Cal Power TrueWave TW5250, Service Manual

Page 1: ...ek com Web www programmablepower com TrueWave Switching Amplifier Service Manual Models TW5250 TW3500 TW1750 This Service Manual is incomplete without the TrueWave Operation Manual which contains deta...

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Page 3: ...es only Notice of Copyright TrueWave Switching Amplifier Service Manual 2010 AMETEK Programmable Power Inc All rights reserved Exclusion for Documentation UNLESS SPECIFICALLY AGREED TO IN WRITING AMET...

Page 4: ...ii This page intentionally left blank...

Page 5: ...nnel 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 v...

Page 6: ...instructions of AMETEK is opened modified or disassembled in any way without AMETEK s consent or is used in combination with items articles or materials not authorized by AMETEK The Buyer may not ass...

Page 7: ...1 6 1 6 HOUSEKEEPING BOARD HSKP 1 7 1 7 POWER CONDITIONER MODULE 1 8 1 7 1 RECTIFIER INPUT 1 8 1 7 2 POWER FACTOR CORRECTION PFC INPUT 1 8 1 7 3 DC DC CONVERTER 1 9 1 8 AMPLIFIER MODULE 1 9 1 9 GLOSS...

Page 8: ...3 15 EXTERNAL PHASE REFERENCE CALIBRATION 3 22 3 16 PHASE A TO PHASE B CALIBRATION 3 23 3 17 PHASE A TO PHASE C CALIBRATION 3 25 3 18 EXTERNAL GAIN CONTROL CALIBRATION 3 27 3 19 LOW RANGE CURRENT CALI...

Page 9: ...FIGURE 1 1 TW 5250 1 2 FIGURE 1 2 DIGITAL CONTROL BOARD BLOCK DIAGRAM 1 4 FIGURE 1 3 ANALOG PROCESSOR BOARD BLOCK DIAGRAM 1 6 FIGURE 1 7 POWER CONDITIONER MODULE BLOCK DIAGRAM 1 8 LIST OF TABLES TABL...

Page 10: ...TABLE OF CONTENTS TW SERIES viii This page intentionally left blank...

Page 11: ...s at the module or board level is most valuable should the service person find it necessary to investigate a suspected fault or malfunction within the power source 1 2 SYSTEM OVERVIEW Figure 1 1 shows...

Page 12: ...C PWR MOD C RECTIFIER OR PFC DC DC BACKPLANE AMPLIFIER A AMPLIFIER B AMPLIFIER C 290VDC BUS 290VDC BUS 290VDC BUS 290VDC BUS 290VDC BUS 290VDC BUS BACKPLANE OUTPUT FILTER INPUT FILTER 3 INPUT 208 VAC...

Page 13: ...k and input filter to the power module s through W1 2 and 3 where it is rectified via the PFC or rectifier input stage s The rectified voltages are then delivered to the DC DC converter s where 290V b...

Page 14: ...essor operating with a 16 bit data bus The processor system memory consists of one 256K x 16 20ns static RAM one 256K x 16 90ns FLASH ROM 64K x 8 120ns PROM and 8K x 8 EEPROM The PROM is used during b...

Page 15: ...fault or user defined values Performs system self test Enters main control loop The main control loop reads the keypad for user input updates the displays and data buffers with current readback values...

Page 16: ...main control loop All waveform generation and measurements are handled by the DSP Current mode of operation is also controlled by the DSP Hardware faults are monitored by the DSP and appropriate acti...

Page 17: ...alibration scaling and presentation to the user 1 6 HOUSEKEEPING BOARD HSKP The HSKP board receives 48Vdc input from the power module s via the backplane board where the 48V inputs are paralleled and...

Page 18: ...stage is delivered through a soft start circuit and rectified by a 3 phase bridge rectifier developing a 380 Vdc bus When the system is configured for USA input the rectifier is wired as a 3 phase ful...

Page 19: ...ops switches the 380 Vdc bus supplied by the rectifier or PFC input stage at a rate of 140 kHz The output transformer and three full wave bridge rectifier circuits then generate the two 290 Vdc and 48...

