CW-M SERIES AC POWER SOURCE Operation Manual This manual covers models: CW 801M CW 1251M CW 2501M Contact Information Telephone: 800 733 5427 (toll free in North America) 858 450 0085 (direct) Fax: 858 458 0267 Email: Domestic Sales: domorders.sd@ametek.com International Sales: intlorders.sd@ametek.com Customer Service: service.ppd@ametek.com Web: www.programmablepower.com March 2011 Document No.
About AMETEK AMETEK Programmable Power, Inc., a Division of AMETEK, Inc., is a global leader in the design and manufacture of precision, programmable power supplies for R&D, test and measurement, process control, power bus simulation and power conditioning applications across diverse industrial segments. From bench top supplies to rack-mounted industrial power subsystems, AMETEK Programmable Power is the proud manufacturer of Elgar, Sorensen, California Instruments and Power Ten brand power supplies.
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Important Safety Instructions Before applying power to the system, verify that your product is configured properly for your particular application. 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 WARNING (below) chassis ground. The equipment used contains ESD sensitive ports. When installing equipment, follow ESD Safety Procedures.
Product Family: CW 801M, CW 1251M, CW 2501M Warranty Period: One Year WARRANTY TERMS AMETEK Programmable Power, Inc.
CONTENTS 1 INTRODUCTION ............................................................ 1-1 2 SPECIFICATIONS .......................................................... 2-1 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3 INSTALLATION ............................................................. 3-1 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4 Output ..................................................................................................... 2-1 Current ...............................................................
Elgar CW-M Series 4.4 5 OPERATION ................................................................... 5-1 5.1 5.2 6 Setting the Phase Angle ......................................................................... 4-8 Parallel and Multiphase Operation .......................................................... 5-4 Remote Control Signals .......................................................................... 5-5 MAINTENANCE.............................................................. 6-1 6.1 6.
SECTION 1 INTRODUCTION Elgar's ContinuousWave™ (CW) Series power sources deliver up to 1250 VA in a 2U high (3.5 inches) rackmount chassis, and 2500 VA in a 5.25 inch chassis. This low profile design is also suitable for benchtop use. The CW Series models have three power ratings: 800 VA, 1250 VA, and 2500 VA. The switchmode, Power Factor Corrected (PFC) design efficiently delivers clean AC power.
Elgar CW-M Series Transformer coupled output, 500 VRMS isolation voltage between either output terminal to chassis Power-up to previous front panel setting or 0 Volts (switch selectable) Universal Input: 90–264 VAC (CW 801M), 103–264 VAC (CW 1251M), 180–264 VAC (CW 2501M) Optional front panel locking knobs 1–year calibration interval CE Mark Figure 1-1.
SECTION 2 SPECIFICATIONS Note: Product specifications are subject to change without notice. 2.1 OUTPUT Power CW 801M: 800 VA CW 1251M: 1250 VA CW 2501M: 2500 VA Power Factor of Load: 0 lag to 0 lead Phase: All models single phase output Voltage Ranges: 0 to 135 VAC RMS or 0 to 270 VAC RMS manual switch (consult factory for custom output voltages) Accuracy: 1% of range for voltages >5V Resolution: 0.1V Total Harmonic Distortion: 0.25% typical <100 Hz add 0.
Elgar CW-M Series Load Regulation: ±0.1% of full scale voltage for a full resistive load to no load Line Regulation: ±0.1% of full scale for a ±10% line change from nominal line voltage Remote Voltage Sense: 5 VRMS total lead voltage drop 2.2 CURRENT CW 801M: 6.00 ARMS in 135 VAC range or 3.00 ARMS in 270 VAC range CW 1251M: 9.40 ARMS in 135 VAC range or 4.70 ARMS in 270 VAC range CW 2501M: 18.60 ARMS in 135 VAC range or 9.30 ARMS in 270 VAC range Frequency Range: 45 to 500 Hz Accuracy: ±0.
Elgar CW-M Series 2.4 FRONT PANEL Controls Power On/Off switch Output On/Off/Reset switch: Operates output isolation relays. Off also resets faults.
Elgar CW-M Series 2.
Elgar CW-M Series 2.7 GENERAL Dimensions CW 801M: 3.5" H (89 mm) x 19" W (483 mm) x 20.6" D (524 mm) CW 1251M: 3.5" H (89 mm) x 19" W (483 mm) x 20.6" D (524 mm) CW 2501M: 5.25" H (133 mm) x 19" W (483 mm) x 20.6" D (524 mm) Weight CW 801M: 48 lbs. (22 kg) CW 1251M: 53 lbs. (24 kg) CW 2501M: 86 lbs. (39 kg) Shipping Weight CW 801M: 56 lbs. (25 kg) CW 1251M: 61 lbs. (28 kg) CW 2501M: 94 lbs.
