Ametek Sorensen DCS8-350E User manual

M362295-01 Rev D www.programmablepower.com
DCS-E 3kW Series
DC Power Supplies
Operation Manual
This manual covers models:
DCS8-350E DCS55-55E
DCS12-250E DCS60-50E
DCS20-150E DCS80-37E
DCS40-75E DCS150-20E

i
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.
AMETEK Inc. is a leading global manufacturer of electronic instruments and electromechanical
devices with annualized sales of $2.5 billion. The Company has over 11 000 colleagues working
at more than 80 manufacturing facilities and more than 80 sales and service centers in the United
States and around the world.
Trademarks
AMETEK is a registered trademark of AMETEK Inc.
Other trademarks registered trademarks and product names are the property of their respective
owners and are used herein for identification purposes only.
Notice of Copyright
DCS-E 3kW Series DC Power Supplies Operation Manual © 2006-2008 AMETEK Programmable
Power Inc. All rights reserved.
Exclusion for Documentation
UNLESS SPECIFICALLY AGREED TO IN WRITING AMETEK PROGRAMMABLE POWER INC.
(“AMETEK”):
(a) MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER
DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES DAMAGES COSTS OR
EXPENSES WHETHER SPECIAL DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL
WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH
INFORMATION WILL BE ENTIRELY AT THE USER’S RISK AND
(c) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH
ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE
TRANSLATION THE ACCURACY CANNOT BE GUARANTEED. APPROVED AMETEK CONTENT
IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT
WWW.PROGRAMMABLEPOWER.COM.
Date and Re ision
November 2015 Revision D
Part Number
M362295-01
Contact Information
Telephone: [phone] (toll free in North America)
858 450 0085 (direct)
Fax: [phone]
Email: sales.[email protected]
[e-mail]
Web: www.programmablepower.com

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iii
Important Safety Instructions
Before applying power to the system, verify that your product is configured properly for your
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.
WARNING
The equipment used contains ESD sensitive parts. When installing
equipment, follow ESD Safety Procedures. Electrostatic discharges might
cause damage to the equipment.
Only qualified personnel who deal with attendant hazards in power supplies, are allowed to perform
installation and servicing.
Ensure that the AC power line ground is connected properly to the Power Rack input connector or
chassis. Similarly, other power ground lines including those to application and maintenance
equipment must be grounded properly for both personnel 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 voltages within the chassis.
However, depending on the user’s application configuration, HIGH VOLTAGES HAZARDOUS TO
HUMAN SAFETY may be normally generated on the output terminals. The customer/user must
ensure that the output power lines are labeled properly as to the safety hazards and that any
inadvertent contact with hazardous voltages is eliminated.
Guard against risks of electrical shock during open cover checks by not touching any portion of the
electrical circuits. Even when power is off, capacitors may retain an electrical charge. Use safety
glasses during open cover checks to avoid personal injury by any sudden component failure.
Neither AMETEK Programmable Power Inc., San Diego, California, USA, nor any of the subsidiary
sales organizations can accept any responsibility for personnel, material or inconsequential injury,
loss or damage that results from improper use of the equipment and accessories.
SAFETY SYMBOLS

