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Amrel PQ Series Operation Manual

Programmable dc power supply
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OPERATION MANUAL
PQ Series
Programmable DC Power Supply
Revision 1.0
Release Date: 04/11/02
/AMERICAN RELIANCE, INC.
11801 GOLDRING ROAD, ARCADIA, CA 91006
PHONE: (626) 303-6688 FAX: (626) 358-3838

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  • Page 1 OPERATION MANUAL PQ Series Programmable DC Power Supply Revision 1.0 Release Date: 04/11/02 /AMERICAN RELIANCE, INC. 11801 GOLDRING ROAD, ARCADIA, CA 91006 PHONE: (626) 303-6688 FAX: (626) 358-3838...

  • Page 2: Limited Warranty

    LIMITED WARRANTY American Reliance warrants to the original user or purchaser that your unit is free from any defects in material or workmanship for a period of one year from the date of purchase. If any defect is discovered within the warranty period, American Reliance will repair or replace the unit, subject to verification of the defect or malfunction, upon delivery or prepaid shipment to American Reliance.
  • Page 3 El Monte, CA 91732 Attn: RMA # _________________ Please obtain return authorization from AMREL before returning any product. The instrument must be carefully packed, preferably in its original carton with PE Foam, and should be accompanied by a letter or note containing the following information:...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Section Title Page 1.0 GENERAL INFORMATION Description Features Cooling Installation Power Requirements Specifications 2.0 OPERATING INSTRUCTIONS General Operation Controls and Indicators Preparation for Use 2.3.1 Unpacking 2.3.2 Electrical Check Modes of Operation 2.4.1 Normal Mode 2.4.2 Constant Voltage 2.4.3 Constant Current Remote Sensing Standard Programming...
  • Page 5 3.0 PRINCIPLES OF OPERATION General Theory of Operation 3.2.1 Power Circuit 3.2.2 Input Board 3.2.3 Chopper Module 3.2.4 Inverter Module 3.2.5 Output Module 3.2.6 Other Printed Circuit Boards 4.0 MAINTENANCE AND TROUBLE SHOOTING General Trouble Shooting Guide Calibration 4.3.1 Control Board 4.3.2 Driver Board...

  • Page 6: General Information

    PQ SERIES power supplies can operate as a voltage source or current source depending on the control settings and load conditions. If the power supply is operating as a voltage source and the load increases to a point beyond the current command setting, the power supply automatically crosses over to current mode control and operates as a current source at that setting.

  • Page 7: Cooling

    Section 2.14. PQ Series power supplies are optionally available for operation on 440/480 V, 3 N , 50 to 60 Hz mains. Units are normally wired for 480 V operation and information concerning conversion is covered in Section 2.14.
  • Page 8 Programming resistors: 1 K S full scale for output voltage, output current, over voltage shutdown, and over current shutdown. Ambient Temperature: 0 to 50°C. Storage Temperature: -25 to +85°C. Temperature coefficient: 0.04 %/°C of maximum output current. Size: 5¼"H x 19"W x 24"D, see figure 1.1 for details. Weight: 125 lbs for 10 kW models, 97 lbs for 6.6 kW models, and 74 lbs for 3.3 kW models.
  • Page 9 6.6 KW MODELS AND RATINGS INPUT CURRENT (Aac) VOLTS AMPS RIPPLE EFF. 208/240 V 440/480 V MODEL mVrms MODELS MODELS PQ10-600 PQ16-400 PQ20-330 PQ32-200 PQ40-165 PQ50-130 PQ80-82 PQ100-66 PQ125-53 PQ160-41 PQ200-33 PQ250-26 PQ375-17 PQ500-13 PQ625-10...
  • Page 10 3.3 KW MODELS AND RATINGS INPUT CURRENT (Aac) VOLTS AMPS RIPPLE EFF. 208/240 V 440/480 V MODEL mVrms MODELS MODELS PQ10-300 PQ16-200 PQ20-165 PQ32-100 PQ40-82 PQ50-65 PQ80-41 PQ100-33 PQ125-26 PQ160-20 PQ200-16 PQ250-13 PQ375-8 PQ500-6 PQ625-5 Notes: 1) Rating specified at 208 and 440 V input. 2) Specifications subject to change without notice.
  • Page 11 Figure 1.1 PQ Series package drawing...

