Xantrex XKW 150-7, Operating Manual

Page 1: ...Operating Manual XKW 1000 Watt Series Programmable DC Power Supply XKW 8 125 XKW 20 50 XKW 33 33 XKW 40 25 XKW 60 18 XKW 80 13 XKW 150 7 XKW 300 3 5 XKW 600 1 7 ...

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Page 3: ...Operating Manual for XKW 1000 Watt Series Programmable DC Power Supply ...

Page 4: ...e right to use parts or products of original or improved design in the repair or replacement If Xantrex repairs or replaces a product its warranty continues for the remaining portion of the original Warranty Period or 90 days from the date of the return shipment to the customer whichever is greater All replaced products and all parts removed from repaired products become the property of Xantrex Xa...

Page 5: ...he product exchanged under warranty What does this warranty not cover This Limited Warranty does not cover normal wear and tear of the product or costs related to the removal installation or troubleshooting of the customer s electrical systems This warranty does not apply to and Xantrex will not be responsible for any defect in or damage to a the product if it has been misused neglected improperly...

Page 6: ...WILL XANTREX BE LIABLE FOR ANY SPECIAL DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES LOSSES COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND ANY LOSS OR DAMAGE TO PROPERTY ANY PERSONAL INJURY ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE OR THE INCORRECT INSTALLATION INTEGRATION OR OPERATION OF T...

Page 7: ...our product user manual for limitations on uses of the product Specifically please note that this power supply is not intended for use in connection with life support systems and Xantrex makes no warranty or representation in connection with any use of the product for such purposes Xantrex Technology Inc 8999 Nelson Way Burnaby British Columbia Canada V5A 4B5 Information About Your Power Supply Pl...

Page 8: ...ous energy for some time after power is removed CAUTION Operate the power supply in an environment free of flammable gases or fumes To ensure that the power supply s safety features are not compromised use the power supply as specified in this manual and do not substitute parts or make any unauthorized modifications Contact the service technician for service and repair help Repairs must be made by...

Page 9: ...f input and output power as well as the observance of safe techniques while making supply or pin connections and any changes in switch settings Main Sections Section 1 Features and Specifications Describes the power supply and lists its features and specifications Section 2 Installation Goes through basic setup procedures Describes inspection cleaning shipping and storage procedures Includes AC in...

Page 10: ...ng Manual for XKW 1kW Series Power Supply Power Supply Safety Markings Alternating Current Off Supply Earth Ground Terminal Caution Hot Surface Protective Conductor Terminal Caution Check manual for additional information On Supply ...

Page 11: ...edure 23 Inspection Cleaning and Packaging 24 Initial Inspection 24 Periodic Cleaning 24 Returning Power Supplies to the Manufacturer 25 Return Material Authorization Policy 25 Packaging for Shipping or Storage 26 Location Mounting and Ventilation 27 Ventilation Requirements 27 Rack Mounting 27 AC Input Power 28 AC Input Voltage Selection 28 Input Line Impedance 29 Functional Tests 30 Voltage Mode...

Page 12: ...h External Current Sources 44 Remote OVP Sensing 45 Remote ON OFF 46 Remote ON OFF by Contact Closure 46 Remote Programming of Output Voltage and Current Limit 47 Remote Programming Switch SW1 47 Programming With External Voltage Sources 48 Programming With an External Resistance 50 Programming With an External Current Source 51 Remote Monitoring and Status Indicators 52 Using Over Temperature Pro...

Page 13: ...gramming or RS 232 control It is designed for a broad range of development system and burn in applications and uses high frequency switching regulator technology to achieve high power density in a small package size See Table 1 1 for the list of available models Table 1 1 Available Voltage and Current Ranges Model Voltage Range Current Range 8 125 0 8 V 0 125 A 20 50 0 20 V 0 50 A 33 33 0 33 V 0 3...

