Elgar CW 1251M User manual

ELGAR ELECTRONICS CORPORATION
9250 Brown Deer Road
San Diego, CA 92121-2294
1-800-733-5427
Tel: [phone]
Fax: [phone]
Email: [email protected]
www.elgar.com
CW-M SERIES
AC POWER SOURCE
Operation Manual
This manual covers models:
CW 801M
CW 1251M
CW 2501M
©2002 by Elgar Electronics Corporation
This document contains information proprietary to Elgar Electronics Corporation. The information contained herein is
not to be duplicated or transferred in any manner without prior written permission from Elgar Electronics Corporation.
March 8, 2002 Document No. M161570-01 Rev E
Advanced Test Equipment Rentals
www.atecorp.com 800-404-ATEC (2832)
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ELGAR ONE–YEAR WARRANTY
Elgar Electronics Corporation (hereinafter referred to as Elgar) warrants its products to be free from defects in
material and workmanship. This warranty is effective for one year from the date of shipment of the product to
the original purchaser. Liability of Elgar under this warranty shall exist provided that:
• the Buyer exposes the product to normal use and service and provides normal maintenance on the
product;
• Elgar is promptly notified of defects by the Buyer and that notification occurs within the warranty period;
• the Buyer receives a Return Material Authorization (RMA) number from Elgar’s Repair Department prior to
the return of the product to Elgar for repair, phone 800-73-ELGAR (800-733-5427), ext. 2295;
• the Buyer returns the defective product in the original, or equivalent, shipping container;
• if, upon examination of such product by Elgar it is disclosed that, in fact, a defect in materials and/or
workmanship does exist, that the defect in the product was not caused by improper conditions, misuse,
or negligence; and,
• that Elgar QA seal and nameplates have not been altered or removed and the equipment has not been
repaired or modified by anyone other than Elgar authorized personnel.
This warranty is exclusive and in lieu of all other warranties, expressed or implied, including, but not limited
to, implied warranties of merchantability and fitness of the product to a particular purpose. Elgar, its agents,
or representatives shall in no circumstance be liable for any direct, indirect, special, penal, or consequential
loss or damage of any nature resulting from the malfunction of the product. Remedies under this warranty
are expressly limited to repair or replacement of the product.
CONDITIONS OF WARRANTY
• To return a defective product, contact an Elgar representative or the Elgar factory for an RMA number.
Unauthorized returns will not be accepted and will be returned at the shipper’s expense.
• For Elgar products found to be defective within thirty days of receipt by the original purchaser, Elgar will
absorb all ground freight charges for the repair. Products found defective within the warranty period, but
beyond the initial thirty-day period, should be returned prepaid to Elgar for repair. Elgar will repair the unit
and return it by ground freight pre-paid.
• Normal warranty service is performed at Elgar during the weekday hours of 7:30 am to 4:30 pm Pacific
time. Warranty repair work requested to be accomplished outside of normal working hours will be subject to
Elgar non-warranty service rates.
• Warranty field service is available on an emergency basis. Travel expenses (travel time, per diem expense,
and related air fare) are the responsibility of the Buyer. A Buyer purchase order is required by Elgar prior to
scheduling.
• A returned product found, upon inspection by Elgar, to be in specification is subject to an inspection fee and
applicable freight charges.
• Equipment purchased in the United States carries only a United States warranty for which repair must be
accomplished at the Elgar factory.
Committed to Quality...Striving for Excellence
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SAFETY NOTICE
Before applying power to the system, verify that the instrument is configured properly for the user’s
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.
Installation and servicing must be performed by qualified personnel who are aware of dealing properly
with attendant hazards. This includes such simple tasks as fuse verification.
Ensure that the AC power line ground is connected properly to the 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.
Due to filtering, the unit has high leakage current to the chassis. Therefore, it is essential to operate this
unit with a safety ground.
Some circuits are live even with the front panel switch turned off. Service, fuse verification, and
connection of wiring to the chassis must be accomplished at least five minutes after power has been
removed via external means; all circuits and/or terminals to be touched must be safety grounded to the
chassis.
These operating instructions form an integral part of the equipment and must be available to the
operating personnel at all times. All the safety instructions and advice notes are to be followed.
Neither Elgar Electronics Corporation, 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.
