HIGH VOLTAGE POWER SUPPLY INSTRUCTION MANUAL Model: BRC-15-1111R-STD-J37 Document: MAN00238 Revision: A UNIVERSAL VOLTRONICS CORP. 57 COMMERCE DRIVE BROOKFIELD, CONNECTICUT 06804-3405 USA TEL: 203-740-8555 FAX: 203-740-9555 www.voltronics.
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HIGH VOLTAGE POWER SUPPLY INSTRUCTION MANUAL Title: High Voltage Power Supply Instruction Manual, BRC-15-1111R-STD-J37 Revision History Rev Description A Initial Release of document for use Document: MAN00238A Doc. #: MAN00238 Rev: A Prepared by: S. Savulak Date: 2003-04-28 Approved by: U. Uhmeyer Date: 2003-04-30 Date 2003-04-30 App’d U. Uhmeyer Page 3 of 28 R:\Documents\MAN Manuals\MAN00238A BRC-15-1111R-STD-J37.
Contents Document: MAN00238A 1. Introduction 2. Warnings 3. Unpacking 4. Installation 5. User Interface 6. Theory of Operation 7. High Voltage ON 8. Specification 9. Circuit Board Adjustments 10. Faults / Troubleshooting 11. Drawing List 12. Replacement Bills of Material 13. Factory Test Procedure (ATP) Page 4 of 28 R:\Documents\MAN Manuals\MAN00238A BRC-15-1111R-STD-J37.
UNIVERSAL VOLTRONICS CORP. TERMS AND CONDITIONS OF SALE UNLESS OTHERWISE EXPRESSLY AGREED IN WRITING, ALL SALES ARE SUBJECT TO THE FOLLOWING TERMS AND CONDITIONS 1. GENERAL. Universal Voltronics Corp. ("Seller") hereby offers for sale to the buyer named on the face hereof ("Buyer") the products listed on the face hereof (the "Products") on the express condition that Buyer agrees to accept and be bound by the terms and conditions set forth herein.
RESPECT TO THE AFFECTED PRODUCTS. This warranty is provided by Seller solely to Buyer as the first commercial purchaser of the goods.
1. INTRODUCTION This high voltage power supply incorporates the latest in high frequency, high power switching technology. Each unit is neatly packaged in a single, rack-mountable chassis with approximate dimensions of 10.5" high X 19" wide (maximum) X 21" deep (approximately 2 additional inches are required behind the chassis for connections). Operation of the power supply can be accomplished locally via the front panel controls and/or remotely via the rear panel User Interface connector J4.
2. WARNINGS DANGER HIGH VOLTAGE RISK OF ELECTRICAL SHOCK REFER SERVICING TO QUALIFIED PERSONNEL This power supply operates at a high enough voltage and possesses sufficient stored energy to be capable of killing a human. DO NOT TAKE SAFETY FOR GRANTED! Pay strict attention to the safety information and warnings in this manual. This power supply produces extremely high voltages. DO NOT attempt to adjust any load connection with high voltage on.
3. UNPACKING Remove the unit from its carton, but do not discard the packing materials; retain the packing materials and carton in case the unit needs to be returned. Inspect the unit for dents or other damage, which may have occurred during shipping. In the unusual event that shipment damage has occurred, contact the transportation company and the manufacturer immediately. If additional materials have been enclosed in the shipping crate (such as cables etc.), inspect them as well.
4. INSTALLATION Symbol Definitions Protective Conductor Terminal Indicates where to connect safety ground conductor from AC line source. Caution: Risk of Electric Shock Indicates that high voltages, capable of causing injury, are present on the output connector. Caution: Refer to Manual for Further Instructions Directs user to manual for further detailed instructions on installation and operation. Refer to Section 2 of this manual.
