Rev D

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Summary of Contents for Sorensen DCS-E Series

Page 1 ©1998 by Sorensen, Division of Elgar Electronics Corporation This document contains information proprietary to Sorensen, Elgar Electronics Corporation. The information contained herein is not to be duplicated or transferred in any manner without prior written permission from Sorensen. April 28, 1998 Document No.
Page 2 Buyer returns the defective product in the original, or equivalent, shipping container; • if, upon examination of such product by Sorensen it is disclosed that, in fact, a defect in materials and/or workmanship does exist, that the defect in the product was not caused by improper conditions, misuse, or negligence;...
Page 3 All the safety instructions and advice notes are to be followed. Neither Sorensen, San Diego, California, USA, nor any of the subsidiary sales organizations can accept any responsibility for personal, material or consequential injury, loss or damage that results from improper use of the equipment and accessories.
Page 4 Earth (Ground) Terminal ABOUT THIS MANUAL This manual has been written expressly for the Sorensen DCS 1KW series of power supplies which have been designed and certified to meet the 1997 Low Voltage and Electromagnetic Compatibility Directive Requirements of the European Community. Units that comply with the directive are designated by an ‘E’...
Page 5 TABLE OF CONTENTS SECTION 1. FEATURES AND SPECIFICATIONS..................... 1-1 1.1 D ................................ 1-1 ESCRIPTION 1.2 O ............................... 1-1 PERATING ODES 1.3 P ............................. 1-1 OWER UPPLY EATURES 1.4 S ..............................1-2 PECIFICATIONS 1.4.1 Electrical Specifications..........................1-2 1.4.2 Mechanical Specifications..........................1-3 SECTION 2.
Page 6 TABLE OF CONTENTS (Continued) SECTION 3. THEORY OF OPERATION......................3-1 3.1 P (A2 A ) ...........................3-1 OWER IRCUIT SSEMBLY 3.1.1 Basic Off-Line Switching Regulator Theory ....................3-1 3.1.2 Simplified Full Bridge Converter Theory .......................3-1 3.1.3 Detailed Circuit Description..........................3-3 3.2 M (A1 A ) ...........................3-8 ETER IRCUIT...
Page 7 SORENSEN DCS SERIES MANUAL FEATURES and SPECIFICATIONS SECTION 1. FEATURES AND SPECIFICATIONS Description DCS Series power supplies are 1000W supplies designed to provide highly stable, continuously variable output voltage and current for a broad range of development, system and burn-in applications. The series consists of ten models designated by the DCS prefix, followed by the output voltage and current ratings.
Page 8 FEATURES and SPECIFICATIONS SORENSEN DCS SERIES MANUAL • External indicator signals for remote monitoring of OVP status, local/remote programming status, thermal shutdown, and output voltage and current. • Optional IEEE-488 interface for complete remote programming and readback capability. Specifications 1.4.1...
Page 9 SORENSEN DCS SERIES MANUAL FEATURES and 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: 1mS recovery to 1% band for 30% step load change from 70% to 100% or...
Page 10 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 Service Department, Sorensen Company. Customer Service Inquiries: 1-800-458-4258. Initial Inspection The equipment should be inspected for damage as follows: •...
Page 11 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL 5. Reinstall the cover and replace screws. 6. Install a 125Vac 20Amp plug and cord ensuring that the neutral (white) wire and line (black) wire are connected in the correct positions and that the safety ground wire is connected to the ground screw.
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Page 13 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL 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 14 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION Controls, Connectors, and Indicators Refer to Figure 2-1 and the descriptions below. 2.5.1 Front Panel 1. AC Power Switch 2. AC Input Circuit Breaker 3. OVP Adjust Potentiometer: Manual adjustment for OVP trip level 4.
Page 15 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL Table 2-1 J3 Program, Sense and Monitor Connector Description (D-subminiature 25 Pin Female) * PIN NUMBER FUNCTION 1..... AC/DC Shutdown Input (12-250Vac or 12-130Vdc) TTL Shutdown Input 2..... Return for Shutdown Input Signals +12Vdc Output (1k ohm source impedance) 3.....
Page 16 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION 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.