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SAFETY SYMBOLS
CAUTION
Risk of Electrical Shock
CAUTION
Refer to Accompanying Documents
Off (Supply)
Standby (Supply)
On (Supply)
Direct Current (DC)
Alternating
Three–Phase
Fuse
Earth (Ground) Terminal
Protective Conductor Terminal
Current (AC)
Alternating Current

Elgar CW-M Series
CONTENTS
1INTRODUCTION ...............................................................1
2SPECIFICATIONS.............................................................3
2.1 Output.........................................................................................................3
2.2 Current .......................................................................................................3
2.3 Measurement..............................................................................................4
2.4 Front Panel.................................................................................................4
2.5 Rear Panel Connections.............................................................................6
2.6 Input ...........................................................................................................6
2.7 General.......................................................................................................7
2.8 Options and Accessories............................................................................8
3INSTALLATION ................................................................9
3.1 Unpacking ..................................................................................................9
3.2 Wire Gauge Selection...............................................................................10
3.3 Mounting Instructions ...............................................................................13
3.4 Cooling .....................................................................................................13
3.5 Power In Connections ..............................................................................18
3.6 Power Out Connections............................................................................20
3.7 Sense Connections ..................................................................................21
3.8 Parallel Connected Units ..........................................................................23
3.9 Multiphase Connected Units.....................................................................23
4SET-UP ...........................................................................25
4.1 CONFIG Dipswitch ...................................................................................25
4.2 Setting the CONFIG Dipswitch .................................................................26
4.3 Parallel and Multiphase Configurations ....................................................27
4.4 Setting the Phase Angle ...........................................................................31
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Elgar CW-M Series
5OPERATION....................................................................33
5.1 Parallel and Multiphase Operation ........................................................... 35
5.2 Remote Control Signals ........................................................................... 36
6MAINTENANCE...............................................................37
6.1 Periodic Service ....................................................................................... 37
6.2 Fuse Replacement ................................................................................... 37
LIST OF FIGURES
Figure 1–1 ContinuousWave (Model CW1251M) Front Panel........................................1
Figure 3–1 Slide Mounting............................................................................................13
Figure 3–2 Mounting Dimensions, Front and Rear Views (CW 801M, CW 1251M) .....14
Figure 3–3 Mounting Dimensions, Front and Rear Views (CW 2501M) .......................15
Figure 3–4 Mounting Dimensions, Top and Side Views (CW 801M, CW 1251M) .......16
Figure 3–5 Mounting Dimensions, Top and Side Views (CW 2501M) .........................17
Figure 3–6 Input Power Connections ...........................................................................18
Figure 3–7 Output Power Connections.........................................................................20
Figure 3–8 Output Voltage Sensing Configuration .......................................................21
Figure 3–9 Sense Connections ....................................................................................22
Figure 4–1 CW Rear Panel ..........................................................................................25
Figure 5–1 CW Front Panel Controls............................................................................33
Figure 5–2 External Control Connector ........................................................................36
LIST OF TABLES
Table 3–1 Recommended Wire Gauge Selection Guide ..............................................10
Table 3–2 Recommended Cables ................................................................................19
Table 4–1 CONFIG Dipswitch Functions......................................................................26
Table 4–2 Phase Angles ..............................................................................................31
Table 6–1 Replacement Fuses.....................................................................................37
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Elgar CW-M Series
1 INTRODUCTION
Elgar's ContinuousWave™ (CW) Series power sources deliver up to 1250 VA in a 2U
high (3.5 inches) rackmount chassis, and 2500 VA in a 5.25 inch chassis. This low
profile design is also suitable for benchtop use. The CW Series models have three
power ratings: 800 VA, 1250 VA, and 2500 VA. The switchmode, Power Factor
Corrected (PFC) design efficiently delivers clean AC power.
Voltage, current, and frequency settings are quickly adjusted from the front panel knobs
(10–turn potentiometers). Also, the sources can be programmed remotely from the rear
panel analog port. The output is protected against overvoltage, overcurrent, and over-
temperature conditions. They can be easily paralleled in the field with an additional
parallel cable. A two-speed fan results in quieter operation at lower power levels.
Key features of the CW Series AC power sources include:
• High performance/value design
• Output available at front or rear panel
• Full rated current for two output voltage
ranges: 0 to 135 VAC and
0 to 270 VAC
• Low profile 2U (3.5") rack height for
CW 801M and CW 1251M, and
5.25" rack height for CW 2501M
• Single phase AC output: 45 to 500 Hz
• Multi phase and paralleling
• Measures output voltage, current,
and frequency
• Side air intake, exhaust to rear
• Two large 4-digit, 7-segment
LED displays
• Transformer coupled output,
500 VRMS isolation voltage between
either output terminal to chassis
• Power-up to previous front panel
setting or 0 Volts (switch selectable)
• Universal Input:
90–264 VAC (CW 801M),
103–264 VAC (CW 1251M),
180–264 VAC (CW 2501M)
• Optional front panel locking knobs
• 1–year calibration interval
• CE Mark
Figure 1–1 ContinuousWave (Model CW1251M) Front Panel
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Elgar CW-M Series
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Elgar CW-M Series
2 SPECIFICATIONS
Note: Product specifications are subject to change without notice.