Page 14: ... to compensate for losses in power leads up to 1 V per lead 0 5 V for 8 V model Adjustable Over Temperature Protection OTP External TTL AC or DC shutdown Remote voltage current limit and over voltage protection OVP programming with selectable programming ranges External indicator signals for remote monitoring of OVP status local remote programming status thermal shutdown and output voltage and cur...

Page 15: ...Features and Specifications Front Panel Controls Release 2 2 13 Figure 1 1 Power Supply Front Panel ...

Page 16: ...ower Supply Front Panel on page 13 for front panel controls and indicators Figure 1 2 Power Supply Rear Panel on page 15 for rear panel connectors and switch details and to Figure 1 3 J3 Program Sense and Monitor Connector Description on page 16 for a description of the J3 Program Sense and Monitor Connector Note J3 pins 1 2 and 14 form an isolated control function and may be biased relative to th...

Page 17: ...Features and Specifications Controls Connectors and Indicators Release 2 2 15 Figure 1 2 Power Supply Rear Panel ...

Page 18: ...Features and Specifications Controls Connectors and Indicators 16 Operating Manual for XKW 1kW Series Power Supply Figure 1 3 J3 Program Sense and Monitor Connector Description ...

Page 19: ...0 load variation with constant nominal line voltage 8 mV 125 mA 20 mV 50 mA 33 mV 33 mA 40 mV 25 mA 60 mV 18 mA Meter Accuracy Voltage Current 0 09 V 1 35 A 0 3 V 0 6 A 0 43 V 0 43 A 0 5 V 0 35 A 0 7 V 0 28 A OVP Adjustment Range 0 4 8 8 V 1 0 22 V 1 65 36 3 V 2 44 V 3 66 V Output Noise and Ripple 20 Hz 20 MHz Voltage p p Voltage rms 50 mV 10 mV 50 mV 10 mV 100 mV 10 mV 100 mV 10 mV 150 mV 20 mV D...

Page 20: ...nal line voltage 80 mV 13 mA 150 mV 7 mA 300 mV 3 5 mA 600 mV 1 7 mA Meter Accuracy Voltage Current 0 9 V 0 23 A 1 6 V 0 08 A 4 0 V 0 045 A 7 0 V 0 018 A OVP Adjustment Range 4 88 V 7 5 165 V 15 330 V 30 660 V Output Noise and Ripple 20 Hz 20 MHz Voltage p p Voltage rms 150 mV 20 mV 200 mV 30 mV 200 mV 40 mV 500 mV 100 mV Drift 3 Voltage Current 3 Maximum drift over 8 hours with constant line load...

Page 21: ...Arms or 100 130 Vac at 20 Arms Maximum AC Input Power 1300 W at full load Operational AC Input Voltage 200 250 Vac or 100 130 Vac Input Frequency Range 47 63 Hz Power Factor approx 0 7 at full load Switching Frequency Nominal 100 kHz 200 kHz output ripple 80 V models 80 kHz 160 kHz output ripple Output Hold up Time 15 ms at full load nominal line Maximum Voltage Differential from either output to ...

Page 22: ...e 10 Current 5 Maximum Remote Sense Line Drop Compensation 1 V2 1 The 0 5 V voltage monitor signal is uncalibrated while the 0 5 V current monitor is calibrated 0 0 output 5 V 100 output 2 0 5 V on 8 125 model Operating Temperature Range 0 50 C Storage Temperature Range 55 C to 85 C Humidity Range Up to 80 non condensing Operating Altitude Derate maximum operating temperature by 1 C per 1 000 feet...

Page 23: ...ge 6 pin AMP connector Sense Connector Low voltage Part of J3 DB25 on rear panel High voltage Output connector Analog Programming Connector Part of J3 DB25 on rear panel Chassis Ground 1 chassis ground screw on rear panel Cooling Fan cooled Air exhausts to rear Over temperature shutdown automatic restart Mounting Integral rack mount ears on front panel Dimensions 1 71 in 41 635 mm H x 19 in 482 6 ...

