Elgar 3001 User manual

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MODEL 3001
A%
AC Power Source
Instruction Manual
ELGAR ELEC ORPORATION
01982 by Elgar ElectronicsCorporation
This document contains informationproprietaryto Elgar ElectronicsCorporation.The informationcontained hereinis
not to be duplicatedor transferredin any mannerwithout prior written permissionfrom Elgar ElectronicsCorporation.
March 1982
Document No. 61 2-01 8-92 Rev A
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ELGAR TWO-YEAR WARRANTY
Elgar ElectronicsCorporation(hereinafterreferredto as Elgar)warrants its productsto befree from defects
inmaterialand workmanship. This warranty is effective for two years from the date of shipment of the
productto the original purchaser. Liabilityof Elgar underthis warranty shall existprovidedthat:
the Buyerexposesthe productto normaluseand service and provides normalmaintenanceon the
product;
Elgar ispromptly notified of defects by the Buyerandthat notificationoccurs within thewarranty period;
the Buyerreceivesa Return MaterialAuthorization (RMA) numberfrom Elgar's Repair Department prior to
the returnof the producttoElgarfor repair, phone800-73-ELGAR (800-733-5427),ext. 2295;
the Buyerreturnsthe defective product in the original, or equivalent,shippingcontainer;
if, uponexamination of such productby Elgar it isdisclosedthat, in fact, a defect in materialsand/or
workmanshipdoesexist, that the defect inthe productwas not caused by improperconditions, misuse,
or negligence;and,
that ElgarQA seal and nameplateshave not been altered or removedand the equipment has not been
repairedor modifiedby anyone other than Elgar authorized personnel.
Thiswarranty isexclusiveand in lieuof all other warranties, expressedor implied, including, but not limited
to, impliedwarranties of merchantabilityand fitness of the productto a particular purpose. Elgar, itsagents,
or representativesshall in no circumstance be liablefor any direct, indirect,special, penal, or consequential
lossor damageof any nature resultingfrom the malfunctionof the product. Remediesunder thiswarranty
are expresslylimitedto repairor replacement of the product.
CONDITIONS OFWARRANTY
To returna defective product,contactan Elgar representativeor the Elgar factory for an RMA number.
Unauthorizedreturnswill not be accepted andwill bereturnedat the shipper's expense.
For Elgar productsfound to bedefective withinthirty days of receipt by theoriginalpurchaser, Elgar will
absorballgroundfreightchargesfor the repair.Productsfounddefective within thewarranty period, but
beyondthe initialthirty-day period, should be returned prepaidto Elgar for repair. Elgarwill repair the unit
and return itby ground freightpre-paid.
Normalwarranty service isperformedat Elgar during the weekday hoursof 7:30 amto4:30 pm Pacific
time. Warranty repairwork requested to be accomplishedoutsideof normalworking hourswill besubject to
Elgar non-warrantyservicerates.
Warrantyfield service isavailableon an emergency basis.Travelexpenses (traveltime, per diem expense,
and relatedair fare) are the responsibility of the Buyer.
A Buyerpurchaseorder is requiredby Elgar priorto
scheduling.
A returned productfound, upon inspection by Elgar,to be inspecification issubjectto an inspectionfee and
applicablefreightcharges.
Equipmentpurchased inthe UnitedStates carriesonly a UnitedStateswarranty for which repair must be
accomplishedatthe Elgarfactory.
Committed to Quality. .. Striving for Excellence
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MODEL 3001
Table of Contents
TABLE OF CONTENTS
SECTION I
GENERAL DESCRIPTION
.............................. -
Introduction 1 1
............................
General Description 1 - 1
SECTION I I
SPEC1FICATIONS
SECT1ON II
I
PRELIMINARY INSPECTION, INSTALLATION AND OPERATION
..........................
InspectionUpon Receipt 3-1
.........................
Installationand Operation 3-1
SECTION IV
THEORY
OF OPERATION
..............................
Introduction 4-1
.............................
Power Supplies 4-2
SECTION V
MAINTENANCE AND ADJUSTMENT
........................... General Information 5-1
............................. Troubleshooting
SECTION VI
PARTS LISTS
General
.................................. 6-1
Spare Parts
............................... 6-1
SECTION VII
DIAGRAMS
General
............ ................. 7-1 17-2
Diagrams .............................. 7-117-2
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List of Illustrations
LIST OF l LLUSTRATIONS
MODEL 3001
PowerOutputDerating
.......................... 1-2
Typical Harmonic Distortion
........................ 1-2
Rear Panel Terminal Strip Connections
.................... 3-2
...........