Page 17 Operation of the 300V or 600V models in the negative output mode is in violation of the European Community’s Low Voltage Directive. NOTE: If a -300V or -600V supply is required, please contact the Sorensen Sales Department or Customer Service for availability. www.valuetronics.com...
Page 18 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION Single Supply Operation (Local Mode) To operate the DCS power supply in local mode, first install the unit and connect the load following the instructions in Sections 2.1 to 2.6. Check that switch SW1 (mounted internally on the main printed circuit board) is set for local operation and that the J3 mating connector on the rear of the unit is in place with jumpers connected for local operation.
Page 19 This is limited by the creepage/clearance distances internal to the construction of the metal shell 25-pin ‘D’ connector mated to J3. If a higher output voltage range is required, contact the Sorensen Sales Department or Customer Service for availability. 2. The maximum allowable current for a series string of power supplies is the rated output current of a single supply in the string.
Page 20 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION 2.9.1 Front Panel OVP Operation To set the trip level from the front panel use the following procedure: With the unit off and disconnected from its AC source remove the cover and check that switches SW1-4 and SW1-8 are closed (factory default setting).
Page 21 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL SWITCH SW1 CONNECTOR J3 1312 OPEN CLOSED 0-5V 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)
Page 22 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION 2.9.3 Remote Programming of OVP with an External Resistance To remotely program the OVP trip level using a 5k ohm external potentiometer use the following procedure. With the unit off and disconnected from its AC source remove the cover, set switch SW1-8 open and check that switch SW1-4 is closed (default factory setting for switch SW1-4).
Page 23 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL 2.9.4 Remote Programming of OVP with External Current Sources To remotely program the OVP trip level using a 0-1mA current source use the following procedure. With the unit off and disconnected from its AC source remove the cover and set switches SW1-4 and SW1-8 closed (default factory setting).
Page 24 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION 2.9.5 Remote OVP Sensing The default configuration for the OVP circuit senses the output voltage at the power supply output terminals. For applications using remote sensing where there is a need to accurately monitor the actual load voltage, the following procedure allows the OVP sense point to be shifted from the power supply output to the sense line connection points.
Page 25 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL 2.11 Remote Programming of Output Voltage and Current Limit The output voltage and current limit of the power supply can be remotely programmed through the rear panel J3 connector using external voltage sources, current sources and resistances. Switch SW1 on the A2 printed circuit board controls the programming as diagrammed below.
Page 26 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION SWITCH SW1 CONNECTOR J3 1312 OPEN CLOSED 0-5V 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)
Page 27 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL SW1-1 SW1-2 PROGRAMMING VOLTAGE OPEN OPEN 0-5Vdc and Local Mode CLOSED CLOSED Not Used CLOSED OPEN 0-10Vdc OPEN CLOSED 0-100mV To remotely program the output current limit, set switches SW1-1 and SW1-2 as shown above, remove the jumpers connecting pins 10 to 11 and 22 to 23 of connector J3 and connect the external voltage source between pins 10 (positive) and 12 (return).
Page 28 SORENSEN DCS SERIES MANUAL INSTALLATION and OPERATION 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 Resistive Programming of the Output Voltage...
Page 29 INSTALLATION and OPERATION SORENSEN DCS SERIES MANUAL 2.11.3 Programming With an External Current Source The output voltage and current limit can be programmed using an external 0-1mA current source. To program the output voltage, set the front panel voltage control to maximum, set switch SW1-3 open (default factory setting) and remove the jumper between pins 20 and 21 of connector J3.
Page 30 SORENSEN DCS SERIES MANUAL 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 31 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.
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Page 33 SORENSEN DCS SERIES MANUAL THEORY OF OPERATION A current shunt (R91) in the output return line develops a voltage dependent on the output current. This current information is compared to the setting of the front panel current limit control in the current control circuit (U4-1 and U15).
Page 34 THEORY OF OPERATION SORENSEN DCS SERIES MANUAL For 230Vac operation rectifier CR35 and filter capacitors C32(A,B,C) and C72(A,B,C) are configured as a full wave bridge. For 115Vac operation the input voltage selector P1 is switched so that CR35, C32(A,B,C) and C72(A,B,C) form a voltage doubler.
