Dynatronix Diamond 10kW Series User manual

Diamond 10kW Manual Dynatronix, Inc.
198-1603-03 Rev 01 Page 1 of 150
OPERATING MANUAL
FOR
Diamond 10kW SERIES
POWER SUPPLY
STANDARD ENCODERS/METERS CONTROL

Page 2 of 150 198-1603-03 Rev 01
Table Of Contents
1. INTRODUCTION........................................................................................................................................................................ 5
1.1. TWO YEAR NEW PRODUCT WARRANTY....................................................................................................................... 5
1.2. CONTACT INFORMATION ......................................................................................................................................................... 6
2. SAFETY PRECAUTIONS.......................................................................................................................................................... 7
3. FUNCTIONAL OVERVIEW...................................................................................................................................................... 9
4. PRODUCT SPECIFICATIONS ............................................................................................................................................... 11
5. INSTALLATION INSTRUCTIONS........................................................................................................................................ 14
5.1. POWER INPUT ........................................................................................................................................................................ 14
5.1.1. Input Power Requirements............................................................................................................................................ 14
5.1.2. Input Power Connection ............................................................................................................................................... 14
5.2. MOUNTING ............................................................................................................................................................................ 14
5.3. OUTPUT POWER CONNECTIONS............................................................................................................................................. 15
5.4. DIGITAL I/O........................................................................................................................................................................... 16
5.4.1. DIGITAL INPUTS.................................................................................................................................................................. 17
5.4.1.1. REMOTE OPERATE CONTROL CONNECTIONS................................................................................................................... 17
5.4.1.2. OPTIONAL REMOTE POWER CONTROL INPUT .................................................................................................................. 17
5.4.2. DIGITAL OUTPUTS .............................................................................................................................................................. 18
5.4.2.1. END OF CYCLE STATUS CONNECTIONS ........................................................................................................................... 18
5.4.2.2. ALARM/FAULT STATUS CONNECTIONS ........................................................................................................................... 18
5.4.2.3. OPERATE STATUS CONNECTIONS .................................................................................................................................... 18
5.5. SERIAL HOST PORT CONNECTIONS........................................................................................................................................ 19
5.6. ANALOG CARD CONNECTIONS (OPTIONAL 138-0471-XX CARD) ......................................................................................... 20
6. OPERATING PROCEDURES ................................................................................................................................................. 24
6.1. FRONT PANEL CONTROLS...................................................................................................................................................... 24
6.1.1. Meters ........................................................................................................................................................................... 24
6.1.2. Encoder Functionality .................................................................................................................................................. 25
6.1.3. Voltage Indicator.......................................................................................................................................................... 25
6.1.4. Current (Amps) Indicator ............................................................................................................................................. 25
6.1.5. Operate / Standby Switch.............................................................................................................................................. 25
6.1.6. Remote / Local Switch................................................................................................................................................... 26
6.1.7. Inhibit Lamp.................................................................................................................................................................. 26
6.1.8. Fault Lamp.................................................................................................................................................................... 26
6.1.9. Over Temperature Lamp............................................................................................................................................... 27
6.2. MENU OVERVIEW.................................................................................................................................................................. 28
6.2.1. Menu Organization....................................................................................................................................................... 28
6.2.2. Menu Access ................................................................................................................................................................. 31
6.2.3. Menu Navigation........................................................................................................................................................... 31
6.3. UNIT CONFIGURATION........................................................................................................................................................... 32
6.3.1. Totalizer Configuration ................................................................................................................................................ 32
6.3.2. Host Port Configuration ............................................................................................................................................... 34
6.3.3. Remote Control Configuration...................................................................................................................................... 35
6.3.4. Power On Configuration............................................................................................................................................... 37
6.3.5. Power Fail Alarm Configuration.................................................................................................................................. 38
6.3.6. Remote Operate/Standby Control (Digital Input)......................................................................................................... 39
6.3.7. Front Panel Button Lock Outs ...................................................................................................................................... 41
6.3.8. Hardware Options Configuration................................................................................................................................. 42
6.3.9. Changing the Unit Configuration Password................................................................................................................. 42
6.3.10. Setting Unit Defaults................................................................................................................................................... 43
6.3.11. Calibration.................................................................................................................................................................. 44
6.4. PROCESS SETUP..................................................................................................................................................................... 45
6.4.1. Manual Cycle Control................................................................................................................................................... 45
6.4.2. Timed Cycle Control (RTC or ATC) ............................................................................................................................. 45
6.4.3. DC Output..................................................................................................................................................................... 48
6.4.4. Pulsed Output ............................................................................................................................................................... 48

