AMETEK SORENSEN DLM 80-7.5 (01) PDF Document

The AMETEK SORENSEN DLM 80-7.5 features the following:

• High power density, 600W, in a 1U half-rack size.

• Appropriate for rack or benchtop applications.

• Fast dynamic response: 500µs, maximum for 50% load steps.

• Low ripple and noise: as low as 3.5 mV(RMS) and 35 mV(PK-PK).

• Universal auto-ranging AC input: 90-132V or 180-264V, without user setup.

• Master/slave paralleling with simple unit-to-unit control interface cable.

• Flexible rack mounting allowing units to be stacked in 1U increments without requiring clearance gaps between units or slides.

• Side-by-side mounting of two units in a 19″ rack.

• Fast response to programming changes with active downprogrammer.

• Constant-voltage and constant-current modes of operation with automatic crossover and mode indicators.

• Two 3.5 digit displays for output voltage, current, and OVP.

• High resolution front panel controls for voltage and current (10-turn potentiometers), and OVP (20-turn trimmer potentiometer).

• Preview switches for output voltage, current, and OVP to set parameters without disrupting load connections.

• Front panel OUTPUT switch for on/off control of output power.

• Remote sensing to compensate for voltage drop of power leads.

• User selectable ranges of 0-5 VDC and 0-10 VDC for programming and monitoring of output voltage and current, and for programming OVP.

• SETUP switch for selecting ranges for programming and monitoring signals.

• Opto-isolated remote shutdown for control of output power.

• Front panel LOCAL/REMOTE switch for selecting programming source.

• LOCAL-LOCKOUT function to disable front panel control while in remote operation.

• Digital I/O for remote control and status annunciation.

• Configuration changes without requiring removal of covers.

• Optional GPIB, LXI™ Class C Ethernet Interface, RS-232, and isolated remote analog control.

• Cooling fan speed control for low noise and extended fan life.

The following table details the electrical specifications for the DLM 600W Series, including the AMETEK SORENSEN DLM 80-7.5 model.

When you first receive your AMETEK SORENSEN DLM 80-7.5, follow these steps for inspection and setup:

Initial Inspection:

1. Visually inspect the shipping container for damage before accepting it from the carrier. Note any damage on the carrier’s receipt.

2. After unpacking, inspect the unit for shipping damage like dents, scratches, or damaged controls. If damage is found, contact the carrier immediately to file a claim and save the shipping materials for inspection.

Location Considerations:

1. The unit is designed for both rackmount and benchtop use. For rack mounting, remove the four feet from the bottom of the chassis.

2. Since the unit is fan-cooled, ensure adequate clearance for air flow. The air intake is at the front and front sides, and the exhaust is at the rear and rear sides.

3. The ambient air temperature at the intake should not exceed 50°C.

To install a single AMETEK SORENSEN DLM 80-7.5 into a rack using the Rack Mount Kit (Sorensen part number DLMRK), follow these steps:

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

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

3. You can mount the unit on either 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 you removed earlier.

5. Install the Single-Unit Rack Mount Bracket on the opposite side from the Extruded Ear using 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. If needed, use one of the two (2) Right Angle Adapter Brackets to match existing vertical rack rail positions.

CAUTION: To prevent internal damage, use only the specified screw lengths. The unit will not be stable on the Chassis Rack Mount Bracket until at least one of the four front panel mounting screws is installed.

To install two AMETEK SORENSEN DLM 80-7.5 units side-by-side in a rack using the Rack Mount Kit (Sorensen part number DLMRK), follow this procedure:

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

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

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. This connects the two units together.

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

5. Position the two Chassis Rack Mount Brackets in the rack. If necessary, use the two (2) Right Angle Adapter Brackets to match your existing vertical rack rail positions.

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

The AMETEK SORENSEN DLM 80-7.5 operates 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, so no user setup is required.

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

The unit has an IEC connector on the rear panel for connecting the AC power cord. The supplied power cord includes a safety ground wire that connects the unit’s enclosure to the safety ground of the AC power source. This connection is made automatically when the cord is plugged in.

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

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

The AMETEK SORENSEN DLM 80-7.5 (a high-voltage model) has an output terminal block with a snap-on cover. Ensure this cover is in place and insulates all connections before operating the unit.

