AMETEK SORENSEN DLM 5-75 (01) PDF Document

Before applying power to the system, verify that your AMETEK SORENSEN DLM 5-75 is configured properly for your particular application.

WARNINGS:

Hazardous voltages may be present when covers are removed. Qualified personnel must use extreme caution when servicing this equipment. Circuit boards, test points, and output voltages also may be floating above (below) chassis ground.

The equipment used contains ESD sensitive ports. When installing equipment, follow ESD Safety Procedures. Electrostatic discharges might cause damage to the equipment.

Only qualified personnel who deal with attendant hazards in power supplies, are allowed to perform installation and servicing.

General Safety Guidelines:

Ensure that the AC power line ground is connected properly to the Power Rack input connector or chassis. Similarly, other power ground lines including those to application and maintenance equipment must be grounded properly for both personnel and equipment safety.

Always ensure that facility AC input power is de-energized prior to connecting or disconnecting any cable.

In normal operation, the operator does not have access to hazardous voltages within the chassis. However, depending on the user’s application configuration, HIGH VOLTAGES HAZARDOUS TO HUMAN SAFETY may be normally generated on the output terminals. The customer/user must ensure that the output power lines are labeled properly as to the safety hazards and that any inadvertent contact with hazardous voltages is eliminated.

Guard against risks of electrical shock during open cover checks by not touching any portion of the electrical circuits. Even when power is off, capacitors may retain an electrical charge. Use safety glasses during open cover checks to avoid personal injury by any sudden component failure.

SAFETY SYMBOLS

Although the AMETEK SORENSEN DLM 5-75 has been fully calibrated and tested prior to shipment, you should inspect the unit when it is first unpacked to ensure no shipping damage has occurred.

1. Perform a visual inspection of the shipping container prior to accepting the package from the carrier. If damage to the shipping container is evident, a description of that damage should be noted on the carrier’s receipt and signed by the carrier’s driver.

2. Perform a visual inspection of the unit after it is removed from the shipping container. Check for shipping damage such as dents, scratches, distortion of the enclosure, or damaged controls. If external damage is evident, there may be internal damage as well.

3. If damage is found, immediately contact the carrier and file a claim for concealed damage. In addition, the shipping container and filler material should be saved for inspection.

The AMETEK SORENSEN DLM 5-75 power supplies are designed for both rackmount and benchtop applications. As shipped, they are configured for benchtop use. For rack mounting, the four feet from the bottom of the chassis must be removed and a rackmount kit added.

Since the units are fan-cooled, they require adequate clearance at the air intake and exhaust so that air flow is not impeded. The air intake is at the front and front sides, while the air exhaust is at the rear panel and rear sides. The temperature of the ambient air at the air intake should not exceed 50°C.

To install a single AMETEK SORENSEN DLM 5-75 into a rack, use the Rack Mount Kit (Sorensen part number DLMRK) and follow these steps:

1. Remove the four (4) rubber feet and mounting hardware from the bottom of the unit and discard.

2. Remove the four (4) truss head screws (two on each side) from the front side panels of the unit. (Do not discard.)

3. The unit can be mounted on the right or left hand side of the rack.

4. Install a Rack Mount Extruded Ear on the front side of the unit using two (2) of the existing truss head screws.

5. Install the Single-Unit Rack Mount Bracket on the opposite side from the Rack Mount Extruded Ear using the two (2) panhead SEMS screws, 6-32UNC-2A x .25″ supplied in the kit.

6. Install the other Rack Mount Extruded Ear on the end of the Single-Unit Rack Mount Bracket using the other two (2) existing truss head screws.

7. Position one of the two Chassis Rack Mount Brackets on the chassis side of the rack, using one of the two (2) Right Angle Adapter Brackets, if required to match existing vertical rack rail positions.

CAUTION: To prevent internal damage, use the specified screw lengths only. Four screws (two on each side), #6-32, at the front sides of the chassis are used for rackmounting. Damage could result if the penetration of screws into the chassis exceeds 0.25″ (6.35 mm).

CAUTION: Use caution when installing the unit. The unit will not stay on the Chassis Rack Mount Bracket until at least one of the four (4) front panel mounting screws is installed.

To install two AMETEK SORENSEN DLM 5-75 units in a rack, use the Rack Mount Kit (Sorensen part number DLMRK) and follow these steps:

1. On both units, remove the four (4) rubber feet and mounting hardware from the bottom and discard.

2. On both units, remove the four (4) truss head screws (two on each side) from the front side panels. (Do not discard.)

3. Install the Tie Bar onto the bottom of the two (2) inner heat sinks using the six (6) Philips flat head screws, 6-32UNC-2A X .31″ supplied in the kit.