6. Connect remote control circuitry (if used) to the rear panel connector, J4, as described in Section 5. 7. With the breaker in the OFF position and the building power OFF, connect AC power lines to the unit. It is very important to use 600V (UL1015) insulated stranded wire of sufficient gauge (#6 AWG or greater) to handle the full load line current. Strip about 0.4 inch (~1 cm) of insulation from the wires before inserting them into the terminal block.
5. USER INTERFACE Operation of the User (Remote) Interface is essentially equivalent to the local front panel controls. Each unit has been shipped from the factory in Remote mode. To change to Local mode operation, use the Local/Remote switch located on the rear panel. See Figure 1 for an illustration of the Local/Remote switch and the Regulator connector located on the rear panel. Functions that are underlined are operational in both Local and Remote modes.
7, 8. High Voltage OFF Control (Input): Connect to a normally closed (NC) set of isolated ("voltage free" or "dry") switch contacts. Operation of these contacts must be momentary (i.e. the contacts stay closed until the switch is operated, at which time they open briefly, and the contacts automatically return to the closed state after an operation). 9, 10. External Interlock (Input): Short these pins together to complete interlock loop. 11, 12.
REAR PANEL LOCAL/REMOTE SWITCH LOCAL REMOTE CR137 CR131 CR133 CR135 CR139 J4 USER INTERFACE PIN 1 CR139 - OVERVOLTAGE FAULT INDICATOR (YELLOW) CR135 - 'SLOW' DC OVERLOAD FAULT INDICATOR (YELLOW) CR133 - ARC RATE COUNTER FAULT INDICATOR (YELLOW) CR131 - RAIL FAULT INDICATOR (YELLOW) CR137 - STEP START SEQUENCE FAULT INDICATOR (YELLOW) 03-13-2002 Figure 1 – User Interface Document: MAN00238A Page 14 of 28 R:\Documents\MAN Manuals\MAN00238A BRC-15-1111R-STD-J37.
6. THEORY OF OPERATION The power supply consists of several sections shown in the following simplified diagram: HV TRANSFORMER RECTIFIER FILTER HV OUTPUT INPUT POWER CIRCUIT V set mA FEEDBACK R1 REGULATOR I set kV FEEDBACK R2 Figure 2 – Power Supply Simplified Diagram NOTE: Vset and Iset above may be produced by either the front panel potentiometers or voltage signals from an external source, depending on whether Local or Remote mode is being used. 6.
6.2 Power Card 853189539P AC power is connected to a three phase bridge rectifier circuit. See Figure 3. The rectifiers power a raw capacitive filter. The inverter switches, in a full bridge configuration, alternate the high voltage transformer primary winding between the rail voltages established by the raw supply capacitors, producing a bipolar square wave signal on the primary winding.
7. HIGH VOLTAGE ON Once the installation is complete, the power supply is ready to be energized. Turn on the system power at the source circuit breaker box. To activate the control electronics, switch the front panel breaker to the ON position. The ‘Power On’ indicator will be illuminated. Local Mode High voltage can be activated if all interlocks and faults are clear. To enable high voltage, press the ‘HV ON’ pushbutton.
8. SPECIFICATION 15.0kV 1.111A SWITCH MODE POWER SUPPLY 8.1 INPUT Voltage Phases: Frequency: Current: 208V ±10% (187-229V) Three 50/60 Hertz 65A max. 8.2 OUTPUT Voltage: Current: Polarity: Regulation: Ripple: 0 to -15.0kV DC 0 to -1.111A DC Changeable (shipped as Negative) ± 0.1% (± 15.0V) 0.5% rms (75V rms) max. 8.
8.6 REMOTE CONTROL Reference Inputs Voltage: Current: 0 to +10V = 0 to -15.0kV DC 0 to +10V = 0 to -1.111A DC Monitor Outputs Voltage: Current: 0 to -15.0kV DC = 0 to +10V DC 0 to -1.111A DC = 0 to +10V DC Digital Signal Inputs HV ON: HV OFF: Momentary contact closure Momentary contact opening Digital Signal Outputs HV On: TTL High 8.7 MECHANICAL Panel Chassis Weight HV Output Control Interface Power Input Ground Connection 19” wide x 7” high max. 21” deep (not including approx.