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SECTION 3 INSTALLATION The Elgar CW series power supply has been fully calibrated and tested prior to shipment. The instrument is ready for immediate use upon receipt. CAUTION! The CW unit weighs from 48 to 86 lbs. (22 to 40 kg), depending on the model. A two–person lift is recommended. WARNING! Hazardous voltages are present when operating this equipment. Please read the Safety Notice at the beginning of this manual prior to installation, operation, or maintenance. 3.
Elgar CW-M Series If the instrument needs to be returned to Elgar, suitable shipping containers and packing materials must be used. If proper packing material is not available, contact Elgar to provide containers and shipping instructions. Before shipping a product to Elgar, you must obtain a Return Material Authorization (RMA) number from Elgar‘s Repair Department. See the warranty page at the front of this manual for details. 3.
Elgar CW-M Series Table 3–1 identifies popular ratings for DC and AC power source cable wire gauges. Table 3–1. Recommended Wire Gauge Selection Guide Column 1 Size (AWG) Column 2 Amperes (Max) Column 3 Ohms/100 ft (1 way) Column 4 IR Drop/100 ft (Col 2 x Col 3) 14 12 10 8 6 4 2 1/0 3/0 15 20 30 40 55 70 95 125 165 0.257 0.162 0.102 0.064 0.043 0.025 0.015 0.010 0.006 3.85 3.24 3.06 2.56 2.36 1.75 1.42 1.25 1.04 The following notes apply to Table 3–1 and to the power cable definition: 1. 1.
Elgar CW-M Series corresponding wire gauge would be 10 AWG. 3. Aluminum wire is not recommended due to soft metal migration at the terminals which may cause long term (on the order of years) poor connections and oxidation. If used, increase the wire gauge by two sizes (e.g., specify 10 gauge aluminum instead of 14 gauge aluminum). 4. Derate the above wire gauge (use a heavier gauge) for higher environmental temperatures since conductor resistance increases with temperature. 5. 6.
Elgar CW-M Series 3.3 MOUNTING INSTRUCTIONS Refer to Figure 3-1 through Figure 3-4 for mounting dimensions and other installation information for the CW Series power supplies. The units are equipped with mounting feet for bench top use. They are mounted to the chassis with pem-nuts and may be removed easily for rack mount application. The units are 3.5" and 5.25" (89 mm and 133 mm) high, and are designed to be installed in a standard 19" (483 mm) RETMA rack.
Elgar CW-M Series Figure 3-2.
Elgar CW-M Series Figure 3-3.
Elgar CW-M Series Figure 3-4.
Elgar CW-M Series Figure 3-5.
Elgar CW-M Series 3.4 COOLING The CW unit employs internal fans to circulate cooling air. The air is drawn into the chassis along its sides, and is exhausted through the rear panel. For maximum product life and reliability, do not allow the airflow to be impeded. CAUTION! Avoid blocking the instrument air intakes or exhaust. 3.5 POWER IN CONNECTIONS Connect input power to the INPUT terminal block on the rear panel as specified below. Refer to Figure 3-6. Figure 3-6.
Elgar CW-M Series 3.5.1 SINGLE–PHASE SUPPLY CONNECTIONS 1. Remove the protective cover from the terminal block. 2. Route the cables through the strain relief device. Refer to Table 3–2 for cable recommendations. 3. Connect SAFETY Ground to the Ground stud located next to the INPUT terminal block. For additional safety, include a loop between the Ground stud and the strain relief device, as shown in Figure 3-6. 4. Connect shields, if any, to the GND connector of the INPUT terminal block. 5.
Elgar CW-M Series WARNING! To protect the operator, the wire connected to the GND terminal must be connected to earth ground. This unit should not be operated without an adequate ground connection. CAUTION! Use wire rated for currents drawn as specified on equipment label. WARNING! A device to disconnect the CW system from the energy supply source is required.
Elgar CW-M Series Figure 3-7.
Elgar CW-M Series 3.7 SENSE CONNECTIONS The CW Series unit can be used with or without remote sense leads connected to the load. Where the sense leads (line and neutral sense) are connected determines the point at which the CW output voltage will be precisely regulated. As shipped, the units are configured for local sense operation. This is achieved by connecting shorting jumpers between the sense and AC output terminals of the rear panel output terminal block, as shown in Figure 3-8.