Page 20: ...he amplifier bus voltages and output neutral to chassis voltages for overvoltage conditions Also monitored are amplifier heatsink temperatures as well as output voltage and current feedback signals al...

Page 21: ...d without authorization WARNING Hazardous voltages are present when operating this equipment Please read the Safety Notice at the beginning of this manual before performing any installation operation...

Page 22: ...ailure to comply can result in serious electrical shock to individuals coming in contact with live voltages at exposed terminals when the unit is energized Once the unit is de energized a wait period...

Page 23: ...es of a TW system Since the TW is such a complex system any fault could be caused by one or more of several assemblies For that reason this manual will list the suspect assemblies in order with the fi...

Page 24: ...y installed Re energize unit and test Unit comes up momentarily and shuts off immediately De energize unit and perform disassembly steps 2 6 1 thru 2 6 5 Insure that the connectors of cable 5161524 01...

Page 25: ...g the following procedure in reverse and referring to the Final Assembly drawing 5161469 located in Section 5 of this manual WARNING Prior to beginning disassembly procedures ensure that AC power has...

Page 26: ...may be covered by white quality seals and therefore the seals will need to be broken Remove cover as shown above 2 6 2 Loosen the front panel by removing the remaining 8 screws securing the front pan...

Page 27: ...OTING 2 7 2 6 3 Remove the fan panel power cables from the Analog board connectors J10 and J11 as shown above 2 6 4 Remove the 4 pan head screws two screws on either side of unit securing the fan pane...

Page 28: ...moved from the chassis as shown above Extreme care must be taken not to damage any components on the Analog board as the fan panel assembly is being removed 2 6 6 Slightly separate the Power On switch...

Page 29: ...back through the front panel 2 6 8 Remove cables from J1 J4 J7 J8 on Analog board and J2 J6 on Control board The front panel assembly can now be completely removed The Housekeeping board can also be r...

Page 30: ...move the Analog and Control boards from the front panel assembly remove the 8 mounting screws securing the boards to the panel and gently separate the boards 2 6 10 Remove the 4 screws attaching the r...

Page 31: ...on model that secure the top bracket to the modules as shown above 2 6 12 To remove the ribbon cable bracket remove the top screw only that secures the bracket to the air baffle as shown above The bot...

Page 32: ...S 2 12 2 6 13 Remove the 4 screws that secure the Signal board to the air baffle 2 6 14 The Signal board can now be removed by disconnecting the 1 2 or 3 ribbon cable connector s depending on model fr...

Page 33: ...air baffle as shown above 2 6 16 Disconnect both the small enable connector P1 and the large input power connector P2 from each of the power modules as shown above Note There may be a small amount of...

Page 34: ...CE AND TROUBLESHOOTING TW SERIES 2 14 2 6 17 Remove the air baffle by lifting straight out as shown above 2 6 18 Any module can now be removed by first gently pulling module towards the front of unit...

Page 35: ...r panel assembly can now be detached by removing the 13 screws around the rear perimeter of the chassis 4 screws on the left side 5 screws on the right side and 4 screws on the bottom When removing th...

Page 36: ...MAINTENANCE AND TROUBLESHOOTING TW SERIES 2 16 This page intentionally left blank...

Page 37: ...quipment listed below or equipment with equivalent capabilities can be used to calibrate the TrueWave s output and measurement The measurement equipment listed meets the 4 1 ratio required by many cal...

Page 38: ...PHA 0 0 0 0 0 0 0 0 0 0 CAL UNIQ OPHAB 0 0 0 0 0 0 0 0 0 0 CAL UNIQ MOPHAB 0 0 0 0 0 0 0 0 0 0 CAL UNIQ OPHAC 0 0 0 0 0 0 0 0 0 0 CAL UNIQ MOPHAC 0 0 0 0 0 0 0 0 0 0 CAL UNIQ GEXTG 1 0 CAL UNIQ OEXTG...