Interconnectionsfor MultiphaseOperation and Delta Hook-Up 4-3
Top View. Model 3001
.......................... 5-3
Bottom View. Model 3001
......................... 5-4
. ................
Model 3001 Overall Schematic. No 512-017-6X 7-317-4
Amplifier Board Schematic. No
. 612-100-6X ................. 7-517-6
Amplifier Board Parts Layout
....................... 7-717-8
Input Power Configurations
....................... 7-917-1 0
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MODEL 3001
SECTION I
GENERAL DESCRIPTION
1-1. INTRODUCTION
1-2.
This manual describesthe Model 3001 AC
Power Source manufacturedby Elgar.
Itprovidesoperating, maintenance, and adjustment
instructions,
a circuit description, a schematic dia-
gram, and
a parts list.
1-3.
The Model 3001 AC Power Source provides
AC power at precise frequencies for testing, motor
operation, and frequencyconversion. Thebasic pow-
er amplifierconsists oftwo
DC suppliesand a direct-
coupledamplifier with
a tappedoutputtransformer.
Theoutputtransformerprovidesnominaloutput
voltageof
115 and 230VAC that areadjustablebe-
tween
O- 130 and 0-260VAC. Total availablepower
is 3000 volt-amperes at fullratedoutputvoltage.
Power
at less thanfull-ratedoutputvoltage is derated
as illustratedinFigure 1-1. Shown in Figure 1-2 isa
curveoftypical harmonicdistortion. Inputpower is
three-phase 120/208V at 50-60 Hz. The powertrans-
former may bewired for three-phase
230V delta or
230/400V wyeat 50-60 Hz. Unitsoperating on
three-phase
480V are availableon special order.
1-4.
Outputpowerfrequency is usuallyestablished
by
a plug-inoscillator. Output frequency range is
45 to 5000 Hz. A variety of plug-inoscillators is
availablewithfrequency accuraciesup to .0001%.
1-5.
The Elgar AC Power Source facilitates
equipmenttests to meet military-specificationop-
erating requirementsover the frequency range of
47-63 Hz or 47 to 425 Hz. The basic power source
output
is single-phase. Multiphase power can be
obtainedhowever, by stacking two or three power
sources,
all driven by the same multi-phaseplug-in
oscillator.
1-6. GENERAL DESCRIPTION
1-7.
The Elgar Model 3001 AC Power Source is
containedin a rack-mountableenclosure. A meter
foroutputvoltage monitoring,
a power on indicator
lamp,
a voltage amplitude control and a power cir-
cuit breaker that applies line powerto the unit are
locatedon the front panel; Coolingair
is drawn
through front-panel grills and exhausted
at the rear
of the enclosure.
1-8.
The enclosurecontains 8 heatsink assem-
blies, which comprise a4-sectionpower amplifier.
Control circuitry
is mounted on plug-incircuit
boards with test points and adjustment controls
available
at the top of the board. Output power is
available at a rear panel terminal strip. Front panel
test pointsare provided for external measurement
of outputvoltage or frequency.
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SECTION I MODEL 3001
OUTPUT VOLTAGE
Figure 1-1. Power Output Derating
FREQUENCY - HZ
Figure 1-2. Typical Harmonic Distortion
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MODEL3001 SECTION II
Output Power
Power Factor
Output Voltage
Output Frequency Range
Distortion
Load Regulation
Line Regulation
Short Circuit Protection
Input Power
Temperature Range
Dimensions
Weight
Slides
SECTION
II
SPEC1FlCATlONS
Unity to f.7
Adjustable 0-65VAC, 0-130VAC or 0-260VAC
Less than 0.9%
Less than
%% 100-1000 HZ
+I%,adjustable to zero for specific load and frequency
Output may be shorted indefinitely and recovers immed-
iately when short
is removed.
Three-phase 120/208VAC,
45-66 Hz or 3-phase
230VACdelta or wye, 9000volt-amperes max.
Three-phase480VAC available on special order
17%"
x 19" relay rack panel by 23" deep overall
Approximately 310 pounds.
Accuride C501 Elgar
PIN 105-501-21
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MODEL 3001
SECTION Ill
SECTION Ill
PRELlMlNARY INSPECTION, INSTALLATIONAND OPERATION
3-1. INSPECTIONUPON RECEIPT
3-2.
The Elgar AC Power Source has been align-
ed and tested prior to shipment. The instrument
is
therefore ready for immediateuse upon receipt.
The following checks should be made, however, to
assure that the instrument has sufferedno damage
during shipment.