When connecting the load, consider these factors for selecting the wire gauge:

1. Wire Current Carrying Capacity: The load wiring must have a current capacity greater than the power supply’s output current rating to prevent damage if the load is shorted.

2. Wire Voltage Drop: For applications where regulation is important, select a wire gauge that minimizes voltage drop over the total length of the load lines.

3. Noise and Impedance Effects: To minimize noise, twist the load wires together for their entire length. This also reduces parasitic inductance and improves dynamic response.

The AMETEK SORENSEN DLM 80-7.5 offers two methods for sensing the load voltage:

Local Sensing:

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

Remote Sensing:

This method compensates for voltage drop across the load wires by measuring the voltage directly at the load. To use remote sensing:

1. Set Position-1 (REM SNS) of the rear panel SETUP switch to ON (up).

2. Connect a separate pair of wires (twisted-pair, at least AWG #22) from the REMOTE SENSE (REM SNS) connector on the rear panel to the load terminals. Connect the positive (+) sense lead to the positive load terminal and the negative (-) sense lead to the negative load terminal.

Important Note: If the unit is set for remote sense but the sense wires are not connected to the load, the unit will revert to local sense, and the output voltage at the rear panel may increase by about 5% above the programmed value. If the sense leads are enabled but not connected to the output at all, the power supply will shut down due to an OVP (Overvoltage Protection) fault.

You can connect up to four identical models in parallel for increased current output. The units operate in a master/slave configuration. Follow these steps for setup:

1. Connect the outputs of the units in parallel at the rear panel output terminals using short, equal-length cables. Connect the load wires to the output terminals of the master unit.

2. Interconnect the master and slave units using the PARALLELING CABLE (Sorensen part number DLMP1). You can use either of the two PARALLEL I/O connectors on the rear panel of each unit.

3. On all slave units, set the SLAVE switch (Position-2) on the rear panel SETUP switch to the ON (up) position.

4. On the master unit, ensure the SLAVE switch (Position-2) on the SETUP switch is set to the OFF (down) position.

5. On the slave units, adjust the front panel OVP setting to its maximum (full scale).

Operation Notes:

• The voltage, current, and OVP are all controlled from the master unit’s front panel.

• The voltage display on the slave units will be blanked out.

• The total load current is the sum of the current displays on all units (master and slaves).

• The OUTPUT switch on the master unit will turn all units on or off. The OUTPUT switch on a slave unit will only turn that specific unit’s output off.

• If any unit shuts down due to a fault (OVP, overtemperature, etc.), all connected units will shut down.

Multiple AMETEK SORENSEN DLM 80-7.5 units can be connected in series to achieve a higher output voltage, up to the 300V(PK) maximum float potential limit for each unit.

To connect units in series, connect the negative terminal of one supply to the positive terminal of the next supply in the chain. The total output voltage is taken from the positive terminal of the first unit and the negative terminal of the last unit in the string.

Key points for series operation:

• Each power supply is adjusted individually.

• The total output voltage is the sum of the individual outputs.

• The output current is the same for each unit and is limited by the lowest current setting among the series-connected units.

• Both local and remote sensing can be used for each individual unit.

CAUTION: To prevent damage to a supply, do not connect the remote sense leads of one supply across the total series string. Remote sense should only be connected across the output of its corresponding unit.

Front Panel:

• VOLTAGE Display (1): Shows the output voltage, or the programmed voltage setting when V/I PREVIEW is pressed, or the OVP setting when OVP PREVIEW is pressed.

• CURRENT Display (2): Shows the output current, or the programmed current setting when V/I PREVIEW is pressed.

• VOLTAGE Control (3): 10-turn potentiometer to adjust the output voltage.

• CURRENT Control (4): 10-turn potentiometer to adjust the output current.

• OVP SET Control (5): 20-turn trimmer potentiometer to adjust the overvoltage protection threshold.

• POWER Switch (6): Turns the unit on and off.

• OUTPUT Switch (7): Enables or disables the DC output.

• V/I PREVIEW Switch (8): Momentary switch to display programmed voltage and current settings.

• OVP PREVIEW Switch (9): Momentary switch to display the programmed OVP setting.

