CW-M SERIES AC POWER SOURCE Operation Manual This manual covers models: CW 801M CW 1251M CW 2501M ELGAR ELECTRONICS CORPORATION 9250 Brown Deer Road San Diego, CA 92121-2294 1-800-733-5427 Tel: (858) 450-0085 Fax: (858) 458-0267 Email: sales@elgar.com www.elgar.com ©2002 by Elgar Electronics Corporation This document contains information proprietary to Elgar Electronics Corporation.
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ELGAR ONE–YEAR WARRANTY Elgar Electronics Corporation (hereinafter referred to as Elgar) warrants its products to be free from defects in material and workmanship. This warranty is effective for one year from the date of shipment of the product to the original purchaser.
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SAFETY NOTICE Before applying power to the system, verify that the instrument is configured properly for the user’s particular application. WARNING! 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. Installation and servicing must be performed by qualified personnel who are aware of dealing properly with attendant hazards.
SAFETY SYMBOLS CAUTION Risk of Electrical Shock Protective Conductor Terminal Direct Current (DC) CAUTION Refer to Accompanying Documents Off (Supply) iv Alternating Current (AC) Three–Phase Alternating Current Standby (Supply) Fuse On (Supply) Earth (Ground) Terminal
Elgar CW-M Series CONTENTS 1 INTRODUCTION ............................................................... 1 2 SPECIFICATIONS ............................................................. 3 3 4 2.1 Output.........................................................................................................3 2.2 Current .......................................................................................................3 2.3 Measurement..........................................................
Elgar CW-M Series 5 6 OPERATION.................................................................... 33 5.1 Parallel and Multiphase Operation ........................................................... 35 5.2 Remote Control Signals ........................................................................... 36 MAINTENANCE............................................................... 37 6.1 Periodic Service ....................................................................................... 37 6.
Elgar CW-M Series 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.
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Elgar CW-M Series 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 Frequency Range: 45 to 500 Hz Accuracy: ±0.5% typical Resolution: 0.1 Hz 2.3 Measurement Voltage Range: 0 to 135/270 VRMS Accuracy: ±1% of range for voltages >5V, measured at point of sense Resolution of Display: 0.1V Current Range: 0 to 6.0 ARMS (CW 801M) 0 to 9.4 ARMS (CW 1251M) 0 to 18.6 ARMS (CW 2501M) Accuracy: ±2% of range for linear loads with current >0.2A for CW 801M and CW 1251M, >0.4A for CW 2501M Resolution of Display: 0.1A Frequency Range: 45 to 500 Hz Accuracy: ±0.
Elgar CW-M Series Meter Select switch: Current/frequency select Output Voltage: Adjusted using 10–turn potentiometer Output Current: Adjusted using 10–turn potentiometer Output Frequency: Adjusted using 10–turn potentiometer Overvoltage Protection: Settable 5 to 300 VRMS using a 15–turn screwdriver adjust potentiometer Displays Voltage: 4–digit, 7–segment large, green LED display Current or Frequency: 4–digit, 7–segment large, green LED display Protection and Isolation Overvoltage: Set screw adjustable Over
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.
Elgar CW-M Series 2.
Elgar CW-M Series 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 3.2 Wire Gauge Selection The following guidelines assist in determining the optimum cable specification for your power applications. These guidelines are equally applicable to both DC and low frequency AC (up to 450 Hz) power cabling. The same engineering rules apply whether going into or out of an electrical device. Thus, this guide applies equally to the input cable and output cable for this Elgar instrument and application loads.
Elgar CW-M Series The following notes apply to Table 3–1 and to the power cable definition: 1. The above figures are based upon insulated copper conductors at 25 C (77 F), two current carrying conductors in the cable plus a safety (chassis) ground. Columns 3 and 4 refer to “one way” ohms and IR drop of current carrying conductors (e.g., a 50-foot cable contains 100 feet of current carrying conductor). 2.