Page 24: ...Features and Specifications Specifications 22 Operating Manual for XKW 1kW Series Power Supply ...

Page 25: ...rocedure See Section 3 Operation for instructions about front panel operation OVP OTP shutdown and using multiple supplies plus you will find remote programming and monitoring described there Step Description Action Reference 1 Inspection Perform an initial physical inspection of the supply Inspection Cleaning and Packaging on page 24 2 Installation Install the supply bench or rack mount ensuring ...

Page 26: ...heck the printed circuit board and its components if you suspect internal damage If the unit is damaged save all packing materials and notify the carrier immediately See packing instructions on page 25 Periodic Cleaning No routine servicing of the power supply is required except for periodic cleaning Whenever a unit is removed from operation clean metal surfaces with naphtha or an equivalent solve...

Page 27: ...ures on page 26 preferably using the original box and packing materials Please ensure that your product is shipped fully insured in the original packaging or equivalent This warranty will not apply where the product is damaged due to improper packaging 2 Include the following The RMA number supplied by Xantrex Technology Inc clearly marked on the outside of the box A return address where the unit ...

Page 28: ...torage or shipping repack the power supply in its original container If the original container is not available seal the unit in a plastic bag and then pack it in a 200 lb 90 kg test corrugated cardboard carton large enough to allow 2 in 5 cm of cushioning material to surround the unit Use a material such as foam slabs or chips 3 Label the carton as shown in Figure 2 1 4 If shipping mark the addre...

Page 29: ...g air to reach the ventilation inputs on the right hand side of the unit and for the fan exhaust air to exit from the rear of the unit Rack Mounting The power supply is designed to fit in a standard 19 in equipment rack Use the rack mount brackets at either end of the front panel to install the power supply in a rack Use adjustable support angles such as Hammond RASA22WH2 or a support bar such as ...

Page 30: ... 20 A input but do not apply to 200 250V operation WARNING Exercise caution when using and servicing power supplies High energy levels can be stored at the output terminals on all power supplies in normal operation In addition potentially lethal voltages exist in the power circuit and the output connector of power supplies which are rated at 40V and over Filter capacitors store potentially dangero...

Page 31: ...d install the attached 115Vac jumper in its place 4 Reinstall the cover and replace the screws 5 Use the adhesive backed 115Vac 20A label supplied with the unit to cover the 230Vac 10A input specification above the rear panel AC connector 6 Install a 130Vac 25A plug and cord ensuring that the neutral white wire and line black wire are connected in the correct positions and that the safety ground w...

Page 32: ... instructions in AC Input Voltage Selection on page 28 and switch the unit on After a short power on delay the front panel meters should light up with both displays reading zero Figure 2 2 Connector J3 Configuration for Local Operation Voltage Mode Operation To check voltage mode operation proceed as follows 1 Connect a DVM rated better than 0 5 accuracy to the rear output terminals observing corr...

Page 33: ...ads of sufficient current carrying capacity and an ammeter range compatible with the unit s rated current output The ammeter should have an accuracy of better than 0 5 4 Set the POWER switch to ON 5 Rotate the CURRENT control slowly clockwise The control range should be from zero to the maximum rated output Compare the test meter reading with the reading on the front panel ammeter Check that the r...

Page 34: ...us gauges of wire rated for 105 C operation Operating at the maximum current rating results in an approximately 30 C temperature rise for a wire operating in free air Where load wiring must operate in areas with elevated ambient temperatures or bundled with other wiring use larger gauges or wiring rated for higher temperatures Table 2 2 Current Carrying Capacity for Load Wiring Load Connection and...

Page 35: ... a distinct set of terminals especially established for distribution Connecting the sense leads to these terminals will compensate for losses and minimize the effect of one load upon another Inductive Loads To prevent damage to the power supply from inductive kickback connect a diode rated at greater than the supply s output voltage and with a current surge rating greater than or equal to the supp...