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198-1603-03 Rev 01 Page 3 of 150
6.4.5. Custom Waveform Output............................................................................................................................................. 50
6.4.6. Ramp Settings ............................................................................................................................................................... 51
6.4.7. Tolerance Settings......................................................................................................................................................... 53
6.5. ERROR MESSAGES................................................................................................................................................................. 54
6.5.1. Error Message Display................................................................................................................................................. 55
6.5.2. Clearing Error Codes ................................................................................................................................................... 56
6.6. RUN SCREENS........................................................................................................................................................................ 57
6.6.1. Meters Run Screen........................................................................................................................................................ 57
6.6.2. Totalizer Run Screen..................................................................................................................................................... 58
6.6.3. Cycle Run Screen.......................................................................................................................................................... 58
6.6.4. Diagnostics Run Screen................................................................................................................................................ 59
6.7. CURRENT AND VOLTAGE SETTINGS....................................................................................................................................... 59
6.7.1. Voltage Setting Adjustment........................................................................................................................................... 59
6.7.2. Current Setting Adjustment........................................................................................................................................... 60
6.8. SETTING ADJUSTMENT AND REGULATION MODES ................................................................................................................ 60
6.8.1. Current Regulation....................................................................................................................................................... 60
6.8.2. Voltage Regulation ....................................................................................................................................................... 61
6.8.3. Current Regulation with Voltage Limit (crossover)...................................................................................................... 61
6.8.4. Voltage Regulation with Current Limit (crossover)...................................................................................................... 61
6.9. CYCLE PAUSE/RESUME USING THE OPER/STBY SWITCH .................................................................................................... 62
7. REMOTE HOST CONTROL................................................................................................................................................... 63
7.1. OVERVIEW............................................................................................................................................................................. 63
7.2. HOST PORT COMMUNICATIONS SETTINGS............................................................................................................................. 63
7.3. HOST PORT CONNECTIONS .................................................................................................................................................... 63
7.4. HOST PORT PROTOCOL.......................................................................................................................................................... 63
8. REMOTE OPERATE/STANDBY CONTROL....................................................................................................................... 64
9. REMOTE ANALOG CONTROL (OPTION) ......................................................................................................................... 64
9.1. REMOTE ANALOG READ BACK.............................................................................................................................................. 64
9.1.1. Analog Output Scaling.................................................................................................................................................. 64
9.2. REMOTE ANALOG SETTING CONTROL................................................................................................................................... 65
9.2.1. Analog Input Scaling .................................................................................................................................................... 65
9.3. REMOTE OPERATE/STANDBY FOR ANALOG CONTROL .......................................................................................................... 65
10. CALIBRATION PROCEDURE............................................................................................................................................. 66
10.1. OVERVIEW........................................................................................................................................................................... 66
10.1.1. Equipment................................................................................................................................................................... 66
10.1.2. Calibration Summary.................................................................................................................................................. 68
10.1.3. Restoring the default calibration values..................................................................................................................... 70
10.2. CALIBRATION STEPS............................................................................................................................................................ 71
10.2.1. Output and Read Back Offset Calibration .................................................................................................................. 71
10.2.2. Output and Read Back Gain Calibration.................................................................................................................... 72
10.2.3. Meter Filter Settings ................................................................................................................................................... 73
10.2.4. Analog Calibration (Optional).................................................................................................................................... 74
11. OPTIONAL FEATURES AND CONTROLS........................................................................................................................ 78
11.1. ANALOG CONTROL CARD.................................................................................................................................................... 78
12. MAINTENANCE ..................................................................................................................................................................... 78
12.1. CLEANING ........................................................................................................................................................................... 78
APPENDIX A: MENU TREE....................................................................................................................................................... 79
A.1 MENU TREE FORMAT............................................................................................................................................................. 80
A.2 MENU NAVIGATION............................................................................................................................................................... 81
A.3 POWER ON/OFF SEQUENCES.................................................................................................................................................. 82
A.3.1 Power On in Standby..................................................................................................................................................... 82
A.3.2 Power On Resume Cycle............................................................................................................................................... 83
A.4 CYCLE PAUSE/RESUME.......................................................................................................................................................... 84

