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SORENSEN
9250 Brown Deer Road
San Diego, CA 92121-2294
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 Sorensen, division of Elgar Electronics Corporation. The information
contained herein is not to be duplicated or transferred in any manner without prior written permission from Sorensen.
April 25, 2002
DLM-E
3kW & 4kW
Power Supplies
Operation Manual
This manual covers models:
DLM5–350E
DLM8–350E
DLM16–185E
DLM32–95E
DLM40–75E
DLM60–50E
DLM80–37E
DLM150–20E
DLM300–10E
DLM600–5E
©2002 by Sorensen, Division of Elgar Electronics Corporation
Series
DLM5–450E
DLM8–450E
DLM16–250E
DLM32–125E
DLM40–100E
DLM60–66E
DLM80–50E
DLM150–26E
DLM300–13E
DLM600–6.6E
Document No. M362000-01 Rev B
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Table of Contents
Troubleshooting
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Summary of Contents for Sorensen DLM5-350E
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Page 1: Power Supplies
©2002 by Sorensen, Division of Elgar Electronics Corporation This document contains information proprietary to Sorensen, division of Elgar Electronics Corporation. The information contained herein is not to be duplicated or transferred in any manner without prior written permission from Sorensen. April 25, 2002... -
Page 5: Safety Notice
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... - Page 6 SAFETY SYMBOLS...
- Page 7 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;...
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Page 8: About This Manual
ABOUT THIS MANUAL This manual has been written expressly for the Sorensen DLM–E 3kW and 4kW series of power supplies, which have been designed to meet the 1997 Low Voltage and Electromagnetic Compatibility Directive Requirements of the European Community. Since the goal of the Low Voltage Directive is to ensure the safety of the equipment operator, universal graphic symbols (see Safety Notice above) have been used both on the unit itself and in this manual to warn the operator of potentially hazardous situations. -
Page 9: Table Of Contents
CONTENTS Safety Notice ........................i Warranty ......................... iii SECTION 1 FEATURES AND SPECIFICATIONS ........1 Description......................1 Operating Modes ....................1 Power Supply Features ..................1 Specifications...................... 3 1.4.1 3 kW DLM–E Electrical Specifications..........3 1.4.2 4 kW DLM–E Electrical Specifications..........4 1.4.3 Additional Specifications............... - Page 10 Contents Sorensen DLM-E Series Location, Mounting, and Ventilation ..............14 2.5.1 Unit Dimensions .................. 14 2.5.2 Rack Mounting ..................14 2.5.3 Ventilation ................... 14 AC Input Power Connection................15 2.6.1 AC Input Power Requirements............15 2.6.2 Input Line Impedance ................. 15 Initial Functional Tests ..................
- Page 11 Sorensen DLM-E Series Contents Using Over Voltage Protection (OVP) .............. 39 4.4.1 Front Panel OVP Operation..............39 4.4.2 Resetting the OVP Circuit..............39 4.4.3 Programming OVP with an External Voltage Source ......40 Using the Shutdown Function................42 4.5.1 STANDBY Switch ................42 4.5.2...
- Page 12 Contents Sorensen DLM-E Series LIST OF FIGURES Figure 2–1. EMI Suppression Filter..................8 Figure 2–2. DLM–E Controls, Connectors, and Indicators (5V–80V models) ..... 11 Figure 2-3. DLM–E Controls, Connectors, and Indicators (150V–600V models) ....12 Figure 2–4. Single Load with Local Sensing (Default)............18 Figure 2–5.
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Page 13: Section 1 Features And Specifications
SECTION 1 FEATURES AND SPECIFICATIONS Description The DLM–E Series 3000 and 4000 watt power supplies are designed to provide highly stable, continuously variable output voltage and current for a broad range of development, system and burn–in applications. Model numbers for this series are designated by the DLM prefix, followed by the output voltage and current ratings. - Page 14 Features and Specifications Sorensen DLM-E Series • High input AC power factor, 0.98 typical, with single–phase input. • Front panel controls for Enable/Standby and Local/Remote modes of operation. • Simultaneous digital display of both DC voltage and current. • Front panel preview switch allows voltage, current, and OVP to be preset from local or remote control.