  • Page 12: Operating Instructions

    2.0 OPERATING INSTRUCTIONS General Operation As shipped, the power supply is configured for local sensing, internal programming, and 208 V, 3 N input. The front panel voltage and current controls set the boundary limits for output voltage and current, respectively. The impedance of the load determines whether the unit is voltage or current controlled and the illumination of the respective mode indicator light indicates the state.

  • Page 13: Electrical Check

    2.3.2 Electrical Check Check that switches S1 and S2, located at the rear of the supply, are set to position 1, the default switch positions. As shown in figure 2.2, switch positions depict normal local sense and programming configurations. It is recommended that the following brief electrical check be made shortly after unpacking the supply.

  • Page 14: Modes Of Operation

    Modes of Operation 2.4.1 Normal Mode PQ series power supplies are normally shipped with its switch settings arranged for constant voltage/constant current, local sensing, and local programming. This is set by the programming switches, S1 and S2, located at the rear of the supply. As illustrated in figure 2.2, all of the programming switches should be set to position 1.

  • Page 15: Constant Current

    Turn off the power supply, remove the short on the output terminals, and connect the load. The unit is now ready for operation. 2.4.3 Constant Current To select a constant current output, proceed as follows: With the supply off, short the output terminals, set all controls to full counterclockwise, and advance the voltage control one turn clockwise.
  • Page 16 Figure 2.3 (a) Standard and (b) remote sensing...
  • Page 17 Figure 2.4 Standard programming configuration using internal potentiometers...

  • Page 18: Remote Programming

    Remote Programming PQ series supplies allow voltage, current, voltage trip, and current trip to be programmed from a remote location. Programming can be accomplished either by resistive, voltage, or current programming circuits. Figure 2.5 illustrates the three alternatives for programming output voltage. The method applies equally to programming an output current, voltage trip, and current trip.
  • Page 19 Figure 2.5 External (a) resistive, (b) voltage, and (c) current programming...

  • Page 20: Voltage Programming

    2.7.2 Voltage Programming Voltage programming requires setting positions 1 and 2 of S2 to 0 and connection of an external voltage reference between terminal 7 of JO2 (positive) and terminal 4 of JO2 (negative). To program an output current, voltage trip, or current trip, use the same method and refer to figure 2.4 for terminal identification.

  • Page 21: Voltage And Current Monitoring

    (10) (11) (12) where: : programming current source. Voltage and Current Monitoring Two operational amplifiers are provided for master/slave series and parallel operation. As illustrated in figure 2.6, these amplifiers can also be used to monitor output voltage and current. These outputs may be used for external instrumentation or process control.
  • Page 22 Figure 2.6 Monitoring output (a) voltage and (b) current Input control lines are or'd with front panel controls for start, stop, interlock set, and reset. To force any state, apply +5 V between the input control line and isolated return. An isolated 5 V, 100 mA source is provided at terminal 14 of JS1 for this application.
  • Page 23 Figure 2.7 Digital control lines Figure 2.8 Digital output monitoring lines...

  • Page 24: Diagnostic Functions

    2.10 Diagnostic Functions Diagnostic functions and mode of control are embedded in the supply's closed loop control. The power supply will operate under voltage control or current control depending on which setting is lowest. Voltage control and current control also contain a soft start function which causes voltage and/or current to ramp to the desired set point after power is initiated.

  • Page 25: Parallel Operation

    2.11 Parallel Operation Two or more PQ Series power supplies can be connected in parallel to obtain a total output current greater than that available from one power supply. The total output current is the sum of the output currents of the individual power supplies. Each power supply can be turned on or off separately.

  • Page 26: Series Operation

    To add a second slave, make the same connections to the current sensing terminals of the master and connect the second slave in parallel with the other two supplies. 2.12 Series Operation Two or more power supplies can be connected in series to obtain a total output voltage greater than that available from one power supply.
  • Page 27 Figure 2.7 Master/slave parallel connection Figure 2.8 Master/slave series connection...