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A.5 DISPLAY SELECT MENU......................................................................................................................................................... 85
A.6 UNIT SETUP MENU ................................................................................................................................................................ 86
A.6.1 Cycle Setup Menu.......................................................................................................................................................... 87
A.6.2 Output Setup Menu........................................................................................................................................................ 88
A.6.3 Reading Setup Menu...................................................................................................................................................... 89
A.6.4 Ramp Setup Menu.......................................................................................................................................................... 90
A.6.5 Tolerance Setup Menu................................................................................................................................................... 91
A.6.6 Error Handling Setup Menu.......................................................................................................................................... 92
A.7 UNIT CONFIGURATION MENU................................................................................................................................................ 93
A.7.1 Totalizer Configuration Menu....................................................................................................................................... 94
A.7.2 Host Port Configuration Menu...................................................................................................................................... 95
A.7.3 Remote Control Configuration Menu............................................................................................................................ 96
A.7.4 System Configuration Menu .......................................................................................................................................... 97
A.7.5 Calibrate Configuration Menu.................................................................................................................................... 104
APPENDIX B: HOST PORT PROTOCOL .............................................................................................................................. 110
B.1.1 Host Protocol Version Information ............................................................................................................................. 110
B.1.2 Command List.............................................................................................................................................................. 110
B.1.3 Command Format........................................................................................................................................................ 112
B.1.4 Formatting Rules......................................................................................................................................................... 112
B.1.5 Unit Addressing (@AA.a)............................................................................................................................................ 114
B.1.6 Communications Settings (factory default) –RS485................................................................................................... 114
B.1.7 CRC Calculation ......................................................................................................................................................... 115
B.1.8 ACK Response Command............................................................................................................................................ 116
B.1.9 NAK Response Command............................................................................................................................................ 117
B.1.10 CRC Disable/Enable Command “c” ......................................................................................................................... 119
B.1.11 Delimiter Text Disable/Enable Command “i” .......................................................................................................... 120
B.1.12 Setup Command “s”: ................................................................................................................................................ 121
B.1.13 Waveform Command “w”:........................................................................................................................................ 124
B.1.14 State Command “a”:................................................................................................................................................. 127
B.1.15 Readings Command “d”: .......................................................................................................................................... 128
B.1.16 Module Status Command “ms”:................................................................................................................................ 130
B.1.17 Error Status Command “m”: .................................................................................................................................... 132
B.1.18 Error History Command “h”:................................................................................................................................... 134
B.1.19 Unit Settings Command “t”: ..................................................................................................................................... 135
B.1.20 Channel Config Command “n”:................................................................................................................................ 138
B.1.21 Unit Info Command “u”: .......................................................................................................................................... 139
APPENDIX C: ERROR CODES................................................................................................................................................ 141
REVISION HISTORY................................................................................................................................................................. 150