4. Install the Rack Mount Extruded Ears on the front outer sides of both units using the existing four (4) truss head screws.

5. Position the two Chassis Rack Mount Brackets in the rack. Use the two (2) Right Angle Adapter Brackets, if required to match existing vertical rack rail positions.

CAUTION: To prevent internal damage, use the specified screw lengths only.

The AMETEK SORENSEN DLM 5-75 will operate from an AC power source rated at 90–132 VAC and 180–264 VAC, at 47–63 Hz. The AC input voltage range is automatically selected by the unit at power-up; no user setup is required.

CAUTION: Exceeding the maximum rated AC input voltage could result in damage to the unit.

An IEC connector on the rear panel connects the unit to the AC power source and provides the safety ground termination. The supplied power cord has a safety ground wire that connects the unit’s enclosure to the AC power source’s safety ground.

WARNING: Operating the unit with the safety ground wire of the power cord disconnected could result in a shock hazard.

The front panel POWER switch does not disconnect the AC input line from the unit. Ensure that access is provided to the rear panel IEC AC input connector or the plug of the line cord for disconnection.

WARNING: To prevent electrical shock, disconnect the AC power cord before making any connections to the unit.

CAUTION: If longer bus bar screws are substituted, ensure that a clearance of at least 0.125” (3.2 mm) exists to the rear panel to prevent an electrical short.

Low-voltage models (5V–60V) have bus bars at the rear for load connection, protected by a two-piece cover. High-voltage models (80V–300V) have an output terminal block with a snap-on cover. Ensure all covers are properly installed before operating.

When selecting wire gauge, consider these factors:

1. Wire Current Carrying Capacity:

Load wiring must have a current carrying capacity greater than the output current rating of the power supply. The following table shows current ratings for various wire gauges based on 500A/cm².

2. Wire Voltage Drop:

For applications where regulation is important, select a wire gauge that maintains an acceptable total voltage drop. The total voltage drop is the sum of the drops in the positive and negative leads.

3. Noise and Impedance Effects:

To minimize noise, load wires and remote sense wires should be a twisted-pair with minimum lead length. Shielding may be necessary in high-noise environments. Twisting load wires also reduces parasitic inductance, improving dynamic response at the load. For long load wires, additional filtering with bypass capacitors at the load terminals may be required.

The AMETEK SORENSEN DLM 5-75 offers two methods for sensing the load voltage: local and remote.

Local Sensing:

This is the default factory setting. It measures the output voltage internally at the rear panel output terminals. To select local sensing, ensure that REM SNS (Position-1) on the rear panel SETUP switch is set to OFF.

Remote Sensing:

Remote sensing is used to compensate for voltage drop across the load wires by measuring the voltage directly at the load. To select remote sensing, set REM SNS (Position-1) on the SETUP switch to ON.

A separate pair of wires (at least AWG #22, twisted-pair) must be routed from the REMOTE SENSE (REM SNS) connector to the load terminals. Connect the positive (+) sense lead to the positive load terminal and the negative (-) sense lead to the negative load terminal.

REM SNS Connector Pinout (Molex #39-30-0023):

Important Notes for Remote Sensing:

If the unit is set for remote sense but the sense wires are not connected, the unit will revert to local sense, and the output voltage at the rear panel will increase nominally 5% above the programmed value.

If remote sensing is enabled but the sense leads are not connected to the output, the power supply will shut down due to OVP.

Up to four AMETEK SORENSEN DLM 5-75 units of the same model can be connected in parallel in a master/slave configuration. The master unit controls the output voltage and total current.

CAUTION: The outputs of paralleled units must be wired in parallel at the rear panel output terminals of the units. Use the shortest practical cable length. Operation of a unit without a negative (return) connection could result in damage.

Setup Procedure:

1. Connect the outputs of the units in parallel at the rear panel output terminals using short cable lengths. Connect the load wires to the output terminals of the master unit.

2. Interconnect the master and slave units with the PARALLELING CABLE (Sorensen part number DLMP1). Either of the two rear panel PARALLEL I/O connectors can be used.

3. For the slave units, select the slave mode by turning ON the SLAVE position (Position-2) of the SETUP switch. The master unit must have the SLAVE position set to OFF.

4. Adjust the OVP setting of the slave units to full scale.

5. The voltage, current, and OVP are adjusted with the controls of the master unit. The voltage display of the slave units will be blanked out. The total load current is the sum of the current displays of all units.

6. The OUTPUT switch of the master unit will turn off all units. The OUTPUT switch of a slave unit will turn off only its output.