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Page 15: Specifications
Sorensen DLM-E Series Features and Specifications Specifications 1.4.1 3 kW DLM–E Electrical Specifications Model 5–350 8–350 16–185 32–95 40–75 60–50 80–37 150–20 300–10 600–5 Output Ratings: Output Voltage 0–5V 0–8V 0–16V 0–32V 0–40V 0–60V 0–80V 0–150V 0–300V 0–600V Output Current 0–350A... -
Page 16: Kw Dlm-E Electrical Specifications
Features and Specifications Sorensen DLM-E Series 1.4.2 4 kW DLM–E Electrical Specifications Model 5–450 8–450 16–250 32–125 40–100 60–66 80–50 150–26 300–13 600–6.6 Output Ratings: Output Voltage 0–5V 0–8V 0–16V 0–32V 0–40V 0–60V 0–80V 0–150V 0–300V 0–600V Output Current 0–450A 0–450A... -
Page 17: Additional Specifications
Sorensen DLM-E Series Features and Specifications 1.4.3 Additional Specifications AC Input: Output Nominal Input Input Input Range Input Current Input Power Power Voltage Option (47–63 Hz) Maximum Factor 230 VAC 3 kW 180–264 VAC L–L 21A RMS 0.98 Single–Phase 208 VAC 3 kW 180–264 VAC L–L... -
Page 18: Mechanical Specifications
Features and Specifications Sorensen DLM-E Series 1.4.4 Mechanical Specifications Unit Dimensions Height Width Depth Weight 87.6 mm (3.5 in) 482.6 mm (19 in) 508 mm (20 in) 18.2 kg (40 lbs.) Output Connector (Models DLM5–XXX through DLM80–XX) Connector type: Nickel–plated copper bus bars Approximate dimensions: 1"... -
Page 19: Section 2 Installation
SECTION 2 INSTALLATION Introduction This section provides recommendations and procedures for inspecting, testing, and installing the DLM–E 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. Become familiar with Controls, Indicators and Rear Panel layout (Section 2.4) 4. -
Page 20: Ac Source Grounding
Installation Sorensen DLM-E Series rated at 40V and over. Filter capacitors store potentially dangerous energy for some time after power is removed. Use extreme caution when biasing the output relative to the chassis due to potentially high voltage levels at the output terminals. The output of the DLM–E Series supplies may be biased up to a maximum voltage relative to the chassis as specified in Section 1 under Additional Specifications. -
Page 21: Operating And Servicing Precautions
2.2.5 Parts and Modifications Do not use substitute parts or make any unauthorized modifications to the power supply to ensure that its safety features are not degraded. Contact Sorensen customer service engineers for service and repair help. Initial Inspection Upon first receiving your DLM–E Series power supply, perform a quick physical check, paying particular attention to front panel controls and indicators as well as rear panel connectors and terminals. -
Page 22: Controls, Connectors, And Indicators
Installation Sorensen DLM-E Series Controls, Connectors, and Indicators Refer to Figure 2–2 or Figure 2-3 (depending on the model) and the descriptions below. 2.4.1 Front Panel User Controls and Indicators 1. CURRENT knob: 10 turn adjustment sets the output current. -
Page 23: Figure 2-2. Dlm-E Controls, Connectors, And Indicators (5V-80V Models)
Sorensen DLM-E Series Installation Figure 2–2. DLM–E Controls, Connectors, and Indicators (5V–80V models) Operation Manual... -
Page 24: Figure 2-3. Dlm-E Controls, Connectors, And Indicators (150V-600V Models)
Installation Sorensen DLM-E Series Figure 2-3. DLM–E Controls, Connectors, and Indicators (150V–600V models) Operation Manual... -
Page 25: Rear Panel
Sorensen DLM-E Series Installation 16. OTEMP (Over Temperature) indicator: Red LED lights when an over temperature shutdown has occurred. 17. LOCK (Lockout) indicator: Green LED lights when in Lockout mode. Activated by connection through rear panel DIP switch. Can only be activated when the front panel LOCAL/REMOTE switch is in the REMOTE position. -