Page 39: ...1 2 3 MEAS LOCAL HIR CURR OFFSET 0 0 CAL 1 2 3 MEAS LOC HIR CURR FREQCAL 1 0 1 0 1 0 1 0 1 0 CAL 1 2 3 MEAS REMOTE LOR CURR GAIN 1 00 CAL 1 2 3 MEAS REMOTE LOR CURR OFFSET 0 0 CAL 1 2 3 MEAS REM LOR...

Page 40: ...ired offset DAC setting VALUE1 256 RDNG1 RDNG1 RDNG2 Set the dc offset calibration register OUTPUT OFF CAL UNIQ DCDAC A B C VALUE1 3 7 DC LOCAL LOW RANGE CALIBRATION Both the measurement and output su...

Page 41: ...0 MEAS1 Send the calculated offset to the TW CAL 1 2 3 MEAS LOC LOR CURR OFFSET VALUE1 Set the TW to 220 volts DC by sending the following GPIB string SOUR 1 2 3 VOLT OFFSET 220 Wait for the DMM to s...

Page 42: ...ement and output subsystems are calibrated at the same time Connect the DMM to the output phase of the TW to be calibrated Set the DMM for auto ranging volts DC Send the following GPIB commands to the...

Page 43: ...ng as MEAS1 MEAS 1 2 3 VOLT Set the TW to 440 volts DC by sending the following GPIB string SOUR 1 2 3 VOLT OFFSET 440 Wait for the DMM to settle Take a DMM reading and record the value as RDGN2 Query...

Page 44: ...URR 5 00 OUTPUT ON SOUR 1 2 3 VOLT OFFSET 0 0 Wait for the DMM to settle and record the value as RDGN1 Send the following query command to the TW and record the return string as MEAS1 MEAS 1 2 3 VOLT...

Page 45: ...EAS2 OFFSET GAIN2 MEAS1 220 0 Update the TW calibration registers by sending the following GPIB strings CAL 1 2 3 MEAS REM LOR VOLT GAIN GAIN2 CAL 1 2 3 OUTP REM LOR VOLT GAIN GAIN1 CAL 1 2 3 OUTP REM...

Page 46: ...e the offset value VALUE1 1 0 MEAS1 Send the calculated offset to the TW CAL 1 2 3 MEAS REM HIR CURR OFFSET VALUE1 Set the TW to 440 volts DC by sending the following GPIB string SOUR 1 2 3 VOLT OFFSE...

Page 47: ...LT OFFSET 0 0 OUTPUT OFF 3 11 LOCAL LOW RANGE FREQUENCY CALIBRATION Connect the TW output to the DMM Set the DMM up for auto ranging AC voltage Set the TW into AC coupling local sense 40 Hz 120V and l...

Page 48: ...te the local low range frequency calibration of the TW by sending the following GPIB string CAL 1 2 3 OUTP LOC LOR VOLT FREQCAL VALUE1 VALUE2 VALUE3 VALUE4 VALUE5 Close the TW s output relay OUTPUT ON...

Page 49: ...ecord this value as MEAS4 MEAS 1 2 3 VOLT Set the TW s frequency to 500 Hz with the following GPIB command SOUR FREQ 500 0 Wait for the DMM reading to settle and record the value as RDNG5 Query the TW...

Page 50: ...the TW s output relay OUTPUT ON Wait for the DMM to settle and record the voltage as MEAS1 Set the TW to 80 Hz SOUR FREQ 80 0 Wait for the DMM to settle and record the voltage as MEAS2 Set the TW to...

Page 51: ...age with the GPIB string below and record this value as MEAS1 MEAS 1 2 3 VOLT Set the TW s frequency to 80 Hz with the following GPIB command SOUR FREQ 80 0 Wait for the DMM reading to settle and reco...

Page 52: ...and open the output with the following GPIB commands SOUR FREQ 60 0 OUTP OFF Calculate the measurement system frequency compensation values VALUE1 RDGN1 MEAS1 VALUE2 RDGN2 MEAS2 VALUE3 RDGN3 MEAS3 VA...

Page 53: ...OUR FREQ 320 0 Wait for the DMM to settle and record the voltage as MEAS4 Set the TW to 500 Hz SOUR FREQ 500 0 Wait for the DMM to settle and record the voltage as MEAS5 Set the TW to 60 Hz and open t...