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v
Product Family: DCS-E 3kW Series DC Power Supplies
Warranty Period: Fi e Years
WARRANTY TERMS
AMETEK Programmable Power Inc. (“AMETEK”) provides this written warranty covering the
Product stated above and if the Buyer discovers and notifies AMETEK in writing of any defect in
material or workmanship within the applicable warranty period stated above then AMETEK may
at its option: repair or replace the Product; or issue a credit note for the defective Product; or
provide the Buyer with replacement parts for the Product.
The Buyer will at its expense return the defective Product or parts thereof to AMETEK in
accordance with the return procedure specified below. AMETEK will at its expense deliver the
repaired or replaced Product or parts to the Buyer. Any warranty of AMETEK will not apply if the
Buyer is in default under the Purchase Order Agreement or where the Product or any part
thereof:
• is damaged by misuse accident negligence or failure to maintain the same as
specified or required by AMETEK;
• is damaged by modifications alterations or attachments thereto which are not
authorized by AMETEK;
• is installed or operated contrary to the 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 assert any claim that the Products are not in conformity with any warranty
until the Buyer has made all payments to AMETEK provided for in the Purchase Order Agreement.
PRODUCT RETURN PROCEDURE
1. Request a Return Material Authorization (RMA) number from the repair facility (must be
done in the country in which it was purchased):
• In the USA contact the AMETEK Repair Department prior to the return of the
product to AMETEK for repair:
Telephone: [phone] ext. 2295 or ext. 2463 (toll free North America)
858-450-0085 ext. 2295 or ext. 2463 (direct)
• Outside the United States contact the nearest Authorized Service Center
(ASC). A full listing can be found either through your local distributor or our
website www.programmablepower.com by clicking Support and going to the
Service Centers tab.
2. When requesting an RMA have the following information ready:
• Model number
• Serial number
• Description of the problem
NOTE: Unauthorized returns will not be accepted and will be returned at the shipper’s expense.
NOTE: A returned product found upon inspection by AMETEK to be in specification is subject to
an evaluation fee and applicable freight charges.

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vii
ABOUT THIS MANUAL
This manual has been written expressly for the Sorensen DCS-E 3kW Series of power supplies,
which have been designed and certified to meet the Low Voltage and Electromagnetic
Compatibility Directive Requirements of the European Community. Units that comply with the
directive are designated by an ‘E’ after the model designator (e.g., DCS 60-50E indicates that the
model is certified) when configured for 230 VAC input only.
Since the goal of the Low Voltage Directive is to ensure the safety of the equipment operator,
universal graphic symbols have been used both on the unit itself and in this manual to warn the
operator of potentially hazardous situations (see Safety Symbols on page ii).
This manual is designed for the user who is familiar with basic electrical laws especially as they
apply to the operation of power supplies. This implies recognition of Constant Voltage and
Constant Current operating modes and the control of input and output power, as well as the
observance of safety techniques while effecting supply or pin connections and any changes in
switch and jumper settings. The more knowledgeable user will find that the detailed schematics
and circuit descriptions available on our website, www.programmablepower.com will enable
greater flexibility in troubleshooting and in configuring new applications.
Section 1 Introducing the DCS-E Series 3kW Supply describes the power supply, lists its
features, and provides specifications .
Section 2 Installation reviews safety and inspection procedures, then goes through the basic
set up procedures. Directions for the assembling of the AC input connector, for the testing of basic
functions, and for connecting the load are also included.
Section 3 Basic Operation provides procedures for local programming mode operation (Constant
Voltage and Constant Current) and remote sensing.
Section 4 Advanced Operation covers remote programming mode operation as well as
procedures for using advanced programming features such as Over Voltage Protection (OVP),
Output Power ON/OFF, and Remote Monitoring. This section also provides procedures for using
multiple supplies in series, in parallel, and in split supply configurations.
Section 5 Theory of Operation provides a block diagram of the power supply, an explanation of
the functions within each block, and more detailed descriptions of the circuitry.
Section 6 Maintenance covers service, calibration and repairs, and includes parts lists.
Section 7 Application Notes is reserved for additional system information.

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M362295-01 Rev D iii
CONTENTS
SECTION 1 INTRODUCING THE DCS-E SERIES 3KW SUPPLY .... 1-1
1.1 Description.....................................................................................................1-1
1.2 Features.........................................................................................................1-1
1.3 Specifications.................................................................................................1-2
1.3.1 Electrical Specifications
1
.....................................................................1-2
1.3.2 Mechanical Specifications...................................................................1-3
SECTION 2 INSTALLATION .......................................................... 2-1
2.1 Introduction....................................................................................................2-1
2.2 Safety 2-1
2.2.1 High Energy/High Voltage Warning....................................................2-1
2.2.2 AC Source Grounding.........................................................................2-2
2.2.3 Operating and Servicing Precautions..................................................2-2
2.2.4 Parts and Modifications ......................................................................2-2
2.3 Initial Inspection .............................................................................................2-3
2.3.1 Physical Check...................................................................................2-3
2.4 Location, Mounting, and Ventilation................................................................2-3
2.4.1 Unit Dimensions..................................................................................2-3
2.4.2 Rack Mounting....................................................................................2-4
2.5 AC Input Power..............................................................................................2-4
2.5.1 AC Input Power Connection................................................................2-4