Page 36: ...d Cable diameter must be between 0 120 and 0 650 3 Insert strain relief tab A into DC output connector slot A Insert strain relief tab B into DC output connector slot B See Figure 2 4 4 Install screws in holes provided on outside of strain relief pieces Thread through to screw standoff inside opposite piece Tighten to clamp outer jacket of output cord securely ensuring that the side of the strain ...

Page 37: ...upply output terminals the sense pins are connected to pins 25 positive output and 24 return of connector J3 For remote sensing the local operation jumpers are removed and pins 13 and 12 are connected directly to the positive and negative terminals of the load On 150V 300V and 600V models the sense connections are available through the output connector See Figure 1 3 J3 Program Sense and Monitor C...

Page 38: ...Installation Local and Remote Sensing 36 Operating Manual for XKW 1kW Series Power Supply ...

Page 39: ...nected for local operation also the factory default See Figure 3 1 Set both the current and voltage controls fully counterclockwise Voltage Mode Operation For voltage mode operation turn the current control fully clockwise and then adjust the voltage control to obtain the desired output voltage Current Mode Operation For current mode operation turn the voltage control 1 2 turn clockwise the curren...

Page 40: ...of one supply to the positive terminal of the next supply The total voltage available is the sum of the maximum voltages of each supply add voltmeter readings The maximum allowable current for a series string of power supplies is the rated output current of a single supply in the string Note The maximum allowable sum of the output voltages is 600V This is limited by the voltage rating of certain i...

Page 41: ...ower supply output The second solution is to disable the OVP circuit by removing resistor R93 from the A2 PCB Split Supply Operation Split supply operation is used to obtain two positive voltages with a common ground or a positive negative supply To obtain two positive voltages connect the negative terminals of both supplies together The positive terminals will supply the required voltages with re...

Page 42: ...rogramming methods voltage resistance or current through the J3 connector at the rear of the unit Please see Parallel Operation on page 39 for how to disable OVP for parallel operation Front Panel OVP Operation To set the trip level from the front panel use the following procedure 1 With the unit off and disconnected from its AC source remove the cover and check that switches SW1 4 and SW1 8 are c...

Page 43: ...ible clicking is heard or 20 turns maximum 2 Remove the default jumper connecting pins 16 and 3 of connector J3 and connect the voltage source between pins 3 positive and 12 negative Set the programming source voltage to maximum 3 Turn the unit on and adjust the output to the desired trip voltage 4 Slowly reduce the programming voltage until the red OVP indicator lamp lights and the power supply s...

Page 44: ... Voltage Protection OVP 42 Operating Manual for XKW 1kW Series Power Supply Figure 3 3 SW1 J3 Configuration for 0 10Vdc OVP Programming J3 sense line voltage and current control jumpers shown set for local operation ...

Page 45: ... 16 of connector J3 Connect the tap and the clockwise end of the potentiometer to pin 12 Set the potentiometer fully clockwise 3 Turn the unit on and adjust the output to the desired trip voltage 4 Slowly turn the potentiometer counter clockwise until the red OVP indicator lamp lights and the power supply shuts down 5 Turn the POWER switch to OFF 6 Turn the voltage control knob to minimum 7 Turn t...

Page 46: ...ard or 20 turns maximum 3 Remove the default jumper connecting pins 16 and 3 of connector J3 and connect the current source between pins 3 positive and 12 negative Set the programming source to 1mA 4 Turn the unit on and adjust the output to the desired trip voltage 5 Slowly reduce the programming current until the red OVP indicator lamp lights and the power supply shuts down 6 Turn the POWER swit...

Page 47: ...e line connection points 1 Shut the unit off and disconnect it from its power source Remove the cover from the unit 2 Using a sharp exacto knife cut the component side trace connecting the right hand side of resistor R89 to the via marked OVP LOC 3 Install a piece of insulated 22 AWG wire from the via marked OVP RMT C near the trace cut just made to the via marked OVP RMT C1 near capacitor C51 4 R...