7. Turning off the POWER switch of any unit will result in shutdown of all units.

8. A fault in any unit will result in shutdown of all units.

9. External control and interface selections are done with the master unit.

PARALLEL I/O Connector Pinout:

Multiple AMETEK SORENSEN DLM 5-75 units of the same model can be connected in series to obtain a higher output voltage, within the limits of the 300V(PK) maximum float potential. The supplies are interconnected with the negative terminal of one supply being connected to the positive terminal of another.

CAUTION: To prevent damage to a supply, do not connect the remote sense leads of one supply across the total series string.

The total output voltage is the sum of the individual outputs, and is derived from the positive terminal of the first unit and the negative terminal of the last unit in the string. Each supply is adjusted individually. The output current is the same for each unit. Either local or remote sensing can be used for each individual unit.

The AMETEK SORENSEN DLM 5-75 family requires freewheeling and blocking diodes while driving inductive loads or batteries to protect the power supply from damage caused by power being fed back into the supply and from high voltage transients.

Suggested Procedure for Diode Selection:

The Peak Reverse Voltage ratings should be a minimum of 2-3 times the Power Supply maximum output voltage.

The Continuous Forward Current ratings should be a minimum of 1.5 times the Power Supply maximum output current.

A heatsink may be required. There also may be a need for higher voltage rated parts, dependent on load circuit design and inductor values.

A blocking diode is used in series with the output for applications like battery charging. A freewheeling (or flyback) diode is used in parallel with an inductive load.

Power-On Check

1. Ensure POWER and OUTPUT switches are OFF (buttons out).

2. Ensure no connections to the REMOTE ANALOG INTERFACE connector, and all positions of the SETUP switch are OFF (down).

3. Turn VOLTAGE and CURRENT controls fully counter-clockwise.

4. Turn OVP control fully clockwise.

5. Connect the power cord to an AC source.

6. Turn the POWER switch ON (button in). The unit will run a power-up routine for ~7 seconds. All LEDs will light, fans will run at max speed, and OVP/FAULT monitors will reset.

7. After power-up, ensure both digital displays are on and indicate zero. The OVP, FAULT, EXT-OFF, REM and OUTPUT LEDs should be off.

8. Turn the POWER switch ON.

9. Turn the CURRENT control fully clockwise.

10. Ensure the VOLTAGE indicator is on and the CURRENT indicator is off.

Constant-Voltage Mode Operation Check

1. Ensure POWER and OUTPUT switches are OFF.

2. Connect a digital voltmeter (DVM) to the output terminals.

3. Turn the VOLTAGE control fully counter-clockwise.

4. Turn the CURRENT control fully clockwise.

5. Turn POWER and OUTPUT switches ON.

6. Slowly turn the VOLTAGE control clockwise and observe the values on the VOLTAGE display and the DVM. Adjust across the full range.

7. Compare the DVM reading with the front panel display to verify accuracy.

8. Ensure the VOLTAGE indicator is on and the CURRENT indicator is off.

Constant-Current Mode Operation Check

1. Ensure POWER and OUTPUT switches are OFF.

2. Connect a DC shunt across the output terminals (ensure rating exceeds supply capability).

3. Connect a DVM across the DC shunt.

4. Turn the CURRENT control fully counter-clockwise.

5. Turn the VOLTAGE control fully clockwise.

6. Turn POWER and OUTPUT switches ON.

7. Slowly turn the CURRENT control clockwise and observe the CURRENT display and DVM. Adjust across the full range.

The AMETEK SORENSEN DLM 5-75 automatically crosses over between CV and CC modes based on the load resistance and the VOLTAGE and CURRENT settings.

Adjustment for Constant-Voltage (CV) Operation:

1. Turn the POWER switch ON and the OUTPUT switch OFF.

2. Press the V/I PREVIEW switch. Adjust the VOLTAGE control to the desired output voltage. Adjust the CURRENT control to a value greater than the maximum expected load current.

3. Turn the OUTPUT switch ON. The VOLTAGE indicator should be ON and the CURRENT indicator should be OFF.

Adjustment for Constant-Current (CC) Operation:

1. Turn the POWER switch ON and the OUTPUT switch OFF.

2. Press the V/I PREVIEW switch. Adjust the CURRENT control to the desired output current. Adjust the VOLTAGE control to a value greater than the maximum expected compliance voltage of the load.