Contents Sorensen DCS-E Series 3kW Supplies
iv M362295-01 Rev D
2.5.2 AC Input Power Requirements............................................................2-4
2.5.3 AC Input Connector Assembly............................................................2-5
2.5.4 Strain Relief Assembly........................................................................2-6
2.6 Initial Functional Tests....................................................................................2-8
2.6.1 Power-on Check .................................................................................2-8
2.6.2 Voltage Mode Operation Check..........................................................2-8
2.6.3 Current Mode Operation Check ..........................................................2-9
2.6.4 Front Panel Function Checks..............................................................2-9
2.7 Load Connection ..........................................................................................2-10
2.7.1 Load Wiring ......................................................................................2-10
2.7.2 Making the Connections....................................................................2-11
2.7.3 Connecting Single Loads..................................................................2-12
2.7.4 Connecting Multiple Loads................................................................2-12
SECTION 3 BASIC OPERATION.................................................... 3-1
3.1 Introduction ....................................................................................................3-1
3.2 Standard Operation........................................................................................3-1
3.2.1 Operating Modes and Automatic Crossover........................................3-1
3.2.2 Local Programming Mode Operation ..................................................3-3
3.3 Using Remote Sensing...................................................................................3-4
3.3.1 Connecting Remote Sense Lines........................................................3-4
SECTION 4 ADVANCED OPERATION ........................................... 4-1
4.1 Introduction ....................................................................................................4-1
4.2 Configuring for Remote Programming, Sensing, and Monitoring....................4-2
4.2.1 Programming, Monitoring, and Control Functions...............................4-2
4.2.2 Locating Jumpers, Switch, and Connector..........................................4-4
4.2.3 Resetting Jumpers and Switch............................................................4-5
4.2.4 Making J3 Connections.......................................................................4-6

Sorensen DCS-E Series 3kW Supplies Contents
M362295-01 Rev D v
4.3 Remote Programming: Output Voltage and Current Limit................................4-7
4.3.1 Programming Output Voltage and Current Limit with the REM/LOC Switch
4-8
4.3.2 Programming Output Voltage.............................................................4-9
4.3.3 Programming Output Current Limit...................................................4-12
4.4 Using Over Voltage Protection (OVP) ..........................................................4-14
4.4.1 Front Panel OVP Operation..............................................................4-14
4.4.2 Resetting the OVP Circuit.................................................................4-14
4.4.3 Programming OVP with an External Voltage Source........................4-15
4.5 Using the Shutdown Function.......................................................................4-16
4.5.1 STANDBY Switch.............................................................................4-16
4.5.2 Programming the Shutdown Function...............................................4-16
4.5.3 Shutdown Application - Contact Closure...........................................4-19
4.6 Remote Monitoring of Readback Signals and Status Indicators...................4-21
4.6.1 Readback Signals.............................................................................4-21
4.6.2 Status Indicators...............................................................................4-21
4.7 Using Multiple Supplies................................................................................4-22
4.7.1 Configuring Multiple Supplies for Series Operation...........................4-22
4.7.2 Configuring Multiple Supplies for Parallel Operation.........................4-23
4.7.3 Configuring Multiple Supplies for Split Supply Operation..................4-24
4.8 Output Voltage Biasing.................................................................................4-25
SECTION 5 THEORY OF OPERATION ........................................... 5-1
5.1 Introduction....................................................................................................5-1
5.2 Basic Functional Blocks .................................................................................5-1
5.2.1 AC Input and RFI Filter (A5 PCB).......................................................5-2
5.2.2 AC Input Rectifier and Inrush Limiting Circuit (A6 PCB)......................5-2
5.2.3 PWM, Sync and Power Transformer Drive Circuit (A3 PCB) ..............5-2
5.2.4 Power Transformer, Output Rectifiers, Output Filter Inductor and
Capacitors, and Local Sense Connections (Power Stage, A7 PCB and
A8 PCB) .............................................................................................5-2

