INSTRUCTION MANUAL FOR 500A/102A/152A/202A POWER SUPPLY Document: 83-493-001 Rev. K TDK-Lambda Americas 405 Essex Road, Neptune, NJ 07753 Tel: (732) 922-9300 Fax: (732) 922-9334 Web: www.US.TDK-Lambda.
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ONE YEAR WARRANTY TDK-Lambda Americas, Inc. (405 Essex Road, Neptune, N.J. 07753), warrants that the unit is free from defects in material or workmanship for a period of ONE YEAR from the date of initial shipment. TDK-Lambda Americas Inc. will service and, at its option, repair or replace parts which prove to be defective. This will be done free of charge during the stated warranty period.
TDK-Lambda MANUFACTURER'S PRODUCT DECLARATION INTENDED PURPOSE (USE) The Power Supplies described by this manual are defined by TDK-Lambda Americas Inc. as a component for use in the composition of an apparatus as defined in Article 1 (1) of the EMC Directive (89/336/EEC). These products, as individual components, do not perform in themselves a direct function for the user of the end product.
TDK-Lambda Description of symbols used in product labeling SYMBOL PUBLICATION DESCRIPTION EC Council European Community Directive 93/68/EEC Conformity Assessment Product Mark IEC 348 Attention, consult Accompanying documents IEC 60417-1-5036 Dangerous voltage IEC 60417-1-5019 Protective earth (e.g. power line earth ground) IEC 60417-1-5017 Functional earth (e.g.
ELECTRICAL STANDARDS All company primary standards are either certified or are traceable to certification by the National Institute of Standards and Technology. CLAIM FOR DAMAGE IN SHIPMENT This instrument received comprehensive mechanical and electrical inspection before shipment. Immediately upon receipt from the carrier, and before operation, this instrument should be inspected visually for damage caused in shipment. If such inspection reveals damage in any way, a claim should be filed with the carrier.
TABLE OF CONTENTS CHAPTER 1 INTRODUCTION ........................................................................................................................1 1.1 DESCRIPTION.......................................................................................................................................1 CHAPTER 2 SPECIFICATIONS .....................................................................................................................2 2.1 AVERAGE CHARGING RATE ...........................
CHAPTER 5 APPLICATIONS .......................................................................................................................16 5.1 DETERMINING CAPACITOR CHARGE TIME.....................................................................................16 5.2 VOLTAGE REVERSAL ........................................................................................................................16 5.3 PARALLELING UNITS ............................................................................
CHAPTER 1 INTRODUCTION 1.1 DESCRIPTION The Series 500A/102A/152A/202A are High Voltage Switching Power Supplies designed specifically for charging capacitors in laser systems and other pulsed power applications. The 500A provides 500 J/s. the102A is 1000 J/s, 152A is 1,500 J/s, and the 202A provides 2000 J/s of average power and can be paralleled indefinitely for higher total system power. TDK-Lambda Americas Inc.
CHAPTER 2 SPECIFICATIONS 2.1 AVERAGE CHARGING RATE 500J/s, 1000J/s, 1500J/s, 2000J/s at rated Output Voltage 2.2 PEAK CHARGING RATE 550J/s, 1100J/s, 1650J/s, 2200J/s at rated Output Voltage 2.3 NUMBER OF MODELS IN SERIES 12 Standard (others at extra cost) 2.4 STANDARD VOLTAGE RANGES 1kV, 1.5kV, 2kV, 3kV, 4kV, 5kV, 5kV, 10kV, 15kV, 20kV, 30kV and 40kV. All models continuously variable from 0 to 100% of rated output voltage. 2.4.1 LINEARITY Linear to within 1% of full scale. 2.4.2 ACCURACY 1% of rated. 2.