Page 35 SORENSEN DCS SERIES MANUAL THEORY OF OPERATION Models DCS 150-7, DCS 300-3.5 and DCS 600-1.7 On DCS 150-7 and DCS 300-3.5, diodes CR301-CR304 form the rectifier bridge with resistors R301-R304 and capacitors C301-C304 providing snubbing for the diodes. Resistor R305 and capacitor C305 form the snubber on the secondary of transformer T1.
Page 36 THEORY OF OPERATION SORENSEN DCS SERIES MANUAL Auxiliary Supply and 6.2V Reference Circuit Transformer T4, rectifier CR42 and capacitors C9 and C10 provide the raw dc supply voltages from which the +12V and +5V auxiliary supplies are derived by three terminal regulators U10 and U11 respectively. Two additional regulators (U12 and U13) provide the 12V feed to drive FETs Q7-Q12, Q18 and Q19 on the primary of T2, and the 12V feed to PWM U6.
Page 37 SORENSEN DCS SERIES MANUAL THEORY OF OPERATION Remote Programming of the Output Voltage During remote programming of the output voltage with an external voltage source (0-5V or 0-10V) the local operation jumpers connecting J3 pins 8 to 9 and 20 to 21 are removed and the external source is connected between pins 9 (positive) and 12 (negative) of connector J3.
Page 38 THEORY OF OPERATION SORENSEN DCS SERIES MANUAL Meter Circuit (A1 Assembly) The A1 assembly is comprised of the voltmeter and ammeter displays, the output voltage and current limit controls, the local operation OVP adjusting potentiometer and the indicator LEDs. The operation of the voltage and current controls, the OVP potentiometer and the indicator LEDs is covered in the A2 description in Section 3.1.
Page 39 Units requiring repair during their warranty period should be returned to Sorensen for service. Unauthorized repairs performed by anyone other than Sorensen Company during the warranty period may void the warranty. Any questions regarding repair should be directed to the Service Department, Sorensen Company, Division of Elgar Company.
Page 40 MAINTENANCE SORENSEN DCS SERIES MANUAL 4.3.2 Internal Troubleshooting After reading the caution in Section 4.3 and completing the preliminary checks described in Section 4.3.1, remove the cover and proceed with internal troubleshooting using the information contained in Figure 4-1 as a guide to isolate the problem to a specific area of the circuit.
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Page 43 SORENSEN DCS SERIES MANUAL MAINTENANCE R11 R8 Figure 4-2 Refer to “About This Manual” for an explanation of these symbols. www.valuetronics.com...
Page 44 Most assemblies consist of parts common to all series models as well as parts which are model-specific, or differential. Parts Ordering Do not substitute parts without first checking with Sorensen's Service Department. Parts may be ordered from the factory with the information in the following sections. Order parts from:...
Page 45 PARTS LISTS SORENSEN DCS SERIES MANUAL Table 5-2. DCS 1 kW Parts Lists Number Assembly 1066830-008 Output PCB Assembly 1066830-01 Output PCB Assembly 1066830-020 Output PCB Assembly 1066830-080 Output PCB Assembly 5360726-01 Rectifier PCB Assembly 5360726-02 Rectifier PCB Assembly 5360726-03...
Page 46 SORENSEN DCS SERIES MANUAL DRAWINGS and SCHEMATICS SECTION 6. DRAWINGS AND SCHEMATICS General This section contains drawings and schematic diagrams for the DCS 1 kW power supply. The schematic diagrams should be used to understand the theory of operation and also be used as an aid in troubleshooting the unit.
Page 47 DRAWINGS and SCHEMATICS SORENSEN DCS SERIES MANUAL Table 6-2. DCS 1 kW Drawings/Schematics By Model Number Final Mother Mother Front Panel Front Panel Output Rectifier Rectifier Assembly Drawing Assembly Schematic Assembly Schematic Assembly Assembly Schematic Drawing Drawing Drawing Drawing Model...

This manual is also suitable for:

Dcs8-125e Dcs60-18e Dcs20-50e Dcs80-13e Dcs33-33e Dcs150-7e ... Show all