1. inspect the shippingcontainer before
accepting
it from the carrier. If damage
tothe container is evident, remove the
instrument from the container and vis-
ually inspect for damage tothe instru-
ment parts.
2. Ifany damage tothe instrument or con-
tainer
is evident, adescription of the
damage should be noted on the carrier's
receipt, and signed
by the driver or car-
rier's agent. Save all shippingcontainers
and filler material for inspection.
3. Forward a report of any damage to the
Elgar Repair Department 9250 Brown
Deer Road, San Diego
CA 92121-2294.
ELGARwill provide instructionsfor repair
or replacementof the instrument.
--_--__-_C_ ---
3-3. INSTALLATION AND OPERATION
1. The Elgar AC Power Source is designed
for installation in astandard electrical
equipment rack. Install the power source
s6 that the flow of cooling air intothe
front panel grill and out the rear panel
grill
is unobstructed.
2. Insertthe plug-in oscillator.
3. Connectthe loadtothe appropriate ter-
minal of the rear panel power output ter-
minal block (see Figure
3-1 ).
4. Connect the input power terminal block
on the rear panel toan appropriate source
of three-phasepower. Phase sequence is
immaterial.
WARNING
Do not connect inputpower tothe
output terminal block. Seriousdam-
age tothe power source may result.
5. Turn front panel POWER switch ON. The
pilotlampilluminateswhen power
is applied.
6. Adjust front panel AMPLITUDE control
for the desired output voltage as indicat-
ed on the front panel voltmeter.
NOTE
Certain Elgar plug-in oscillatorsdo
not requirethe use of the front panel
AMPLITUDE control. Others are
remotely programmed. Consult the
oscillator instructionmanual.
3-4.
Thefrontpanelvoltmeter is connectedacross
a 0-1 30VACwindingoftheoutputtransformer. For
the 0-260VACconnection, the meter indicatesone
half oftheoutputvoltage. The0-65VACrequires
changeson intzrnal terminai boardTB4,see Pg.
7-3.
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SECTION I II
MODEL 3001
PARALLELJUMPER CONNECTIONS FOR 115VACOPERATION SERIES JUMPER CONNECTIONS FOR 230VAC OPERATION
TB2 OUTPUT
POWER
/
TB1 INPUT
POWER
/
Figure 3-1.
Rear Panel Terminal Strip Connections
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MODEL 3001
SECTION IV
SECTION IV
THEORY OF OPERATION
4-1. INTRODUCTION
4-2.
The Model 3001 containstwo identical
power amplifiersconnected in
a bridgeconfigura-
tion. An output transformer, connected between
the outputs of the two amplifiers, transformsthe
output voltage to the desired value and isolatesthe
load from the amplifier circuit common.
4-3.
Each amplifier consists of an amplifier cir-
cuit board and four heatsink assemblies containing
44 power transistors.
4-4.
The input signal, approximately 2V RMS, is
provided by the plug-inoscillator. For most oscil-
latorsthe input signal amplitude
is controlled by
front panel AMPLiTUDE control, R6. The signal
from
R6 is applied to the first amplifier board,
through
ClOl and R129 to the base of first ampli-
fier transistor
0101. The signal is also applied
through
R 102 to invertingoperational amplifier
2101. 2101 invertsthe input signal to providean
equal signal phase shifted
180' for the second am-
plifier board.
0101 and Q102 are connected as a
differential amplifier to providehigh DC stability.
This preventscirculation of large
DC currents in
the primary of output transformer
T2. The out-
put of
Q102 is applied to the base of QlO3 which
providesdrive signals to the complementary drive
stage
Q1O5 and Q1O7. 0105 operates as an emitter
follower todrive emitter follower
Q591 which pro-
vides base drive signals to the upper half of the push-
pullclass
B power amplifier. Q107 is operated as
a common-emitterstage to provide phase inversion
of the drive signals to the lower half of
the power
amplifiers. The output of
0107 is applied to emit-
ter follower
Q701 which provides base drive signals
to the lower half of the power amplifier.
4-5,
Emitter followers 0501 and Q701 are
mountedon power amplifier heatsink assemblies.
Each emitter follower drives
10 identicalpower
transistors mountedon the same heatsink assembly
and
11 morepower transistorsmountedon an ad-
jacent heatsinkassembly.These
21 powertransistors
ineach halfof theamplifier are paralleled, with
.22
ohmemitterresistorstoensureequal currentdivision
betweenthetransistors. The upper halfofthepower
amplifier operates from
a +42VDC power supply
and the lower half from
a -42VDC power supply.