  • Page 28: Pulse Loading

    2.14 Conversion to 240/440 V Operation PQ series supplies are normally wired for 208 V, 3 N operation. For conversion to 240 V, 3 N operation, two connections have to be changed inside the supply. Disconnect all power leads to the power supply and remove the top cover. Locate main transformer T1.
  • Page 29 AC INPUT: A: Phase A input. B: Phase B input. C: Phase C input. GND: System ground. DC OUTPUT: VO+: Positive output. VO- : Negative output. PROGRAMMING INPUTS: REF GND: Reference ground. VO1+: Positive output sense. VO1-: Negative output sense. VS+: Non-inverting input to voltage sense amplifier.
  • Page 30 IVREF: Voltage control reference current. IIREF: Current control reference current. ITVREF: Over voltage trip reference current. ITIREF: Over current trip reference current. RV: Voltage control resistance. RI: Current control resistance. RTV: Over voltage trip control resistance. RTI: Over current trip control resistance. VREF: Voltage control input reference.
  • Page 31 OPTICALLY ISOLATED DIGITAL OUTPUTS: Standby: Standby. Power: Control circuit power. Int Ctl: Internal control. Ext Ctl: External control. PGM Line: Program line shutdown. Over Voltage: Over voltage trip shutdown. Over Current: Over current trip shutdown. Phase Loss: Phase loss shutdown. Thermal: Thermal overload shutdown.

  • Page 32: Principles Of Operation

    The output of the main power transformer is converted to dc via rectifiers. Low voltage versions of the PQ Series power supply use midpoint diode configurations and higher voltage versions use bridge configurations. The dc output voltage is filtered with a pie section filter. This, in combination with the dc link inductors, form a double stage inductive capacitive (LC) filter.
  • Page 33 Figure 3.1 Block diagrams...

  • Page 34: Theory Of Operation

    of a problem, the control board is signaled to shutdown the system. The display board contains light-emitting diodes for displaying diagnostic conditions and provides an interface for meters and switches. It also channels control and diagnostic functions to optical isolators for external functions. All diagnostic functions are directly coupled to the error signal.

  • Page 35: Input Board

    Board. The Interface Board contains programming switches and interface external connectors for custom user connections. Thermal switches TB1 and TB2 are connected to the two main heatsinks where the the main power semiconductors are mounted. 3.2.2 Input Board Schematic* 108208 illustrates the Input Board. The Input Board contains system fuses, optional EMI filter, fuse detector, and 3 N ac voltage detector.

  • Page 36: Output Module

    The remaining printed circuit boards consist of the Gate Driver Board, 108945; the Control Board, 108944; Display Board, 108846; and Interface Board, 108947. These boards are strictly small signal and should be treated as replaceable subassemblies. * Schematic will be provided by AMREL upon signing Non Disclosure agreement...

  • Page 37: Maintenance And Trouble Shooting

    4.0 MAINTENANCE AND TROUBLE SHOOTING General The PQ Series power supplies consist of a multistage power processing system. Because of its complexity, it is highly recommended that all repairs be performed by the factory or qualified power supply technician. Before attempting maintenance or repair, the technician should be familiar with the components of the systems and the theory of operation.

  • Page 38: Calibration

    Calibration 4.3.1 Control Board Current Reference Calibration Set the power supply for remote resistive programming (see figures 2.4 and 2.5) using two external, precision 1K resistors. Set positions 2 and 4 of switch S2 to 0 and connect 1K precision, external resistors between terminals 20 and 4 of JO2 and terminals 21 and 5 of JO2.

  • Page 39: Driver Board

    Place the dc voltmeter across terminal 2 of JO2 and terminal 4 of JO2. With power applied to the control circuit and with the main contactor off, adjust potentiometer P3 for a null at terminal 2 of JO2. Using current mode control, increase the output current to half rating and adjust potentiometer P4 to 1.00 V.

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