2.9 POWER FACTOR Non PFC 0.65 All models PFC 0.98 Table 2-3 Power Factor 2.10 EFFICIENCY Better than 85% 2.11 STORED ENERGY Less than 0.3 Joules all models 2.12 STABILITY 0.2% TO 300 Hz. For higher repetition rates, consult factory 2.13 PULSE TO PULSE REPEATABILITY ±0.2% TO 300 Hz. For higher repetition rates, consult factory 2.14 TEMPERATURE COEFFICIENT 100ppm per ºC 2.15 AMBIENT TEMPERATURE Storage -40 to +85ºC. Operating -20 to +45ºC 2.16 HUMIDITY 90%, non-condensing 2.
2.22 ACCESSORIES • • • Detachable 8 feet (2.4 meters) HV Cable (see Table 2.1) 15 pin “D” plug mating control connector Operating Manual 2.23 OPTIONS 2.23.1 Suffix –SYS Parallel Operation 2.23.2 Suffix –LH “Low Inhibit” - A +10 to 15 volt (high) signal will allow power supply operation. A 0 to +1.5 volt (low) signal will inhibit the supply. 2.23.3 SUFFIX –EN “Low Enable” - A +10 to 15 volt (high) signal will disable power supply operation. A 0 to +1.5 volt (low) signal will enable the supply. 2.23.
D Figure 2-1 Mechanical Dimensions for 500A, 102A, 152A Outputs up to 6KV (for grounding instructions see SECTION 3.6) 5 83-493-001 Rev.
Figure 2-2 Mechanical Dimensions for 500A, 102A, 152A Outputs from 7KV to 40KV (for grounding instructions see SECTION 3.6) 6 83-493-001 Rev.
Figure 2-3 Mechanical Dimensions for 202A Outputs up to 6KV (for grounding instructions see SECTION 3.6) 7 83-493-001 Rev.
Figure 2-4 Mechanical Dimensions for 202A Outputs from 7KV to 40KV (for grounding instruction see SECTION 3.6) 8 83-493-001 Rev.
CHAPTER 3 INSTALLATION 3.1 INITIAL INSPECTION The shipping container should contain the following items: power supply, HV output cable, male 15-pin “D” remote control connector and operator’s manual. Examine the items immediately for damage. Locate the serial number label on the side of the power supply and verify the model number, the input voltage rating and the output voltage rating and polarity. In the event of any damage promptly notify the transportation company and the TDK-Lambda Americas Inc.
WARNING: 102A, 152A AND 202A PFC Models are only available with 220 VAC Nominal. For 152A Models Suffix 110 at 110-120 VAC must be operated with the internal fuses F1 and F2 (on the Inverter Board) replaced by copper bus provided with the supply. Use external 30A UL/VDC Approved Fuse/Circuit Breaker. NOTE: For Application at less than 10 Hz, please see section 5.7.
3.5 CONNECTING HIGH VOLTAGE OUTPUT POTENTIAL LETHAL VOLTAGE Ensure that the power supply is off and disconnected from the input power and never operate the power supply without a load capacitor. Make sure that all load capacitors are discharged and shorted to ground before making any connections. TDK-Lambda Americas Inc. recommends the use of safety dump switches in high voltage discharge circuits. Never handle the HV cable during operation. This power supply is designed to operate with a capacitive load.
3.6 GROUNDING THE PRODUCT 3.6.1 GROUNDING OF INPUT LINE The supply is grounded through the ground terminal of the input connector. A protective ground connection by the way of the grounding conductor in the input terminal is essential for safe operation. 3.6.2 OUTPUT GROUND CONNECTION It is important that there be a ground connecting the supply to the load as shown in Figure 3-3. See Figure 2-1 and 2-2, for grounding cable configuration. Figure 3-3 Output Ground Connection 3.6.
CHAPTER 4 OPERATION 4.1 REMOTE CONTROL The Series 500A/102A/152A/202A is easily controlled through the remote connector on the input panel of the unit. Only the ENABLE/RESET, V PROGRAM and GND signals are required for operation. The remaining signals are provided for status monitoring and fault diagnosis. A schematic diagram showing the suggested interface circuit is shown in Figure 4-1. This table is for a standard configuration.