4-6. The power amplifier transistors are protect-
ed from overload by current limit transistors
01 04
and Q106. The current inthe upper half of the
power amplifiers
is sampled by R502. The voltage
from
R502 is applied through R123 to the base of
upper current limittransistor
0104. When the
voltage reaches the conduction threshold (approxi-
mately
.6V) of 0104, 0104 conductsand diverts
drive current from the base of
(2105, thus prevent-
ingany further increase inoutput current. Simul-
taneously, the current inthe lower half of the pow-
er amplifier
is sampled by R7. The voltage from
R7 is applied through R 124 to the base of lower
limit transistor
(2106. QlO6 conductswhen the
current inthe lower half of the power amplifier
reaches limit threshold and prevents further increase
inthe output current. The resistor-diodenetwork
in the base circuits of
QlO4 and QlO6 senses the
amplifier output voltage and modifiesthe bias volt-
ages of
0104 and Q106 to further reduce the out-
putcurrent under short circuit or severe overload
canditions, thus preventingexcess dissipation in the
power amp1ifier transistors.
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SECTION IV MODEL3001
4-7. Negativevoltage feedback
is taken from the
amplifier output tothe base of Q101 through R130
and C112. Voltage regulationof the output trans-
former
is compensatedby adjustable positivecur-
rent feedback. The power amplifier current
is Sam-
pled by current transformer 13. The signal from
T3
is attenuatedby REGULATION potentiometer
R 127 and applied through R 103, R104 and (2103
to the base of Q101. The signal from R127
is also
applied through
R 103, R 106and C104 to opera-
tional amplifier 2101 to compensate the signal to
the second power amplifier.
4-8.
Thermostats on the heatsink assemblies are
connected tothe collector circuit of (2103 to pro-
tect the power amplifier from overheating. Ifany
of the thermostatsclose, the drive signals to the
power amplifier are removed.
4-9.
The second power amplifier is identicalto
the first.
R 127 and 21 01 on the second amplifier
circuit board have no function. They are installed
so that identicalcircuit boards may be used.
4-10. POWER SUPPLIES
4-1
1.
Plus and minus 42VDC for the first power
amplifier are developed by bridgerectifiers BR1,
BR2 and BR3 from the secondary voltages of three-
phase power transformer TI. CIAand
8 and C2A
and Bare filter capacitors for these supplies and
R1 A and Band R2A and 8 are bleeder resistors,
4-12. Similary, plus and minus42VDC for the
second power amplifiersare developed by bridge
rectifiers 8R4,
BR5 and BR6. C3A and
B and C4A
and Bare filter capacitors for these supplies and
R3A and Band R4A and
B are bleeder resistors.
4-13. Input Power
4-14. The Model 3001 requiresthree-phase
45 to
66 Hz power. Each legof the three-phase power
transformer has two 115V windings which may be
interconnected inseries or parallel for 1
15V or
230V wye or delta operation. On special order, a
transformer can be supplied with two 230V wind-
ings on each leg for 230 or 460V power. All the
transformer primary connectionsare brought to an
input power terminal block inside the chassis where
the required interconnectionsare made. Phase
sequence of the input power
is immaterial.
4-1
5.
Interconnectionsfor MultiphaseOperation
4-1
6. Two or three Model 3001 power sources
may be used togenerate two-phase or three-phase
AC power. Two-phaseor three-phasesignalsare
generated in
a two-phaseor three-phaseoscillator
installedinthe master power amplifier. Signals
from the oscillator are carried to one or two slave
power amplifiers, each of which has
a dummy oscil-
lator plug-inwhich makes the requiredsignal inter-
connectionsinstalled in
it.
The front panel AM-
PLITUDE control on the master amplifier controls
the amplitudeof
all the amplifiersoutputs simul-
taneously. The front panel AMPLITUDE controls
of the slave amplifier(s)however, must initially be
set so that their output voltages equal the master
amplifier output voltage.
4-1 7.
Two-phaseoperation requirestwo power
sources. Three-phaseoperation may be accom-
plished with the three power sources in "wye" con-
nection, or with two power sources in either "wye"
or open-deltaconnection. The use of three Model
3001's for three-phaseoperation provides9000VA
total output while the use of two power sources
provides 5200VA total poweroutput. A morede-
tailed circuit description of two-phaseand three-
phase power sources is providedin the oscillator
instruction manuals.