Elgar CW-M Series To utilize remote sensing at the user's load, follow these steps: 1. Remove the protective cover from the terminal block. 2. Route the cables through the strain relief device located above the terminal block. Twisted shielded leads for power and sense leads are recommended for the lowest noise operation. If used, shields should be connected to a CW output terminal block GND ground connector, as shown in Figure 3-9. 3. Disconnect local–sense shorting jumpers. See Figure 3-9. 4.
Elgar CW-M Series 3.8 PARALLEL CONNECTED UNITS To achieve higher output power than what is available from one unit, you can connect up to six units in parallel. This is referred to as ‗master/slave‘ operation. For a master/slave configuration, designate one unit as the master and the others as slaves. This is done by both switch settings (see Section SECTION 4) and wiring connections. Connect the master as described in the preceding steps.
SECTION 4 SET-UP Once installation is complete and all cable connections are secure, check the settings on the 12-position CONFIG dipswitch located on the rear panel. Refer to Figure 4-1. Configure the switch prior to applying unit power. Figure 4-1. CW Rear Panel 4.1 CONFIG DIPSWITCH The CONFIG dipswitch comes preset from the factory for stand-alone operation. With these settings, the unit powers up to the current voltage and operates in constant current mode.
Elgar CW-M Series Table 4–1.
Elgar CW-M Series 4.3 PARALLEL AND MULTIPHASE CONFIGURATIONS To operate parallel and/or multiphase configurations, set the switches, cables, and wiring as shown in the examples below. 4.3.1 SETUP FOR THREE-PHASE, TWO PARALLELED PER PHASE CONFIGURATION Figure 4-5.
Elgar CW-M Series 4.3.2 SETUP FOR SIX IN PARALLEL CONFIGURATION Figure 4-6.
Elgar CW-M Series 4.3.3 SETUP FOR SIX-PHASE CONFIGURATION Figure 4-7.
Elgar CW-M Series 4.3.4 SETUP FOR TWO-PHASE CONFIGURATION Figure 4-8.
Elgar CW-M Series 4.3.5 SETUP FOR THREE-PHASE CONFIGURATION Figure 4-9.
Elgar CW-M Series 4.4 SETTING THE PHASE ANGLE For multiphase operation, set switches 9 through 12 for the desired phase angle as specified below, in Table 4–2. Table 4–2.
SECTION 5 OPERATION The controls and indicators for the CW series power source are detailed below in Figure 5-1. Figure 5-1. CW Front Panel Controls POWER SWITCH Press the top portion of the switch to turn power on, press the bottom portion of the switch to turn the power supply off. When power is turned on, the unit goes through a power up cycle that may take several seconds before it is ready for operation.
Elgar CW-M Series V RANGE HIGH/LOW Switch. This switch allows you to select the 0V-135V range or the 0V-270V range of output voltage. The output current available on the low voltage range is twice that available on the high voltage range. NOTE: This switch should not be toggled while the system output is turned on. Doing so will cause the output to turn off, and a fault condition will be indicated.
Elgar CW-M Series CURRENT MODE Lamp. This lamp, located directly over the numeric display, indicates when the output current has reached its selected limiting value, i.e., the power supply is operating in the constant current mode. CURRENT Knob. A large, multi-turn knob allows you to set the point of inception of the constant current mode. FREQUENCY Knob. A large, multi-turn knob allows you to set the operating frequency.
Elgar CW-M Series 5.1 PARALLEL AND MULTIPHASE OPERATION Follow the instructions in Section 3.8, Section 3.9, and Section SECTION 4 to set up paralleled or multiphase units. Turn on the slaves prior to the master unit. If the master is tuned on first, it will initialize in a fault condition, and it will need to be reset. If a fault occurs, the fault light on the unit with the fault and the fault light on the master will light.
Elgar CW-M Series 5.2 REMOTE CONTROL SIGNALS A nine-pin ‗D‘ connector on the rear panel, marked EXT CONTROL, provides for the application of DC voltage signals to control both the voltage amplitude and frequency of the power supply‘s output signal. A 0V–5V signal has full scale control over either function. The effect of the external analog control signal is additive with the setting of the function‘s front panel control setting. The combined effect is full scale limited.
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SECTION 6 MAINTENANCE 6.1 PERIODIC SERVICE No routine maintenance on the CW Series unit is required, aside from periodic cleaning. Once a unit is removed from service, it may be cleaned with isopropyl alcohol (or an equivalent solvent) on the metal surfaces, and a weak solution of soap and water on the front panel. Low pressure compressed air may be used to remove dust from in and around components on the printed circuit boards. 6.
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