Figure 4-1 Example of Interface Connection 14 83-493-001 Rev.
4.2 INITITIAL CHECK-OUT PROCEDURE LETHAL VOLTAGES PRESENT ONLY QUALIFIED PERSONNEL TRAINED IN THE SAFETY ASPECTS OF VOLTAGE SHOULD PERFORM INITIAL CHECKOUT PROCEDURES. HIGH The power supply should have no visible damage or defects and the cover should be securely fastened. Properly connect the input power (Section 3.5), control connector (Sec. 4.1) and HV output (Sec. 3.5, and 3.6).
CHAPTER 5 APPLICATIONS For clarification and further technical assistance specific to your applications, please contact TDK-Lambda Americas Inc. 5.1 DETERMINING CAPACITOR CHARGE TIME The ratings of these supplies are as follows: 500A – 500 J/s, 102A – 1000 J/s, 152A – 1500J/s, 202A-2000J/s average charge rate. Although the measure of Joules/sec equates to Watts, Stored Energy per unit time is more convenient when working with energy storage capacitors.
A series terminating resistor (or series inductor or clamp diode) must be added as shown if the average value of the peak current exceeds 110% of the normal output current. When choosing Rs, ensure it can withstand the full output voltage across it as well as the power dissipation caused by discharging Co (see Table 5.1) and Cc (20pF/ft) (65.62 pf/m) each cycle as well as conducting the normal output current. It’s power dissipation can be calculated as Pd = (Io² Rs) + ½ (Co + Cc) V² (REP RATE).
5.4 MEASURING HIGH VOLTAGES WARNING: EXTREME CAUTION MUST ALWAYS BE EXERCISED WHEN TAKING ANY HIGH VOLTAGE MEASUREMENTS. IT SHOULD BE DONE ONLY BY QUALIFIED PERSONNEL WHO ARE TRAINED IN THE SAFETY ASPECTS OF WORKING WITH HIGH VOLTAGE. A sample of the output voltage is available in the REMOTE connector. If it is desired to measure the HV output externally, care must be taken to understand the accuracy of the measurement.
Figure 5-3 HV Bias Measurements 5.5 DETERMINING AC LINE CURRENT IL = Line current IL = P = Average output power P VL = Line voltage VL PF X EFF PF = Power factor (.65 min) EFF = 0.85 Ex: A 152A operating from 115V – 10% and delivering 1000W average. IL = 1000 x 0.9 = 17.5 A (115)(.65)(0.85) When charging very large capacitor banks requiring many seconds or minutes to reach end-of-charge, the power supply will display a load fault and go into a 50% duty cycle protection mode.
5.7 LONG CHARGE TIME WITH POWER FACTOR CORRECTED (PFC) UNITS It is advised that you consult the factory if this type of operation is required. On supplies with active Power Factor Correction there is a limit to the length of the charge time. With all capacitor charging supplies, the peak output power capability is twice the joule per second rating. At pulse rates greater than approximately 20Hz, the internal filter capacitors can average the power drawn from the power factor correcting circuit.
CHAPTER 6 MAINTENANCE AND CALIBRATION 6.1 SAFETY PRECAUTIONS ONLY QUALIFIED PERSONNEL TRAINED IN THE SAFETY ASPECTS OF HIGH VOLTAGE SHOULD PERFORM CALIBRATION. The calibration steps described in this section require operation of the power supply with the cover removed. Proceed with extreme caution as hazardous voltages are exposed throughout the unit. Safety glasses must be worn to prevent serious injury in the event of a component failure (e.g., power transistors readily explode during fault conditions).