• LOCAL(REMOTE) Switch (10): Toggles between front-panel and remote analog programming control.

• REM (Remote) Indicator (11): Lights when the unit is in remote programming mode.

• OUTPUT Indicator (12): Lights when the DC output is enabled.

• VOLTAGE Indicator (13): Lights when in constant-voltage mode.

• CURRENT Indicator (14): Lights when in constant-current mode.

• OVP Indicator (15): Red LED lights when OVP has been tripped.

• FAULT Indicator (16): Red LED lights for overtemperature or summary fault shutdown.

• EXT OFF Indicator (17): Lights when the output is turned off via the remote shutdown signal.

Rear Panel:

• AC Line Input (18): IEC connector for the AC power cord.

• ANALOG INTERFACE Connector (21): D-sub connector for remote programming, monitoring, and control.

• REMOTE SENSE (REM SNS) Connector (22): Connector for remote voltage sense leads.

• PARALLEL I/O Connector (23): Two connectors for master/slave parallel operation.

• SETUP Switch (24): 8-section switch for configuring remote sensing, slave mode, and remote I/O voltage ranges.

• Ground Stud (25): #6-32 stud for chassis ground connection.

• POSITIVE/NEGATIVE DC Output (26, 27): Terminal block for load connection on high-voltage models like the DLM 80-7.5.

Power-On Check:

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

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

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

4. Turn the OVP control fully clockwise.

5. Connect the power cord to an AC source.

6. Press the POWER switch ON (button in). The unit will run a 7-second power-up routine: all LEDs and display segments will light up, and the fan will run at maximum speed.

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

Constant-Voltage Mode Operation Check:

1. With POWER and OUTPUT switches off, connect a digital voltmeter (DVM) to the output terminals.

2. Turn the VOLTAGE control fully counter-clockwise and the CURRENT control fully clockwise.

3. Turn the POWER and OUTPUT switches ON.

4. Slowly turn the VOLTAGE control clockwise. The output voltage on the DVM and the unit’s display should increase. Verify the VOLTAGE indicator is on and the CURRENT indicator is off.

Constant-Current Mode Operation Check:

1. With POWER and OUTPUT switches off, connect a suitable DC shunt across the output terminals. Connect a DVM across the DC shunt.

2. Turn the CURRENT control fully counter-clockwise and the VOLTAGE control fully clockwise.

3. Turn the POWER and OUTPUT switches ON.

4. Slowly turn the CURRENT control clockwise. The output current should increase. Verify the CURRENT indicator is on and the VOLTAGE indicator is off.

The AMETEK SORENSEN DLM 80-7.5 automatically crosses over between Constant Voltage (CV) and Constant Current (CC) mode depending on the load resistance relative to your voltage and current settings.

To Set for Constant-Voltage (CV) Operation:

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

2. Press and hold the V/I PREVIEW switch. While holding it, adjust the VOLTAGE control to your desired output voltage and adjust the CURRENT control to a value greater than the maximum expected load current.

3. Release the preview switch and turn the OUTPUT switch ON. The VOLTAGE indicator should be lit, indicating CV mode.

To Set for Constant-Current (CC) Operation:

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

2. Press and hold the V/I PREVIEW switch. While holding it, adjust the CURRENT control to your desired output current and adjust the VOLTAGE control to a value greater than the maximum expected compliance voltage of the load.

3. Release the preview switch and turn the OUTPUT switch ON. The CURRENT indicator should be lit, indicating CC mode.

Adjusting the OVP Threshold:

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

2. Press and hold the OVP PREVIEW switch. The VOLTAGE display will show the current OVP threshold setting.

3. While holding the switch, use a small screwdriver to adjust the OVP SET control to the desired threshold. This value must be higher than your intended operating voltage.

4. Release the OVP PREVIEW switch.

When the OVP is tripped, the output is turned off, and the red OVP indicator on the front panel will light up.