Diamond 10kW Manual Dynatronix, Inc.
198-1603-03 Rev 01 Page 5 of 150
1. Introduction
1.1. TWO YEAR NEW PRODUCT WARRANTY
DYNATRONIX, INC., hereby warrants to the purchaser that all new products sold are guaranteed against defects in
materials or manufacture for two years after shipment. DYNATRONIX, INC., expressly reserves the right to offer an
extended warranty at its sole discretion. Such express warranty shall not be deemed effective unless expressly
authorized by DYNATRONIX, INC., personnel. DYNATRONIX, INC., at its sole discretion, will repair or replace any
defective products that are returned in accordance within the time period proscribed by this warranty.
All products for repair or examination must be returned to DYNATRONIX, INC., prepaid. The defective product, as
repaired or replaced, requires the issuance of a Return Material Authorization Number (“RMA”) from DYNATRONIX,
INC., personnel prior to acceptance for repair or replacement by DYNATRONIX, INC. An RMA will be issued upon
determination by DYNATRONIX, INC., personnel that the defective product requires factory repair. The customer
assumes all shipment expenses of the returned product to and from DYNATRONIX, INC., within the warranty period.
DYNATRONIX, INC.’s liability, under this warranty, shall in any event not exceed the original purchase price of the
product. To make a claim under this warranty, it is the responsibility of the purchaser to immediately contact
DYNATRONIX, INC., and provide proof of the product’s model, part number, input and output voltage and serial
number. DYNATRONIX, Inc., will then determine whether the product remains under warranty.
This warranty DOES NOT COVER failures caused by any of the following:
1. Misuse, negligence or accident;
2. Alterations made by individuals or parties not directly employed by DYNATRONIX, INC.
This warranty DOES NOT EXTEND to commercial sub-assemblies that are guaranteed by a manufacturer’s warranty.
This warranty becomes effective upon the date the product is shipped. In the event that a product no longer covered
by the NEW PRODUCT WARRANTY is sent for repair, the provisions of the REPAIR WARRANTY as detailed below
govern.
DYNATRONIX, INC., EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, INCLUDING, WITHOUT LIMITATION,
ALL EXPRESS WARRANTIES, THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND
THE IMPLIED WARRANTY OF MERCHANTABILITY. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND
THE DESCRIPTION ON THE FACE HEREOF. REPAIR WARRANTY
DYNATRONIX, INC., hereby warrants to the purchaser that products previously purchased as new from
DYNATRONIX, INC., and returned to DYNATRONIX, INC., for repair or replacement be hereby governed by the
provisions of the REPAIR WARRANTY. DYNATRONIX, INC., expressly reserves the right to extend the REPAIR
WARRANTY to products not purchased from DYNATRONIX, INC., at its sole discretion. The REPAIR WARRANTY
shall exclude all products not purchased from DYNATRONIX, INC., unless expressly authorized by DYNATRONIX,
INC., personnel.
DYNATRONIX, INC., guarantees that all repairs be free from defects for ninety (90) days after return shipment to
purchaser. Product failures not related to repairs done by DYNATRONIX, INC., shall not be covered by the REPAIR
WARRANTY. DYNATRONIX, INC., further warrants that repair investigations that fail to identify product defects shall
be guaranteed for a ninety (90) day period after return shipment to customer. In the event that the product fails within
the stated ninety (90) day period after the inspection, DYNATRONIX, INC., agrees to assume the in-out freight costs
for subsequent returns of the product, experiencing the complained of problem, for an additional ninety (90) day
period. Effective Date: January 1, 2006

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1.2. Contact Information
Contact Information
Corporate Headquarters
Dynatronix, Inc
462 Griffin Boulevard
Amery, WI 54001 USA
Telephone: [phone]
FAX: [phone]
Toll-Free USA: [phone]
www.dynatronix.com
Customer Support
Dynatronix, Inc.
462 Griffin Boulevard
Amery, WI 54001 USA
Phone [phone]
Fax [phone]
Toll-Free USA: [phone]
[email protected]
www.dynatronix.com