Page 26: Location, Mounting, And Ventilation
Installation Sorensen DLM-E Series Location, Mounting, and Ventilation The DLM–E system supply is designed for use in rack mounted applications. Ensure that sufficient space is allowed for cooling air to reach the ventilation inlets on the front of the unit, and for fan exhaust air to exit from the rear of the unit. -
Page 27: Ac Input Power Connection
Sorensen DLM-E Series Installation AC Input Power Connection Before you can use the DLM–E system supply, you must determine your AC input power requirements and connect an appropriate cable or line cord to the input connector. The power supply is shipped with an input connector cover which you need to remove to make the input power connections. -
Page 28: Initial Functional Tests
Installation Sorensen DLM-E Series Initial Functional Tests Before connecting the unit to an AC outlet, make sure that the POWER switch is in the Off position, (down) and that the voltage and current control knobs are turned fully counter– clockwise. The two smaller switches directly to the right of the POWER switch should be depressed up to put the unit in the ENABLE and LOCAL position. -
Page 29: Load Conductor Ratings
Sorensen DLM-E Series Installation 2.8.1 Load Conductor Ratings As a minimum, load wiring must have a current capacity greater than the output current rating of the power supply. This ensures that the wiring will not be damaged even if the load is shorted. -
Page 30: Making The Connections
Installation Sorensen DLM-E Series 2.8.3 Making the Connections Load connections to the power supply are made at the positive and negative output terminals (or bus bars) at the rear of the power supply. See Figure 2–2. The power supply provides three load wiring mounting holes on each bus bar terminal, as specified in the following table. -
Page 31: Connecting Multiple Loads
Sorensen DLM-E Series Installation Figure 2–5. Single Load with Remote Sensing (Local sense lines shown are default J11 to busbar connections) 2.8.5 Connecting Multiple Loads Proper connection of distributed loads is an important aspect of power supply applications. Two common methods of connection are the parallel power distribution method and the radial distribution method. -
Page 32: Figure 2-6. Multiple Loads With Local Sensing
Installation Sorensen DLM-E Series Figure 2–6. Multiple Loads with Local Sensing (Local sense lines shown are default J11 to busbar connections) Figure 2–7. Multiple Loads with Remote Sensing (Local sense lines shown are default J11 to busbar connections) Operation Manual... -
Page 33: 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 DLM–E 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 34: Figure 3-1. Operating Modes
Basic Operation Sorensen DLM-E Series 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 35: Local Programming Mode Operation
Sorensen DLM-E Series 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 36: Using Remote Sensing
Basic Operation Sorensen DLM-E Series 6. Adjust the voltage control to the required voltage (this will be the maximum compliance voltage for applications using current mode operation). 7. Adjust the current control to the required current limit setting. 8. Release the V&I PREVIEW button. -
Page 37: Figure 3-3. J11 Sense Connector
Sorensen DLM-E Series Basic Operation 5. The optimal point for the shield ground must be determined by experiment, but the most common connection point is at the power supply's return output connection at the load. 6. Turn the power supply ON. - Page 38 Basic Operation Sorensen DLM-E Series This page intentionally left blank. Operation Manual...