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MODEL 3001
OUTPUT CONFIGURATIONS FOR MODEL 3001
N
Ba
3-PHASE OPEN DELTA 0-130 VAC
7 A0
3-PHASE
WYE (2 AMPLIFIER 0-130 V L-Nl
A8
b230VACCONNECTION 10
SECTION IV
EACH AMPLIFIER PLUS lNTERCONNECTlON BETWEEN
UNITS VALlO FOR ALL BUT 2 AMP WYE
TANDEM OPERATION
NOTE: For tandem operation at 130V total, internal jumpers for output transformer must be changed.
For tandem operation,
260V output use standard internal connections and 0-130V output.
\
\
\
\
/
\
PHASE
/ SOURCE
Figure 4-1. Interconnections for Multiphase Operation and Delta Hook-Up
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MODEL 3001
SECTION V
SECTION V
MAINTENANCEAND ADJUSTMENT
51. GENERAL INFORMATION
5.2. Questions concerning the operation, repair
or servicingof this instrumentshould be directedto
the Elgar Repair Department, 9250 Brown Deer
Road, San Diego
CA 92121-2294. Include the
model number and serial number in any
correspondenceconcerningthis instrument.
5-3. Factory Repair
5-4.
Should it be necessary to return an instru-
ment to the factory for repair, please contact Elgar
Corporation Service Departmentfor authorization
to make shipment. DO NOT RETURN THE UNIT
WITHOUT AUTHORIZATION.
frequency range of the power source. The regula-
tion may require re-adjustmentifthe load
is highly
reactiveor ifzero regulation
is desired for a specific
load and frequency. To make this adjustment, dis-
connect the load and read the output voltage. Con-
nect the load and adjust R127 until the same read-
ing
is obtained.
NOTE
Ifthe load
is heavy enough to cause cur.
rent limit transistors
(2104 and (2105 to
conduct, the output voltage will be re-
duced, givingan indication of poor load
regulation. Loadvoltage fall-offdue to
current limiting actionshould not be
compensated by the regulationadjust-
ment.
5-5. Test Points
5-9. Periodic Maintenance
5-6. Test pointsand adjustment controlsare
conveniently provided
at the top of the amplifier
circuit board, accessible by removingthe top cover
of the instrument. The test pointsare
as follows:
TPI
- Circuit common - turret terminal
TP2
- Amplifier output - Red
TP3
- Oscillator signal - Orange
In addition, the output transformer secondary con-
nectionsare available
at the front panel binding
posts.
5-7. Output RegulationAdjustment
5-8. The regulationadjustment, R 127, is set at
the factory to give +I% load regulationover the
510. The only periodic maintenancerequired by
the Model 3001 power source
is occasional clean-
ingof the heatsinks. The heatsinks may be inspect-
ed through the front panel air grill. Ifenough dust
and dirt have accumulatedto restrictthe air flow,
an air jet should be directed through the front panel
grill while the instrument
is operating. Ifthis does
not dislodge the dirt, the heatsink must be removed
to be cleaned.
51 1. TROUBLESHOOTING
5-12. Circuit Breaker Trips
5-13.
If the circuit breaker trips at no load, a
fault ineither the power transistorsor power recti-
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SECTION V
MODEL 3001
fien is indicated. Unplug all the heatsinks and try
the circuit breaker.
If it does not trip, look for a
shorted power transistor, tpower transistors can be
tested with an ohmmeter). If the circuit breaker
still trips, look
for a shorted rectifier diode. If all
diodes and filter capacitors are good, a fault in the
power transformeror wiring harness
is indicated.
5- 14. Output Distortion
5- 1 5.
Output distortion may be caused by over-
loadingor improper setting of the circuit limitad-
justments.
Check the loadcurrent waveform with
an oscilloscope since some high crest factor loads
may draw considerably morepeak current than
is
indicated by a load ammeter.
5- 17.
Ifoverheating causes one of the therrnas:ats
to close, the output voltage will fall to zero. C
--
heating may be caused by restricted air flow or
excessive enwronmental temperature (greaterthan
5O0C).
5-18.
No Output at Front Panel Terminals
5-19.
Ifthe front panel voltmeter indicatesnor-
mal output, but output voltage does not appear on
the front panel terminals,
check that the proper
series or parailel jumper connectionshavebeen
made on the rear panel output terminal strip.
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MODEL 3001
SECTION V
AMPI
NO. :
TB1 INPUT TBZ OUTPUT
POWER
i"
184 POWER
\ P J1
PL~G-IN
OSCILLATOR
Figure 5-1. Top View, Model 3001
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SECTION V
Figure 5-2. Bottom View, Model 3001
,HEAl
NO.
MODEL 30Q1
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