Contents Sorensen DCS-E Series 3kW Supplies
vi M362295-01 Rev D
5.2.5 Output Current Shunt, Shunt Amplifier, and Down Programmer (A4 PCB)
5-2
5.2.6 Control, Programming, OVP, Shutdown, Monitoring, and Auxiliary Supply
Circuits (A2 PCB)................................................................................5-3
5.2.7 Front Panel Displays and Local Operating Mode Controls (A1 PCB)..5-4
5.3 Detailed Circuit Descriptions...........................................................................5-4
5.3.1 AC Input and RFI Filter Circuit (A5 PCB) ............................................5-5
5.3.2 Input Rectifier and Inrush Limiting Circuit (A6 PCB)............................5-5
5.3.3 PWM, Sync Circuit, Power Transformer Drive Circuit, and Power
Transistor Bridge (A3 PCB).................................................................5-5
5.3.4 Power Transformer, Output Rectifiers, Output Filter Inductor and
Capacitor, and Down Programmer Circuit (A4 PCB, A7 PCB, A8 PCB,
and Power Stage Assembly)...............................................................5-6
5.3.5 Auxiliary Supply, OVP, Control, Programming, Monitor Circuit (A2 PCB)5-
7
5.3.6 Front Panel Displays and Controls (A1 PCB)....................................5-14
SECTION 6 MAINTENANCE .......................................................... 6-1
6.1 Introduction ....................................................................................................6-1
6.1.1 Units Under Warranty .........................................................................6-1
6.2 General Service and Repair ...........................................................................6-1
6.2.1 Periodic Maintenance..........................................................................6-1
6.2.2 Servicing Precautions .........................................................................6-2
6.2.3 Parts Replacement and Repairs .........................................................6-2
6.2.4 Unusual or Erratic Operation...............................................................6-2
6.3 Calibrating for Programming Accuracy...........................................................6-2
6.3.1 Voltage Programming Circuit Calibration ............................................6-3
6.3.2 Current Programming Circuit Calibration ............................................6-3
6.4 Replaceable Parts..........................................................................................6-4
6.4.1 Parts Replacement and Modifications.................................................6-4
6.4.2 Ordering Parts ....................................................................................6-4
6.4.3 DCS-E 3kW Parts Lists by Model Number..........................................6-5

Sorensen DCS-E Series 3kW Supplies Contents
M362295-01 Rev D vii
SECTION APPLICATION NOTES ................................................ -1
7.1 Battery Charging............................................................................................7-1
7.2 Load Considerations ......................................................................................7-1
7.2.1 Inductive Loads ..................................................................................7-1
LIST OF FIGURES
Figure 1-1 DCS-E Series (3kW) Supply Front Panel Controls and Indicators...........1-4
Figure 1-2 DCS-E Series (3kW) Supply Rear Panel Connectors and Terminals
(including optional internal GPIB Interface) .............................................1-5
Figure 2-1 AC Connector and Contacts....................................................................2-5
Figure 2-2 Wire Preparation .....................................................................................2-5
Figure 2-3 Contact Orientation..................................................................................2-6
Figure 2-4 AC Wire Locations...................................................................................2-6
Figure 2-5 Strain Relief, as Supplied ........................................................................2-7
Figure 2-6 Strain Relief Assembly.............................................................................2-7
Figure 2-7 Connector J3 Default Configuration.........................................................2-8
Figure 2-8 Maximum Load Wire Length..................................................................2-11
Figure 2-9 Single Load with Local Sensing (Default) ..............................................2-12
Figure 2-10 Single Load with Remote Sensing.......................................................2-12
Figure 2-11 Multiple Loads with Local Sensing.......................................................2-13
Figure 2-12 Multiple Loads with Remote Sensing...................................................2-13
Figure 3-1 Operating Modes.....................................................................................3-2
Figure 3-2 Local Mode Default Configuration............................................................3-3
Figure 3-3 Connecting Remote Sense Lines ............................................................3-5
Figure 4-1 Connector J3 Pin Descriptions (for Remote Programming,
Remote Monitoring, and Sense Connections) .........................................4-3
Figure 4-2 Internal Jumpers and Switch (Default Settings Shown) ...........................4-4
Figure 4-3 Programming Output Voltage and Current Limit Using the
REM/LOC Switch ....................................................................................4-8
Figure 4-4 Programming Output Voltage with a 0-5 Vdc Source...............................4-9