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Page 39: Section 4 Advanced Operation
SECTION 4 ADVANCED OPERATION Introduction The DLM–E Series power supplies offer the following standard features: • Remote Programming of Output Voltage and Current Limit with 0–5V, 0–10V or 0–5k ohms (Section 4.3) • Overvoltage Protection (OVP) with front panel control or 0–5, 0–10V or 0–5k ohms programming (Section 4.4) •... -
Page 40: Configuring For Remote Programming, Sensing, And Monitoring
Advanced Operation Sorensen DLM-E Series Configuring for Remote Programming, Sensing, and Monitoring This section lists front panel switch, J11 connector, and rear panel DIP switch functions for the DLM–E Series supplies. Subsequently, it provides a location diagram (Section 4.2.2), in addition to procedures for resetting the jumpers and switches (Section 4.2.3), and for reconfiguring or... -
Page 41: Rear Panel Dip Switch
Sorensen DLM-E Series Advanced Operation Pin No. Function Pin No. Function Remote Output Enable Remote Shutdown Input (+). Positive or 1 = Enable, 0 = Disable negative true logic selection with S1 Remote Shutdown Return (–) +5 VDC Aux. Output... -
Page 42: Resetting Rear Panel Dip Switch Settings
Advanced Operation Sorensen DLM-E Series Switch Open Position Closed Position Function Position (Up) * (Down) S1-1 Voltage Programming Input Range 0–5 VDC 0–10 VDC S1-2 Current Programming Input Range 0–5 VDC 0–10 VDC S1-3 OVP Programming Input Range 0–5 VDC 0–10 VDC... -
Page 43: Remote Programming Of Output Voltage And Current Limit
Sorensen DLM-E Series Advanced Operation NOTE When the front panel LOCAL/REMOTE Switch is moved to REMOTE operation, voltage, current, and OVP programming functions must be remotely programmed. For clarity, only the connections for the function being described are shown in the following figures. -
Page 44: Programming Output Voltage And Current Limit With The Remote/Local Switch
Advanced Operation Sorensen DLM-E Series 4.3.1 Programming Output Voltage and Current Limit with the REMOTE/LOCAL Switch The front panel 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 45: Programming Output Voltage
Sorensen DLM-E Series Advanced Operation 4.3.2 Programming Output Voltage Programming Output Voltage with a 0–5 VDC or 0–10 VDC Source 1. Set S1-1, the rear panel DIP Switch, UP, in the open position for 0–5 VDC programming range. 2. Set S1-1, the rear panel DIP Switch, DOWN, in the closed position for 0–10 VDC programming range. -
Page 46: Figure 4-5. Programming Output Voltage With A 0-5K Ohm Resistance
Advanced Operation Sorensen DLM-E Series Programming Output Voltage with Resistance 1. Set S1-1, the rear panel DIP Switch, UP, in the open position for 0–5k ohm programming range. 2. Connect pins 9 (voltage programming input/positive) and 21 (1mA current source for voltage control) to the counter–clockwise end of the potentiometer and connect the tap... -
Page 47: Programming Output Current Limit
Sorensen DLM-E Series Advanced Operation 4.3.3 Programming Output Current Limit Programming Output Current Limit with a 0–5 VDC or 0–10 VDC Source 1. Set S1-2, the rear panel DIP Switch, UP, in the open position for 0–5 VDC programming range. -
Page 48: Figure 4-7. Programming Output Current Limit With A 0-5K Ohm Resistance
Advanced Operation Sorensen DLM-E Series Programming Output Current Limit with a 0–5k Ohm Resistance 1. Set S1-2, the rear panel DIP Switch, UP, in the open position for 0–5k ohm programming range. 2. Connect pins 10 (current programming input/positive) and 22 (1mA current source for current control) to the counter–clockwise end of the potentiometer and connect the tap... -
Page 49: Remote Programming Only The Output Voltage Or Current Limit
Sorensen DLM-E Series Advanced Operation 4.3.4 Remote Programming Only the Output Voltage or Current Limit The front panel REMOTE/LOCAL switch allows you to switch back and forth between remote and local programming signals for all three programming inputs of Voltage, Current, and OVP. -
Page 50: Figure 4-9. Programming Output Current Remotely, Local Control Of Voltage Limit/Ovp
Advanced Operation Sorensen DLM-E Series Remote Programming of the Current Limit Only CAUTION! Always remove J3 mating connector from supply before soldering. For remote programming of current limit only: 1. Turn off power to the supply. 2. Connect a programming source between pins 10 (current limit programming input/positive) and 12 (return). -
Page 51: Using Over Voltage Protection (Ovp)
Sorensen DLM-E Series 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 52: Programming Ovp With An External Voltage Source
Advanced Operation Sorensen DLM-E Series 4.4.3 Programming OVP with an External Voltage Source CAUTION! Always remove J3 mating connector from supply before soldering. Programming OVP with a 0–5 VDC or 0–10 VDC Source 1. Set S1-3, the rear panel DIP Switch, UP, in the open position for 0–5 VDC programming range. -