Page 54: ...2 MEAS 1 2 3 VOLT Set the TW s frequency to 160 Hz with the following GPIB command SOUR FREQ 160 0 Wait for the DMM reading to settle and record the value as RDNG3 Query the TW s output put voltage wi...

Page 55: ...libration data with the following GPIB command CAL 1 2 3 MEAS REM LOR VOLT FREQCAL VALUE1 VALUE2 VALUE3 VALUE4 VALUE5 3 14 REMOTE HIGH RANGE FREQUENCY CALIBRATION Connect the TW output to the DMM Set...

Page 56: ...utput relay SOUR FREQ 80 0 OUTPUT OFF Calculate the calibration constants VALUE1 240 0 MEAS1 VALUE2 240 0 MEAS2 VALUE3 240 0 MEAS3 VALUE4 240 0 MEAS4 VALUE5 240 0 MEAS5 Update the remote high range fr...

Page 57: ...string below and record this value as MEAS3 MEAS 1 2 3 VOLT Set the TW s frequency to 320 Hz with the following GPIB command SOUR FREQ 320 0 Wait for the DMM reading to settle and record the value as...

Page 58: ...counter time up to measure phase angle Set up the TW for the external refout low range local sense 40 Hz 120 V and close the output relay by sending the following GPIB commands SYST EXT CLOCK REFOUT...

Page 59: ...calibration data via the GPIB CAL UNIQ OPHA VALUE1 VALUE2 VALUE3 VALUE4 VALUE5 3 16 PHASE A TO PHASE B CALIBRATION Note this calibration step only applies to TW3500 and TW5250 systems Connect the coun...

Page 60: ...e counter timer to settle and record the phase angle as RDNG3 Query the TW for the phase angle with the following command and record the value as MEAS3 MEAS2 PHASE Set the TW frequency to 320 Hz via t...

Page 61: ...GN4 MEAS4 VALUE5 1 0 RDGN5 MEAS5 Update the calibration data via the GPIB CAL UNIQ MOPHAB VALUE1 VALUE2 VALUE3 VALUE4 VALUE5 3 17 PHASE A TO PHASE C CALIBRATION Note this calibration step only applies...

Page 62: ...the GPIB SOUR FREQ 160 0 Wait for the counter timer to settle and record the phase angle as RDNG3 Query the TW for the phase angle with the following command and record the value as MEAS3 MEAS2 PHASE...

Page 63: ...S2 VALUE3 1 0 RDGN3 MEAS3 VALUE4 1 0 RDGN4 MEAS4 VALUE5 1 0 RDGN5 MEAS5 Update the calibration data via the GPIB CAL UNIQ MOPHAC VALUE1 VALUE2 VALUE3 VALUE4 VALUE5 3 18 EXTERNAL GAIN CONTROL CALIBRATI...

Page 64: ...the power analyzer to measure current Set up the TW to DC coupling low range local sense 13 ampere current limit output relay closed and 12 volts with the following GPIB programming strings OUTP COUP...

Page 65: ...er analyzer Set up the power analyzer to measure watts Set up the TW to AC coupling low range local sense 13 ampere current limit output relay closed and 54 volts with the following GPIB programming s...

Page 66: ...power analyzer Set up the power analyzer to measure watts Set up the TW to AC coupling low range local sense 13 ampere current limit output relay closed and 54 volts with the following GPIB programmi...

Page 67: ...rrent Set up the TW to AC coupling low range remote sense 40 Hz 13 ampere current limit output relay closed and 120 volts with the following GPIB programming strings OUTP COUP AC SOUR VOLT RANGE LOW S...

Page 68: ...AS4 MEAS 1 2 3 CURR Program the TW to 500 Hz using the string below SOUR 1 2 3 FREQ 500 Wait until the power analyzer has stabilized and record the current reading as RDNG5 Query the TW s current usin...

Page 69: ...ng as RDNG1 Query the TW s watts using the GPIB string below and record this value as MEAS1 MEAS 1 2 3 POW Program the TW to 80 Hz using the string below SOUR 1 2 3 FREQ 80 Wait until the power analyz...