Product Name: UNIVOLT N 61 B Revision Date: 20Mar2007 Page 1 of 9 ______________________________________________________________________________________________________________________ MATERIAL SAFETY DATA SHEET SECTION 1 PRODUCT AND COMPANY IDENTIFICATION PRODUCT Product Name: UNIVOLT N 61 B Product Description: Base Oil and Additives Product Code: 730846-00, 97P847 Intended Use: Electrical insulating oils COMPANY IDENTIFICATION Supplier: EXXON MOBIL CORPORATION 3225 GALLOWS RD. FAIRFAX, VA.
Product Name: UNIVOLT N 61 B Revision Date: 20Mar2007 Page 2 of 9 ______________________________________________________________________________________________________________________ SECTION 4 FIRST AID MEASURES INHALATION Remove from further exposure. For those providing assistance, avoid exposure to yourself or others. Use adequate respiratory protection. If respiratory irritation, dizziness, nausea, or unconsciousness occurs, seek immediate medical assistance.
Product Name: UNIVOLT N 61 B Revision Date: 20Mar2007 Page 3 of 9 ______________________________________________________________________________________________________________________ Response Center can be reached at (800)424-8802. PROTECTIVE MEASURES Avoid contact with spilled material. Warn or evacuate occupants in surrounding and downwind areas if required due to toxicity or flammability of the material. See Section 5 for fire fighting information. See Section 3 for Significant Hazards.
Product Name: UNIVOLT N 61 B Revision Date: 20Mar2007 Page 4 of 9 ______________________________________________________________________________________________________________________ PERSONAL PROTECTION Personal protective equipment selections vary based on potential exposure conditions such as applications, handling practices, concentration and ventilation. Information on the selection of protective equipment for use with this material, as provided below, is based upon intended, normal usage.
Product Name: UNIVOLT N 61 B Revision Date: 20Mar2007 Page 5 of 9 ______________________________________________________________________________________________________________________ Flammable Limits (Approximate volume % in air): LEL: N/D UEL: N/D Autoignition Temperature: >315°C (599°F) Boiling Point / Range: 260C (500F) - 371C (700F) Vapor Density (Air = 1): > 5 at 101 kPa Vapor Pressure: < 0.013 kPa (0.
Product Name: UNIVOLT N 61 B Revision Date: 20Mar2007 Page 6 of 9 ______________________________________________________________________________________________________________________ data for structurally similar materials. CHRONIC/OTHER EFFECTS For the product itself: Prolonged and/or repeated skin contact with low viscosity materials may defat the skin resulting in possible irritation and dermatitis.
Product Name: UNIVOLT N 61 B Revision Date: 20Mar2007 Page 7 of 9 ______________________________________________________________________________________________________________________ DISPOSAL RECOMMENDATIONS Product is suitable for burning in an enclosed controlled burner for fuel value or disposal by supervised incineration at very high temperatures to prevent formation of undesirable combustion products.
Product Name: UNIVOLT N 61 B Revision Date: 20Mar2007 Page 8 of 9 ______________________________________________________________________________________________________________________ HYDROTREATED LIGHT NAPHTHENIC DISTILLATE (PETROLEUM) 1 = ACGIH ALL 2 = ACGIH A1 3 = ACGIH A2 4 = OSHA Z 5 = TSCA 4 64742-53-6 4, 13 --REGULATORY LISTS SEARCHED-6 = TSCA 5a2 11 = CA P65 REPRO 7 = TSCA 5e 12 = CA RTK 8 = TSCA 6 13 = IL RTK 9 = TSCA 12b 14 = LA RTK 10 = CA P65 CARC 15 = MI 293 16 = MN RTK 17 = NJ RTK 18
Product Name: UNIVOLT N 61 B Revision Date: 20Mar2007 Page 9 of 9 ______________________________________________________________________________________________________________________ ----------------------------------------------------------------------------------------------------------------------------------------------------The information and recommendations contained herein are, to the best of ExxonMobil's knowledge and belief, accurate and reliable as of the date issued.
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