Page 53: Figure 4-11. Remote Programming Of Ovp With A 0-5K Ohm Resistance
Sorensen DLM-E Series Advanced Operation Programming OVP with a 0–5k Ohm Resistance 1. Set S1-3, the rear panel DIP Switch, UP, in the open position for 0–5 k ohm programming range. 2. Connect the external programming source between pins 3 (OVP programming input/positive) and 12 (return). -
Page 54: Using The Shutdown Function
Advanced Operation Sorensen DLM-E Series 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 55: Shutdown Application - Contact Closure
Sorensen DLM-E Series Advanced Operation Figure 4–12. Using Shutdown with a DC Input (Positive Logic) 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. -
Page 56: Figure 4-13. Using Shutdown With Contact Closure Of A Normally Open Relay (S1-6 Up)
Advanced Operation Sorensen DLM-E Series Figure 4–13. Using Shutdown with Contact Closure of a Normally OPEN Relay (S1-6 Up) Figure 4–14. Using Shutdown with Contact Closure of a Normally OPEN Relay (S1-6 Down) Figure 4–15. Using Shutdown with Contact Closure of a Normally CLOSED Relay (S1-6 Up) -
Page 57: Remote Monitoring
Sorensen DLM-E Series Advanced Operation Figure 4–16. Using Shutdown with Contact Closure of Normally CLOSED Relay (S1-6 Down) Remote Monitoring 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. Rear panel DIP switch S1 settings allow you to select either a 0–5 VDC or a 0–10 VDC range for the output. -
Page 58: Status Indicators
Advanced Operation Sorensen DLM-E Series 4.6.2 Status Indicators Status indicators for thermal shutdown, OVP circuit, programming mode, and operating mode are available via connections on the J3 connector on the rear panel. The following table shows the indicator signals, the J3 connector pin at which they are available, an approximation of the signal magnitude, and the source impedance through which the signal is fed. -
Page 59: Configuring Multiple Supplies For Split Supply Operation
Sorensen DLM-E Series Advanced Operation CAUTION! Remote sensing must not be used during series operation. CAUTION! The remote programming input is internally referenced to the supply's negative output. Do not connect any remote programming input lines on the J3 connector to the supply's positive output. -
Page 60: Figure 4-18. Split Supply Operation Of Multiple Supplies (Two Positive Voltages)
Advanced Operation Sorensen DLM-E Series CAUTION! To prevent possible damage to the supply, do not connect the remote program return line of the negative supply to the common connection. Figure 4–18. Split Supply Operation of Multiple Supplies (Two Positive Voltages) (Local sense lines shown are from J11 to busbars) Figure 4–19. -
Page 61: Configuring Multiple Supplies For Parallel Operation
Sorensen DLM-E Series Advanced Operation 4.7.3 Configuring Multiple Supplies for Parallel Operation Parallel operation is used to obtain a higher current output supply using up to five units. The DLM–E supplies are designed to be easily paralleled with current sharing between units with the use of a simple cable between supplies. -
Page 62: Front Panel Lockout
Advanced Operation Sorensen DLM-E Series Figure 4–20. Parallel Operation of Multiple Supplies (Local sense lines shown are from J11 to busbars) Front Panel Lockout The front panel lockout mode enables a user to disable the front panel controls when the unit is being programmed exclusively through the J3 remote input connector. -
Page 63: Section 5 Maintenance And Troubleshooting
Troubleshooting 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 question regarding repair should be directed to the Service Department, Sorensen Company, Division of Elgar Electronics Corporation, 1-800-458-4258. -
Page 64: Troubleshooting At The Operation Level
Maintenance and Troubleshooting Sorensen DLM-E Series 5.2.2 Troubleshooting at the Operation Level Use the checks in Table 5–1 to ensure the DLM–E Series power supply is configured and connected for default operation at the front panel. If you need any further troubleshooting, call customer service. -
Page 65: Calibration
Sorensen DLM-E Series Maintenance and Troubleshooting Calibration Calibration of the output voltage, current, or OVP is accomplished using multiturn trimpots. Table 5–2 gives the location, function, and effect of each potentiometer. Calibration is performed at the factory during testing. Recalibration should be performed annually and following major repairs. -
Page 66: Ordering Parts
Maintenance and Troubleshooting Sorensen DLM-E Series Ordering Parts Do not substitute parts without first checking with Sorensen's Service Department. Parts may be ordered from the factory with the information below. Order parts from: SORENSEN Sales & Technical Support 9250 Brown Deer Road...
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