2.1 Output
Power
CW 801M: 800 VA
CW 1251M: 1250 VA
CW 2501M: 2500 VA
Power Factor of Load: 0 lag to 0 lead
Phase: All models single phase output
Voltage
Ranges: 0 to 135 VAC RMS or 0 to 270 VAC RMS manual switch
(consult factory for custom output voltages)
Accuracy: 1% of range for voltages >5V
Resolution: 0.1V
Total Harmonic Distortion: 0.25% typical <100 Hz add 0.5%/100 Hz above 100 Hz
AC Noise Level: <50m VRMS typical for CW 801M and CW 1251M,
100m VRMS typical for CW 2501M
Amplitude Stability: ±0.1% of full scale over 8 hours at constant line,
load and temperature after 15 minute warm-up
Load Regulation: ±0.1% of full scale voltage for a full resistive load to no load
Line Regulation: ±0.1% of full scale for a ±10% line change from nominal line voltage
Remote Voltage Sense: 5 VRMS total lead voltage drop
2.2 Current
CW 801M: 6.00 ARMS in 135 VAC range or 3.00 ARMS in 270 VAC range
CW 1251M: 9.40 ARMS in 135 VAC range or 4.70 ARMS in 270 VAC range
CW 2501M: 18.60 ARMS in 135 VAC range or 9.30 ARMS in 270 VAC range
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Elgar CW-M Series
Frequency
Range: 45 to 500 Hz
Accuracy: ±0.5% typical
Resolution: 0.1 Hz
2.3 Measurement
Voltage
Range: 0 to 135/270 VRMS
Accuracy: ±1% of range for voltages >5V, measured at point of sense
Resolution of Display: 0.1V
Current
Range: 0 to 6.0 ARMS (CW 801M)
0 to 9.4 ARMS (CW 1251M)
0 to 18.6 ARMS (CW 2501M)
Accuracy: ±2% of range for linear loads with current >0.2A for CW 801M and
CW 1251M, >0.4A for CW 2501M
Resolution of Display: 0.1A
Frequency
Range: 45 to 500 Hz
Accuracy: ±0.5% of reading
Resolution of display: 0.1 Hz
2.4 Front Panel
Controls
Power On/Off switch
Output On/Off/Reset switch: Operates output isolation relays. Off also resets faults.
Voltage Range switch: Selects 135 Vmax or 270 Vmax range
(Output switch must be off to change range)
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Elgar CW-M Series
Meter Select switch: Current/frequency select
Output Voltage: Adjusted using 10–turn potentiometer
Output Current: Adjusted using 10–turn potentiometer
Output Frequency: Adjusted using 10–turn potentiometer
Overvoltage Protection: Settable 5 to 300 VRMS
using a 15–turn screwdriver adjust potentiometer
Displays
Voltage: 4–digit, 7–segment large, green LED display
Current or Frequency: 4–digit, 7–segment large, green LED display
Protection and Isolation
Overvoltage: Set screw adjustable
Overcurrent: 10–turn potentiometer
Accuracy: ±2% of range for linear loads with current >0.2 A for CW801M and
CW1251M, >0.4A for CW2501M.
Overtemperature: Internal monitor
Isolation Rating: 500V between either output terminal and chassis
Indicators
Output On: Green LED
Voltage Mode: Green LED
Current Mode: Green LED
Slave Mode: Green LED
Fault Mode: Red LED
Output Connector
Universal single socket connector for front panel power out on CW 801M and
CW 1251M
Line and neutral terminals can be switched through rear connector interconnect
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Elgar CW-M Series
2.5 Rear Panel Connections
Input Connector: Covered barrier terminal strip with strain relief
Output Connector: Covered barrier terminal strip with strain relief
Remote output voltage sense: 5 VRMS max total lead voltage drop
Remote Analog Control:
Output voltage control 0 to 5 VDC
Output frequency control 0 to 5 VDC (max slew rate 5V/second)
Dip Switches (see Section 4 on page 25):
Master or Slave field configuration
Output disable/enable at power-up
Overcurrent shutdown enable/disable
2.6 Input
Voltage and Frequency
CW 801M: 90 to 264 VAC, 47 to 63 Hz, single-phase
CW 1251M: 103 to 264 VAC, 47 to 63 Hz, single-phase
CW 2501M: 180 to 264 VAC, 47 to 63 Hz, single-phase
Neutral should be connected to ground at building entrance
Max neutral to chassis voltage: 132V RMS
Current
CW 801M: 13 ARMS max
CW 1251M: 18.5 ARMS max
CW 2501M: 19.5 ARMS max
Power Factor
>0.95 at full load nominal line
Efficiency
>70% at full load
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Elgar CW-M Series
2.7 General
Dimensions
CW 801M: 3.5" H (89 mm) x 19" W (483 mm) x 20.6" D (524 mm)
CW 1251M: 3.5" H (89 mm) x 19" W (483 mm) x 20.6" D (524 mm)
CW 2501M: 5.25" H (133 mm) x 19" W (483 mm) x 20.6" D (524 mm)
Weight
CW 801M: 48 lbs. (22 kg)
CW 1251M: 53 lbs. (24 kg)
CW 2501M: 86 lbs. (39 kg)
Shipping Weight
CW 801M: 56 lbs. (25 kg)
CW 1251M: 61 lbs. (28 kg)
CW 2501M: 94 lbs. (43 kg)
Regulatory Compliance
CE mark
LVD: EN61010-1:1993 + Amendment 2
EMC: EN55011:1991 Group 1, Class A, EN50082-1:1992
Environmental
Cooling: Dual fan speed with side air intake, exhaust to rear
Operating Temperature: 0 to 40°C
Storage Temperature: -40 to +70°C
Humidity: 0 to 85% at 25°C derate to 50% above 40°C (non-condensing)
Altitude: Operating full power available up to 6,000 feet, non-operating to 40,000 feet
Installation Category III, Pollution Degree 2
FOR INDOOR USE ONLY
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Elgar CW-M Series
2.8 Options and Accessories
L: Locking knobs (front panel potentiometers)
Rack Slide Kit (Elgar part number K161570-01)
Parallel Cable (Elgar part number 890-497-40)
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Elgar CW-M Series
3 INSTALLATION
The Elgar CW series power supply has been fully calibrated and tested prior to
shipment. The instrument is ready for immediate use upon receipt.