Contents Sorensen DCS-E Series 3kW Supplies
viii M362295-01 Rev D
Figure 4-5 Programming Output Voltage with a 0-10 Vdc Source...........................4-10
Figure 4-6 Programming Output Voltage with a 0-1 mA Source..............................4-10
Figure 4-7 Programming Output Voltage with a 5k ohm Resistance.......................4-11
Figure 4-8 Programming Output Current Limit with a 0-5 Vdc Source.....................4-12
Figure 4-9 Programming Output Current Limit with a 0-10 Vdc Source...................4-12
Figure 4-10 Programming Output Current Limit with a 0-1 mA Source ...................4-13
Figure 4-11 Programming Output Current Limit with a 5k ohm Resistance.............4-13
Figure 4-12 Remote Programming of OVP with a 0-5 Vdc External
Voltage Source....................................................................................4-15
Figure 4-13 Remote Programming of OVP with a 0 –10 Vdc External
Voltage Source....................................................................................4-16
Figure 4-14 Using Shutdown with a TTL Compatible (Positive Logic).....................4-17
Figure 4-15 Using Shutdown with a TTL Compatible (Negative Logic)....................4-17
Figure 4-16 Using Shutdown with an AC or DC Input (Positive Logic) ....................4-18
Figure 4-17 Using Shutdown with an AC or DC Input (Negative Logic)...................4-18
Figure 4-18 Using Shutdown with Contact Closure
of a Normally OPEN Relay (Positive Logic).........................................4-19
Figure 4-19 Using Shutdown with Contact Closure
of a Normally OPEN Relay (Negative Logic).......................................4-20
Figure 4-20 Using Shutdown with Contact Closure
of a Normally CLOSED Relay (Positive Logic) ....................................4-20
Figure 4-21 Using Shutdown with Contact Closure
of a Normally CLOSED Relay (Negative Logic)...................................4-20
Figure 4-22 Series Operation of Multiple Supplies ..................................................4-22
Figure 4-23 Parallel Operation of Multiple Supplies.................................................4-23
Figure 4-24 Split Supply Operation of Multiple Supplies
(Two Positive Voltages).......................................................................4-24
Figure 4-25 Split Supply Operation of Multiple Supplies
(Positive-Negative Supply)..................................................................4-25

M362295-01 Rev D 1-1
SECTION 1
INTRODUCING THE DCS-E
SERIES 3KW SUPPLY
1.1 DESCRIPTION
The DCS-E Series System Supplies are 3000–watt supplies designed to provide highly stable,
continuously variable output voltage and current for a broad range of development, system, and
burn-in applications. The DCS-E Series employs high frequency switching regulator technology
to achieve high power density and small package size.
The series consists of several models designated by the DCS prefix, followed by their output
voltage and current ratings. For example, the model number DCS 60-50E indicates that the
unit is rated at 0-60 Vdc and 0-50 Amps.
1.2 FEATURES
• Eight models with voltage ranges from 0-8 Vdc to 0-150 Vdc and current outputs from
20A to 350A.
• Input voltage 190-250 Vac, Three Phase, 47-63 Hz or 200-250 Vac, Single Phase,
47-63 Hz. (Output power limited to 2500W for single-phase input.)
• Simultaneous digital display of both DC output voltage and current.
• Ten-turn potentiometer voltage and current controls permit high resolution setting of the
output voltage and current from zero to the model-rated output.
• Front panel push button control of Output Standby Mode, OVP reset, Remote/Local
Programming Mode selection, and preview of voltage, current, or OVP setpoints.
• External indicator signals for Remote Monitoring of OVP Status, Local/Remote
Programming Status, Thermal Shutdown, and Output Voltage and Current.
• Current or Voltage Mode operation with Automatic Mode Crossover to respond to
varying load requirements.
• Flexible output configuration where multiple units can be connected in series or in
parallel to provide increased voltage or increased current.
• Remote Sensing to compensate for losses in power leads up to 1V per lead.