Resetting a Tripped OVP:

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

2. Verify that all power and sense lead connections are correct.

3. Reset the OVP monitor by toggling one of the following OFF and then back ON:

• The front panel OUTPUT switch

• The front panel POWER switch

• The EXTERNAL-OFF signal on the remote analog interface

When using your AMETEK SORENSEN DLM 80-7.5 to charge a battery, take the following precautions:

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

2. With the power supply disconnected from the battery, adjust the VOLTAGE setting to the desired float voltage. If using local sensing, this setting should compensate for the voltage drop across the isolation diode.

3. Adjust the CURRENT setting to the desired charging current limit.

4. Connect the power supply to the battery. Initially, the supply will operate in constant-current mode, charging the battery at the set current limit. As the battery charges, its voltage will rise. When the voltage reaches the set float voltage, the power supply will switch to constant-voltage mode, and the battery current will taper off as it becomes fully charged.

The 8-position SETUP switch on the rear panel configures advanced functions of the AMETEK SORENSEN DLM 80-7.5. The factory default for all positions is OFF (down).

• REM SNS (1): Selects between internal voltage sensing (OFF) and external remote sensing (ON).

• SLAVE (2): Configures the unit for slave operation in a parallel setup (ON) or as a master/standalone unit (OFF).

• IMON, 10V Select (4): Selects the voltage range for the remote current monitor signal.

• VMON, 10V Select (5): Selects the voltage range for the remote voltage monitor signal.

• OVP, 10V Select (6): Selects the voltage range for remote OVP programming.

• I, 10V Select (7): Selects the voltage range for remote current programming.

• V, 10V Select (8): Selects the voltage range for remote voltage programming.

You can program the output voltage remotely using either an external voltage source or an external resistance.

Using a Voltage Source:

1. Use the rear SETUP switch (Position-8) to select the programming range: OFF for 0–5 VDC or ON for 0–10 VDC.

2. Connect your external programming voltage source to the REMOTE ANALOG INTERFACE connector: positive to Pin-9 and negative to Pin-12.

3. Program the other parameters (Current and OVP) to their desired limits. You can use the Auxiliary 5VDC Output (Pin-15) for full-scale programming if needed. This step is mandatory.

4. To enable remote control, connect a jumper from Pin-1 (ANALOG-CONTROL) to Pin-6 (Return) on the interface connector.

Using a Resistance:

1. Set the rear SETUP switch (Position-8) to OFF for the 0-5 VDC programming range.

2. Connect an external programming resistance (0–5 kΩ potentiometer) to the REMOTE ANALOG INTERFACE connector, between Pin-20 (Return) and Pin-21 (Output).

3. Connect a jumper from Pin-21 to Pin-9 (Voltage Programming Input).

4. Program the other parameters (Current and OVP) to their desired limits. This step is mandatory.

5. To enable remote control, connect a jumper from Pin-1 (ANALOG-CONTROL) to Pin-6 (Return) on the interface connector.

Because the unit uses forced convection cooling, dust can accumulate inside. If you are in a dusty environment, periodic cleaning may be necessary.

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

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

Allow the unit to warm up for 30 minutes at no load before starting. You will need a voltmeter, DC shunt, and a programming voltage source. Perform offset adjustments before range adjustments.

Internal Reference Adjustment (R379):

1. Connect a voltmeter from J14-4 (+) to J14-6 (-).

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

Output Voltage Offset Adjustment (R377):

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 for a reading on the external voltmeter of 1% of full scale output voltage.

Output Voltage Range Adjustment (R378):

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

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

3. Iterate the offset and range adjustments until both are accurate.

Output Current Offset Adjustment (R375):

1. Connect a DC shunt across the output terminals.

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

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 for a current through the shunt of 1% of full scale output current.

Output Current Range Adjustment (R376):

1. Using the same setup, change the voltage source to 5.00 VDC.

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

3. Iterate the offset and range adjustments until both are accurate.

Voltage Display Adjustment (R13):

1. Connect a voltmeter across the output terminals.

2. Adjust front panel CURRENT and OVP controls fully clockwise. Turn OUTPUT switch on.

3. Adjust front panel VOLTAGE control for an output of 100% of full scale.

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

Current Display Adjustment (R15):

1. Connect a DC shunt across the output terminals.

2. Adjust front panel VOLTAGE and OVP controls fully clockwise. Turn OUTPUT switch on.

3. Adjust front panel CURRENT control for an output current of 100% of full scale.

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