Page 48: ...tivated The input lines are optically isolated and can therefore be accessed by circuits with a voltage differential of up to 600Vdc Remote ON OFF by Contact Closure An external relay may be used to operate the ON OFF control circuit as follows Connect one side of a normally open relay to pin 15 of connector J3 12V Connect the other side of the relay to pin 14 TTL Shutdown Also connect J3 pin 2 Sh...

Page 49: ...controlled by remote programming the green REMOTE led on the front panel is illuminated Figure 3 6 Switch SW1 Functions Default Settings Shown Notes SW 1 and SW 2 are used in combination to select 0 5Vdc 0 10Vdc and 0 100mA See Table 3 1 Program Voltage Selection on page 49 for settings To set switch SW1 shut the unit off disconnect it from its AC source and remove the cover Make the appropriate s...

Page 50: ...and 20 to 21 on connector J3 Connect the external source between pins 9 positive and 12 return Varying the external voltage from 0 5V will cause the output to vary from 0 100 of rated output Figure 3 7 SW1 J3 Configuration for 0 5V Programming of the Output Voltage J3 sense line OVP and current control jumpers shown set for local operation For programming with a 0 10Vdc source close switch SW1 3 a...

Page 51: ...hes SW1 1 and SW1 2 as shown above remove the jumpers connecting pins 10 to 11 and 22 to 23 of connector J3 and connect the external voltage source between pins 10 positive and 12 return Varying the voltage source from 0 100 causes the current limit to vary from 0 100 of the rated maximum Figure 3 9 J3 Configuration for Remote Programming of the Output Current Limit J3 sense line OVP and voltage c...

Page 52: ... will vary the output voltage from 0 100 of the rated output Figure 3 10SW1 J3 Configuration for Resistive Programming of Output Voltage J3 sense line OVP and current control jumpers shown set for local operation To program the output current limit set switches SW1 1 and SW1 2 open default factory setting and remove the jumpers connecting pins 10 to 11 and 22 to 23 on connector J3 Connect pins 10 ...

Page 53: ...vary the output voltage from 0 100 of the rated output Figure 3 12SW1 J3 Configuration for 0 1mA Current Programming of the Output Voltage J3 sense line OVP and current control jumpers shown set for local operation To program the output current limit set the current control to maximum set switches SW1 1 and SW1 2 open factory setting and remove the jumper between pins 22 and 23 of connector J3 Con...

Page 54: ...t See Section 4 Calibration for location of adjusting holes Status indicators for thermal shutdown OVP operation remote programming and operating mode are also available through the J3 connector Table 3 2 Status Indicators lists the various signals the J3 connector pins where they are available the approximate magnitude of the signal measured with respect to pin 6 of connector J3 and the source im...

Page 55: ...erature sensor and will activate the internal shutdown circuit whenever the maximum temperature is exceeded The red OTP LED on the front panel lights up when an OTP shutdown occurs Resetting the OTP circuit To reset the OTP after it activates 1 The supply recovers to normal operation when the over temperature condition no longer exists OR 1 Turn the AC power switch OFF 2 Correct the situation caus...

Page 56: ...Operation Using Over Temperature Protection OTP 54 Operating Manual for XKW 1kW Series Power Supply ...

Page 57: ...omplished using multiturn trimpots Table 4 1 below gives the circuit designation of the trimpot and the parameter affected by that part Calibration is performed at the factory during testing and recalibration should be unnecessary unless major repairs are required Calibration should be done with the cover on through the access holes in the cover See Figure 4 1 WARNING Exercise caution when using a...

Page 58: ...ons and Parameters Designation Assembly Parameter Affected R7 A2 Output Current Monitor Calibration R46 A2 Output Current Monitor Offset R47 A2 Current Control Circuit Offset R48 A2 Output Current Range R52 A2 Voltage Control Circuit Offset R53 A2 Output Voltage Range R18 A1 Front Panel Voltmeter Calibration R15 A1 Front Panel Ammeter Calibration R46 R48 R47 R7 R52 R53 R15 R18 ...

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