Page 70: ...ALUE2 RDGN2 MEAS2 VALUE3 RDGN3 MEAS3 VALUE4 RDGN4 MEAS4 VALUE5 RDGN5 MEAS5 Update the TW s calibration data CAL 1 2 3 MEAS LOC LOR WATT FREQCAL VALUE1 VALUE2 VALUE3 VALUE4 VALUE5 3 24 REMOTE LOW RANGE...

Page 71: ...e watts reading as RDNG3 Query the TW s watts using the GPIB string below and record this value as MEAS3 MEAS 1 2 3 POW Program the TW to 320 Hz using the string below SOUR 1 2 3 FREQ 320 Wait until t...

Page 72: ...osed and 24 volts with the following GPIB programming strings OUTP COUP DC SOUR VOLT RANGE HIGH SOUR SENSE LOCAL SOUR 1 2 3 CURR 6 5 OUTPUT ON SOUR 1 2 3 VOLT OFFSET 24 Wait until the power analyzer h...

Page 73: ...ollowing GPIB programming strings OUTP COUP AC SOUR VOLT RANGE HIGH SOUR SENSE LOCAL SOUR 1 2 3 CURR 6 5 OUTPUT ON SOUR 1 2 3 VOLT 108 Wait until the power analyzer has stabilized and record the watts...

Page 74: ...OUTPUT ON SOUR 1 2 3 VOLT 108 Wait until the power analyzer has stabilized and record the watts reading as RDNG1 Query the TW s watts using the GPIB string below and record this value as MEAS1 MEAS 1...

Page 75: ...RDNG1 Query the TW s current using the GPIB string below and record this value as MEAS1 MEAS 1 2 3 CURR Program the TW to 80 Hz using the string below SOUR 1 2 3 FREQ 80 Wait until the power analyzer...

Page 76: ...ing equations VALUE1 RDGN1 MEAS1 VALUE2 RDGN2 MEAS2 VALUE3 RDGN3 MEAS3 VALUE4 RDGN4 MEAS4 VALUE5 RDGN5 MEAS5 Update the TW s calibration data CAL 1 2 3 MEAS REM HIR CURR FREQCAL VALUE1 VALUE2 VALUE3 V...

Page 77: ...wer analyzer has stabilized and record the watts reading as RDNG3 Query the TW s watts using the GPIB string below and record this value as MEAS3 MEAS 1 2 3 POW Program the TW to 320 Hz using the stri...

Page 78: ...ere current limit output relay closed and 240 volts with the following GPIB programming strings OUTP COUP AC SOUR VOLT RANGE HIGH SOUR SENSE REMOTE SOUR FREQ 40 SOUR 1 2 3 CURR 6 5 OUTPUT ON SOUR 1 2...

Page 79: ...nd record this value as MEAS4 MEAS 1 2 3 POW Program the TW to 500 Hz using the string below SOUR 1 2 3 FREQ 500 Wait until the power analyzer has stabilized and record the watts reading as RDNG5 Quer...

Page 80: ...CALIBRATION TW SERIES 3 44 This page intentionally left blank...

Page 81: ...ASSEMBLY TW3500 3 5161469 14 FINAL ASSEMBLY TW3500 4 5161469 17 FINAL ASSEMBLY TW5250 1 5161469 18 FINAL ASSEMBLY TW5250 2 5161469 21 FINAL ASSEMBLY TW5250 3 5161469 22 FINAL ASSEMBLY TW5250 4 5161469...

Page 82: ...orporation to order spare parts or assemblies Please specify the assembly number instrument name and instrument series number when ordering Elgar Electronics Corporation 9250 Brown Deer Road San Diego...

Page 83: ...e interconnect diagrams can be used to understand the theory of operation and as an aid in troubleshooting the unit 5 2 DIAGRAMS Table 5 1 lists the diagrams included in this section Number Drawing Ti...

Page 84: ...DIAGRAMS TW SERIES 5 2 This page intentionally left blank Via Acquanera 29 22100 Como tel 031 526 566 r a fax 031 507 984 info calpower it www calpower it...