3. Turn the OUTPUT switch ON. The CURRENT indicator should be ON and the VOLTAGE indicator should be OFF.

Adjustment of OVP Threshold:

1. Turn the POWER switch ON and the OUTPUT switch OFF.

2. Press the V/I PREVIEW switch to set the desired output voltage and current.

3. Press the OVP PREVIEW switch to display the OVP threshold. Adjust the OVP SET control to the desired level. Ensure the OVP setting exceeds the output voltage setting; otherwise, the OVP will trip immediately when the output is turned on.

Resetting OVP:

If the OVP has been activated (OVP indicator is on), perform the following to reset it:

1. Reduce the power supply’s output voltage to below the OVP threshold.

2. Ensure that the connections for the power and sense leads are correct.

3. Reset the OVP monitor by toggling OFF and then back ON either the OUTPUT switch, the POWER switch, or the EXTERNAL-OFF signal of the REMOTE ANALOG INTERFACE.

When using the AMETEK SORENSEN DLM 5-75 to charge a battery, the following precautions should be taken:

1. Connect an isolation diode in series with one of the output terminals of the power supply. This diode prevents the battery from discharging back into the supply if it were turned off. The diode must have suitable current and voltage ratings and should be mounted on an appropriate heat sink.

2. Adjust the VOLTAGE setting to the desired float voltage. This can be done using the V/I PREVIEW switch or with the power supply disconnected from the battery. The VOLTAGE setting should compensate for the voltage drop of the isolation diode if local sensing is used.

3. Adjust the CURRENT setting to the desired current limit value for charging the battery.

When charging, the supply will initially operate in constant-current mode. As the battery charges, its voltage increases until the float voltage is reached. The supply then enters constant-voltage mode, and the battery current will decrease as it becomes fully charged.

The 8-position SETUP switch on the rear panel of the AMETEK SORENSEN DLM 5-75 configures the unit for user requirements. The factory default is all positions OFF (down).

The AMETEK SORENSEN DLM 5-75 can be remotely programmed for output voltage, current, and OVP using either external voltage sources or resistances via the REMOTE ANALOG INTERFACE connector.

General Setup:

When remote programming is enabled, all three parameters (Voltage, Current, OVP) must be set remotely. Parameters not being actively programmed must be connected to a programming source to set them to a desired limit (e.g., full scale). This can be done with resistance programming or by using the AUXILIARY 5V OUTPUT (with the 0–5 VDC range selected).

Enabling Remote Control: Connect Pin-1 (ANALOG-CONTROL) to Pin-6 (Return) to enable remote programming. The front panel REM indicator will light up.

Voltage-Source Programming of Output Voltage:

1. Set SETUP switch Position-8 to OFF for 0–5 VDC range or ON for 0–10 VDC range.

2. Connect the external voltage source positive to Pin-9 and negative to Pin-12.

3. Program current (Pin-10) and OVP (Pin-3) to desired limits.

4. Connect Pin-1 to Pin-6 to enable.

Voltage-Source Programming of Output Current:

1. Set SETUP switch Position-7 to OFF for 0–5 VDC range or ON for 0–10 VDC range.

2. Connect the external voltage source positive to Pin-10 and negative to Pin-12.

3. Program voltage (Pin-9) and OVP (Pin-3) to desired limits.

4. Connect Pin-1 to Pin-6 to enable.

Resistance Programming of Output Voltage:

1. Set SETUP switch Position-8 to OFF for 0–5 VDC programming range.

2. Connect a 0–5 kΩ programming resistance from Pin-20 to Pin-21.

3. Connect a jumper from Pin-21 to Pin-9.

4. Program current (Pin-10) and OVP (Pin-3) to desired limits.

5. Connect Pin-1 to Pin-6 to enable.

Resistance Programming of Output Current:

1. Set SETUP switch Position-7 to OFF for 0–5 VDC programming range.

2. Connect a 0–5 kΩ programming resistance from Pin-23 to Pin-22.

3. Connect a jumper from Pin-22 to Pin-10.

4. Program voltage (Pin-9) and OVP (Pin-3) to desired limits.

5. Connect Pin-1 to Pin-6 to enable.

NOTE: Programming the other parameters to desired limit values is mandatory. The power supply will not work properly without it.

CAUTION: Ensure the unit is unplugged from AC input before making any changes to connections or SETUP switch settings.

The EXTERNAL-OFF control input provides the same functionality as the front panel OUTPUT switch. When asserted, it turns off the output converter, discharges the output capacitors, and resets the OVP and FAULT monitors. It is opto-isolated from other signals.

CAUTION: The maximum float potential of either line of the EXTERNAL-OFF control signal with respect to any other signal of the REMOTE ANALOG INTERFACE is 60V(PK).