Elgar CW-M Series 4. 5. 6. Derate the above wire gauge (use a heavier gauge) for higher environmental temperatures since conductor resistance increases with temperature. Temperature Degrees Current Capability C 40 80% F 104 Derate the above wire gauge (use a heavier gauge) for an increased number of current carrying conductors. This offsets the thermal rise of bundled conductors.
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 Mounting Dimensions, Front and Rear Views (CW 801M, CW 1251M) 14
Elgar CW-M Series Figure 3–3 Mounting Dimensions, Front and Rear Views (CW 2501M) 15
Elgar CW-M Series Figure 3–4 Mounting Dimensions, Top and Side Views (CW 801M, CW 1251M) 16
Elgar CW-M Series Figure 3–5 Mounting Dimensions, Top and Side Views (CW 2501M) 17
Elgar CW-M Series 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 Input Power Connections WARNING! For input voltages >120V, do not reverse LINE and NEUT. Reversed connections will result in pulsing noises from the supply. 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.
Elgar CW-M Series 3.5.2 Split–Phase Supply Connections 120–0–120V 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 NEUT to 120V. 4. Connect LINE to the other 120V. Wiring across the full voltage will allow lower line currents to be used. 5. Reinstall the protective cover on the terminal block. Tighten the strain relief device. 3.5.3 Three–Phase Supply Connections 1.
Elgar CW-M Series 3.6 Power Out Connections 1. Remove the protective cover from the terminal block. 2. A factory jumper has been added to connect NEUTRAL to GROUND. If the front connector requires LINE and NEUTRAL to be reversed, move this jumper to connect LINE to GROUND. See Figure 3–7 below. Most loads require NEUTRAL to be grounded. The factory jumper may be removed if the load has a GROUND or if LINE or NEUTRAL voltages are held to less than 500 VRMS with respect to chassis. 3.
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 4) and wiring connections. Connect the master as described in the preceding steps.
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Elgar CW-M Series 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 Switch Position 1,2 ON Required to enable current master and slave operation OFF Stand-alone unit or phase slave ON Current slave OFF Current master ON Phase slave OFF Phase master ON Output disabled at power-up, Fault LED lit Note: If the output switch is in the ON position at power-up, it has to be moved to the OFF/RESET position, then back to the ON position to enable the output OFF Output enabled at power-up 3 4 5 Function 6–7 — Reserved for future expansion 8
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.
Elgar CW-M Series 4.3.
Elgar CW-M Series 4.3.
Elgar CW-M Series 4.3.
Elgar CW-M Series 4.3.5 Setup for Three-Phase Configuration 4.4 Setting the Phase Angle For multiphase operation, set switches 9 through 12 for the desired phase angle as specified in the table below.
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Elgar CW-M Series 5 OPERATION The controls and indicators for the CW series power source are detailed below. Refer to Figure 5–1. Figure 5–1 CW Front Panel Controls n 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 NUMERIC DISPLAY. This large, four-digit display, located in the voltage cluster, is a digital voltmeter that measures and displays the power supply’s output voltage. If the power supply is operating, but the output power is turned off, then this meter displays the voltage that the output will assume when it is turned on. VOLTAGE MODE LAMP. This lamp, located directly over the numeric display, indicates that the power supply is operating in the constant output voltage mode.
Elgar CW-M Series q FAULT LAMP When lit, this lamp indicates that a fault condition has been detected, and that the system output has been turned off automatically. Some conditions that cause this to occur include: output over-voltage, output over-current, high internal temperature, changing the output voltage range while the output is turned on, starting the system with the output turned on and the unit in power up to zero volts mode, or an internal system failure.
Elgar CW-M Series • Phase slaves display their phase angle instead of frequency. The phase master displays the system frequency. • Each unit in the configuration monitors and displays its own load current. Voltage is displayed only on the master; voltage is blanked out on the current slaves. • Voltage of phase slaves can be adjusted independently of the master, from 0V RMS to approximately 20% of full scale above the master (but not exceeding the full-scale range). 5.
Elgar CW-M Series 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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