Diamond 10kW Manual Dynatronix, Inc.
198-1603-03 Rev 01 Page 7 of 150
2. Safety Precautions
Before proceeding any further through this manual, this section should be read
thoroughly to protect yourself and your equipment.
1. To properly operate this power supply, only electric cords with a dedicated
ground wire are to be used.
2. The electric cord providing power to the machine should be plugged in only to a
grounded outlet that complies with U.L. and/or OSHA safety requirements, or
local regulations.
3. Do not open the power supply cabinet, there are no user serviceable parts. This
power supply contains components that could remain charged and pose an
electric shock hazard for an extended period of time after AC power has been
removed from the unit.
4. Remove AC power from this unit before moving the power supply or servicing the
power supply (including output bus wiring changes) or any equipment connected
to this power supply. Follow your lock out / tag out procedures to ensure that
power is not unexpectedly applied.
5. This unit contains no user serviceable parts. All repairs or modifications to this
unit must be done at the Dynatronix factory, or at an authorized Dynatronix
Service Center, or by a qualified service technician. See the Table of Contents
section for a list of authorized service centers in the USA and Europe.
6. DO NOT wear metal objects on hands or wrists while working with this power
supply.
7. If the equipment is used in a manner other than mentioned in this manual, the
protection provided by this equipment may be impaired.
C A U T I O N
TO REDUCE THE RISK OF ELECTRIC
SHOCK, UNIT MUST BE CONNECTED
TO EARTH GROUND.
REMOVE POWER BEFORE
OPENING PANELS.
TO EARTH GROUND.
REMOVE POWER BEFORE
OPENING PANELS.

Page 8 of 150 198-1603-03 Rev 01
8. This symbol indicates a protective earth connection.
9. This symbol means to consult the product manual for additional information.
10.This label indicates where high AC or DC voltages are located inside of the unit.
Be aware of these locations if power is needed for any work being done inside of
unit. Not doing so may endanger yourself and your equipment.
11.This label indicates where components or surfaces are operating at temperatures
which might cause injury either directly (burn) or indirectly (involuntarily moving
body into another danger). This label is used most often on the output transistor
heatsinks.
!

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198-1603-03 Rev 01 Page 9 of 150
12.If this power supply weighs more than 40lb / 18kg (see Section 4 -
Specifications), it must be lifted by two persons. Always use proper lifting
technique. If power supply was shipped with a fork lift base (the base must be
provided by Dynatronix and must be physically connected to the power supply
housing) use a fork lift to move the power supply. Secure the power supply to
prevent the power supply from falling or tipping.
13.Use of this product for purposes other than those specified in this manual is not
recommended. Use for other purposes may give unexpected results or cause
damage to the power supply and/or the system it is being used in.
3. Functional Overview
Each 10kW power module contains a boost converter and a buck converter. The boost converter
works in current mode control to provide power factor correction. The output of the boost
converter provides power to the buck converter. The buck converter provides the power supply
output with current or voltage regulation modes. Control of both converters is tightly coupled with
a digital control system.
The standard control panel has a volt meter, amp meter, status indicators, function buttons, and
digital encoders to adjust settings. The optional graphic touch screen control panel provides an
intuitive graphical user interface with easy access to menus and power supply settings. Both
control panels provide digital control signals, a serial host port, and an optional analog control card
for external control.
This switch mode power supply provides DC, pulse, or complex waveform outputs. The DC and
pulse settings can be adjusted using the control panel. Complex waveforms are designed using
the provided computer software application. Multiple complex waveforms can be downloaded to
the control panel and then selected to run using the control panel menus.
The following is a general list of features.
DC, Pulse, or custom waveform output
Programmable ramp output (waveform amplitude ramp)
Manual Cycle Control

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Real Time Cycle Control (RTC)
Amp Time Cycle Control (ATC)
User Configurable Totalizer(s) (one per output channel)
Fan speed based on internal temperature
Configurable power fail recovery
Remote operate/standby control (isolated digital input)
Host port control (RS485)
Optional analog control (4-20mA, 05V, 0-10V)
Digital calibration
Alarms and diagnostics
Tolerance (configurable tolerance limits)
Power failure (power fail indication can be enabled or disabled)
Over temperature
Various system diagnostics