With an External Voltage Source:

Assert EXTERNAL-OFF by applying a voltage within the range of 2–30 VDC to the REMOTE ANALOG INTERFACE connector: positive to Pin-14, and return to Pin-2.

With the Internal Auxiliary 5 VDC Output:

The internal AUXILIARY 5 VDC OUTPUT can be used as the voltage source. Connect a switch between Pin-15 (Auxiliary 5 VDC Output +) and Pin-14 (EXTERNAL-OFF Input +). Connect Pin-2 (EXTERNAL-OFF Return) to Pin-6 (Auxiliary 5 VDC Return). Note that using the internal source means opto-isolation is lost, and the external contacts must provide the necessary isolation.

The AMETEK SORENSEN DLM 5-75 provides analog and digital signals for remote monitoring of its status via the REMOTE ANALOG INTERFACE connector.

Remote Analog Monitoring:

These signals are proportional to the output parameters, with user-selectable ranges of 0-5 VDC or 0-10 VDC.

Remote Digital Status Signals:

These are logic-level signals indicating the operational status of the unit.

If your AMETEK SORENSEN DLM 5-75 appears to be operating improperly, first determine if the cause is the power supply, the load, or external control circuits. Configure the unit for basic front panel operation and perform the initial functional tests.

WARNING: POTENTIALLY LETHAL VOLTAGES EXIST IN THE POWER CIRCUITS AND THE OUTPUT OF HIGH VOLTAGE MODELS. Repairs should be done only by experienced technical personnel.

Because the AMETEK SORENSEN DLM 5-75 uses forced convection cooling, dust can accumulate inside. In environments with high concentrations of dust, periodic cleaning may be required.

Clean the exterior of the unit with a mild solution of detergent and water. Apply the solution with a soft cloth; do not apply it directly to the surface of the unit. To prevent damage to materials, do not use aromatic hydrocarbons or chlorinated solvents for cleaning.

WARNING: Calibration procedures are performed with the top cover removed and power on. Potentially lethal voltages exist. Use insulated tools and do not touch any components or circuits.

Allow the unit to warm up for 30 minutes at no load before performing calibration. Perform offset adjustments before range adjustments. Some iteration may be required.

Internal Reference Adjustment:

1. Connect a voltmeter from J14-4 (positive) to J14-6 (negative) on the Main PWA.

2. Adjust potentiometer R379 for a reading of –5.000 VDC.

Output Voltage Offset Adjustment (via Remote Control):

1. Connect a voltmeter across the output terminals.

2. Jumper Pin-1 to Pin-6 of the REMOTE ANALOG INTERFACE to enable remote control.

3. Jumper Pin-15 to Pin-10 and Pin-3 to program current and OVP to full scale.

4. Connect a voltage source, set to 0.050 VDC, from Pin-9 to Pin-12.

5. Adjust potentiometer R377 on the Main PWA for a reading on the external voltmeter of 1% of full scale output voltage.

Output Voltage Range Adjustment (via Remote Control):

1. With the same setup as above, change the voltage source to 5.00 VDC.

2. Adjust potentiometer R378 on the Main PWA for a reading on the external voltmeter of 100% of full scale output voltage.

Output Current Offset Adjustment (via Remote Control):

1. Connect a DC shunt across the output terminals.

2. Jumper Pin-1 to Pin-6 to enable remote control.

3. Jumper Pin-15 to Pin-9 and Pin-3 to program voltage and OVP to full scale.

4. Connect a voltage source, set to 0.050 VDC, from Pin-10 to Pin-12.

5. Adjust potentiometer R375 on the Main PWA for a current through the shunt of 1% of full scale output current.

Output Current Range Adjustment (via Remote Control):

1. With the same setup as above, change the voltage source to 5.00 VDC.

2. Adjust potentiometer R376 on the Main PWA for a current through the shunt of 100% of full scale output current.

Voltage Display Adjustment:

1. Connect a voltmeter across the output terminals.

2. Adjust front panel CURRENT and OVP controls fully clockwise.

3. Turn the OUTPUT switch on.

4. Adjust the front panel VOLTAGE control for an output voltage equal to 100% of full scale.

5. Adjust potentiometer R13 on the Display PWA for a VOLTAGE display of 100% of full scale.

Current Display Adjustment:

1. Connect a DC shunt across the output terminals.

2. Adjust front panel VOLTAGE and OVP controls to fully clockwise.

3. Turn the OUTPUT switch on.

4. Adjust the front panel CURRENT control for an output current equal to 100% of full scale.

5. Adjust potentiometer R15 on the Display PWA for a CURRENT display of 100% of full scale.