CAUTION! The CW unit weighs from 48 to 86 lbs. (22 to 40 kg),
depending on the model. A two–person lift is recommended.
WARNING! Hazardous voltages are present when operating this
equipment. Please read the Safety Notice at the beginning of this
manual prior to installation, operation, or maintenance.
3.1 Unpacking
Perform a visual inspection of the shipping container prior to accepting the package
from the carrier. If extensive damage to the shipping container is evident, a description
of the damage should be noted on the carrier's receipt and signed by the driver of the
carrier agent.
Perform a visual inspection of the instrument when it is removed from the shipping
container. Check for shipping damage such as dents, scratches, distortion, and
damaged connectors.
If damage is not apparent until the instrument is unpacked, a claim for concealed
damage should be placed with the carrier. In addition, the shipping container(s) and
filler material should be saved for inspection. Forward a report of damage to the Elgar
Service Department. Elgar will provide instructions for repair or replacement of the
instrument.
If the instrument needs to be returned to Elgar, suitable shipping containers and packing
materials must be used. If proper packing material is not available, contact Elgar to
provide containers and shipping instructions.
Before shipping a product to Elgar, you must obtain a Return Material Authorization
(RMA) number from Elgar’s Repair Department. See the warranty page at the front of
this manual for details.
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Elgar CW-M Series
3.2 Wire Gauge Selection
The following guidelines assist in determining the optimum cable specification for
your power applications. These guidelines are equally applicable to both DC and low
frequency AC (up to 450 Hz) power cabling. The same engineering rules apply whether
going into or out of an electrical device. Thus, this guide applies equally to the input
cable and output cable for this Elgar instrument and application loads.
Power cables must be able to safely carry maximum load current without overheating or
causing insulation destruction. It is important to everyday performance to minimize IR
(voltage drop) loss within the cable. These losses have a direct effect on the quality of
power delivered to and from instruments and corresponding loads.
When specifying wire gauge, the operating temperature needs to be considered. Wire
gauge current capability and insulation performance drops with the increased
temperature developed within a cable bundle and with increased environmental
temperature. Thus, short cables with generously derated gauge and insulation
properties are recommended for power source applications.
Avoid using published commercial utility wiring codes, which are designed for the
internal wiring of homes and buildings. Although these codes accommodate the safety
factors of wiring loss, heat, breakdown insulation, aging, etc., they consider that up to
5% voltage drop is acceptable. Such a loss directly detracts from the quality
performance specifications of this Elgar instrument. Frequently, these codes do not
consider bundles of wire within a cable arrangement.
In high performance applications, as in motor start-up and associated inrush/ transient
currents, additional consideration is required. The cable wire gauge must consider peak
voltages and currents that may be up to ten times the average values. An underrated
wire gauge adds losses that alter the inrush characteristics of the application and thus
the expected performance.
Table 3–1 identifies popular ratings for DC and AC power source cable wire gauges.
Column 1
Size (AWG)
Column 2
Amperes (Max)
Column 3
Ohms/100 ft (1 way)
Column 4
IR Drop/100 ft (Col 2 x Col 3)
14 15 0.257 3.85
12 20 0.162 3.24
10 30 0.102 3.06
8 40 0.064 2.56
6 55 0.043 2.36
4 70 0.025 1.75
2 95 0.015 1.42
1/0 125 0.010 1.25
3/0 165 0.006 1.04
Table 3–1 Recommended Wire Gauge Selection Guide
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