9. CIRCUIT BOARD ADJUSTMENTS Although each power supply is fully tested and calibrated prior to shipment, there are circuit boards in the unit that may require adjustment at some time during the life of the power supply. These boards are the Regulator board (9120010) and Front Panel board (9120021). Before attempting to make any adjustments inside the power supply chassis, please be sure that the consequences of such an adjustment are completely understood.
R41 R149 R165 R137 R69 R125 Document: MAN00238A Iavg OL Adjust: sets the sensitivity of the HV transformer’s average primary current limit circuit. This protects the power inverter from large values of average current over a period of many inverter cycles. This circuit does not protect against high peaks of instantaneous current. Counter Adjust: sets the sensitivity of the arc counter circuitry which shuts off high voltage if too many arcs or rollbacks occur in a given period of time.
HV REGULATOR PWA REMOTE INTERFACE Figure 4 – Regulator Adjustment Potentiometers Document: MAN00238A Page 22 of 28 R:\Documents\MAN Manuals\MAN00238A BRC-15-1111R-STD-J37.
Figure 5 – Front Panel Adjustment Potentiometers Document: MAN00238A Page 23 of 28 R:\Documents\MAN Manuals\MAN00238A BRC-15-1111R-STD-J37.
10. FAULTS / TROUBLESHOOTING Faults Overcurrent: If the output becomes shorted or if there is a surge in output current due to changes in the load that exceed the rated current, then this circuit will be tripped. Its threshold is set by R137. Once this circuit is tripped, HV is latched off. The power supply will give a fault indication by lighting the ‘Fault’ LED permanently. The ‘HV ON’ light will go out as well. This tells the user to correct the load and reactivate HV.
Rollbacks and the One-Shot Timer As discussed previously, a rollback is distinct from a latched fault in that it does not shut high voltage off permanently. A latched fault requires that an HV ON command be given again before HV can be reactivated. The non-latched circuits cause a brief rollback (or limiting action). This is the case for the fast overload, dV/dt, peak primary current overload, and the average primary current overload circuits.
Troubleshooting A. Equipment B. Resistor Load: 13.5k ohms, 16.7kW Current Sensor: Tektronix Current Probe #P6021 Voltage Sensor: Voltage Divider, 20kV minimum Ratio: 500:1 or greater Frequency Response: 100kHz minimum Resistance: 10 megohms typical Scope Probes: 10:1 and 100:1 Test Equipment: Tektronix Oscilloscope, digital storage recommended Fluke Multimeter Initial Turn-on 1.0 The ‘Power ON’ LED on the front panel board should be illuminated.
C. Common Causes for Faults 1. Over-temperature (symptom: unit deactivates HV; ‘Ready’ indicator briefly off) a. Fan intake and/or outlet is blocked, preventing adequate airflow. b. Ambient air temperature exceeds specifications. 2. Interlock (symptom: unit deactivates HV; ‘Ready’ indicator off) a. Top cover interlock switch open. b. Interlock loop on J4 not shorted. 3. Over-voltage Fault a. Large inductive element connected to output. b. Misconnection of output to external high voltage source. 4.
11. DRAWING LIST System Schematic (Schematic) D-6-7-1557 Power Inverter PWA (Schematic) C-6-1895-39P Front Panel PWA (Schematic) D9120021-013 HV Regulator PWA (Schematic) D9120010-011 High Voltage Module PWA (Schematic) See System Schematic, D-6-7-1557 Output Low end PWA (Schematic) B-6-1891-47AT 12. REPLACEMENT BILLS OF MATERIAL Replacement bills of material are available on request. 13. FACTORY TEST PROCEDURE (ATP) The Acceptance Test Procedure (ATP00255) is available on request.