Introduction Sorensen DCS-E Series 3kW Supplies
1-2 M362295-01 Rev D
• Adjustable Over Voltage Protection (OVP).
• External Shutdown using AC, DC, or TTL compatible signals (positive or negative logic).
• Remote Voltage, Current Limit, and OVP Programming with selectable programming
ranges.
• Optional IEEE-488 (GPIB) interface for complete digital remote programming and
readback capability.
1.3 SPECIFICATIONS
1.3.1 Electrical Specifications
1
Models DCS
8-350E DCS 12-250E DCS 20-150E DCS 40-75E DCS 55-55E DCS 60-50E DCS 80-37E DCS 150-20E
Output Ratings
Output Voltage
Output Current
Output Power
0-8V
0-350A
2800W
0-12V
0-250A
3000W
0-20V
0-150A
3000W
0-40V
0-75A
3000W
0-55V
0-55A
3025W
0-60V
0-50A
3000W
0-80V
0-37A
2960W
0-150V
0-20A
3000W
Line Regulation
2
Voltage
Current
8 mV
350 mA
12 mV
250 mA
20 mV
150 mA
40 mV
75 mA
55 mV
55 mA
60 mV
50 mA
80 mV
37 mA
150 mV
20 mA
Load Regulation
3
Voltage
Current
8 mV
350 mA
12 mV
250 mA
20 mV
150 mA
40 mV
75 mA
55 mV
55 mA
60 mV
50 mA
80 mV
37 mA
150 mV
20 mA
Meter Accuracy
Voltage
Current
0.09V
4.5A
0.13V
3.5A
0.2V
0.1.6A
0.5V
0.85A
0.65V
0.65A
0.7V
0.6A
0.9V
0.47A
1.6V
0.30A
OVP Adjustment
Range
0.4
-
8.8V
0.6
-
13.2V
1
-
22V
2
-
44V
2.75
-
60.5V
3
-
66V
4
-
88V
7.5
-
165V
Output Noise and
Ripple (V)
4
RMS
p–p
(20 Hz – 20 MHz)
10 mV
100 mV
10 mV
100 mV
10 mV
100 mV
20 mV
100 mV
20 mV
100 mV
20 mV
100 mV
20 mV
100 mV
30 mV
200 mV
Analog
Programming
Linearity
Voltage
Current
80 mV
3500 mA
120 mV
2500 mA
200 mV
1500 mA
400 mV
750 mA
550 mV
550 mA
600 mV
500 mA
800 mV
370 mA
1.5V
200 mA
1
Specifications are warranted over a temperature range of 0–50°C with default local sensing. From 50–70°C, derate 2% per °C.
2
For input voltage variation over the AC input voltage range, with constant rated load.
3
For 0-100% load variation, with constant nominal line voltage.
4
Typical peak to peak ripple noise, is measured across a 1uF capacitor at the end of a 3’ load cable with the supply operating at
full load and nominal AC line voltage.
AC Input: 200-250 Vac at 20 Arms Single Phase or 190-250 Vac at 14 Arms Three Phase
(Output power limited to 2500W for single phase input)
Maximum Voltage Differential from output to safety ground: 150 Vdc