Manson Engineering Industrial HCS-3202 User manual

HCS-3200/3202/3204
Laboratory Grade & High RFI Immunity Switching Mode Power Supply with Rotary Encoder Control
User Manual
1. INTRODUCTION
Since the introduction of HCS series power supplies in 2009, we have made numerous improvement within the limits of
the original hardware modules, firmware and software framework.
In the upgraded version of HCS series power supplies, both the hardware and the firmware have been modified, the
application software has a completely design in concert with the value added features.
Added features which can be done on the unit panel.
1. Reset no load current to zero on current meter.
2. Reset the 3 presets to factory default
2. WARNING
• Do not use this power supply near water.
• Do not operate or touch this power supply with wet hands.
• Do not open the casing of the power supply when it is connected to ac mains.
• Refer all servicing to qualified service personnel only.
• Before replacing the AC fuse at AC socket, find out and clear up the cause first.
• Replace the AC fuse with the same type and rating as the original fuse.
• The max. output voltage of Model HCS-3204 is over 60VDC, avoid touch the metal contact part of the output
terminals.
• This power supply is designed for using in non-cascade environment. It is not recommended to connect two or more
power supplies in parallel or in series.
• Analogue Remote Control or Remote Programming via USB function is only suitable for stand-alone one unit
operation.
• Do not use this power supply with electrical motors, solenoid or inductive load that generates a back EMF and
voltage transient which may damage the power supply
3. CAUTION
• Use a grounded 3 pin AC source.
• This unit is for indoor use only.
• Do not operate or place this unit in a humid, dusty, in direct sunlight location or near any heat source.
• Before plugging into local AC mains, check with the rating label at the back of the unit.
• Do not block any ventilation openings of the unit.
• This unit must be used within the specified rating, regular excessive continuous loading may cause damage to the
power supply.
• The gauge size of input power cable must be at least 0.75mm2and the total length of power cable must not exceed
3m.
4. OPERATION ENVIRONMENTAL CONDITION
• 10-80% R.H.
• Altitude up to 2000m
• Installation category: CAT 2
• Pollution degree: 2
• Mains supply voltage fluctuation up to ±10% of the normal voltage

5. CONTROLS AND INDICATORS
(1) LED panel meter display with CC/CV Indictor
(2) Rear Control Indicator (lights up when using Preset/ Remote Control/ Set mode)
(3) Output Voltage Control Knob (control both the main and auxiliary output voltage)
(4) Output Current Control Knob (control both the main and auxiliary output current limit)
(5) Power ON/OFF Switch
(6) Aux. output terminal (max 5A)
Note: HCS-3200: The total rated current (Aux.+Main) is 20A
HCS-3202: The total rated current (Aux.+Main) is 10A
HCS-3204: The total rated current (Aux.+Main) is 5A
(7) Output Terminal (Rated 20A for HCS-3200/ Rated 10A for HCS-3202/ Rated 5A for HCS-3204)
(8) Mode Selection Switch (Normal, Preset, Remote Control, Set Modes)
(9) Recall Selection Switch
(10) Remote Control Terminal
(11) Cooling Fan Air Intake Grille
(12) AC Input Plug
(13) USB port
(for access to computer to run cyclical operation with programmable voltage, current, period time and cycle)
Front
Rear

6. CONTROL MODE SELECTION
There are 4 modes, Normal, Preset, Set and Remote Control mode for the power supply.
Slide the Mode Selection Switch (8) to your desired Mode.
The power supply is factory preset to Normal Mode with maximum current level CC.
6.1 Normal Mode
This is the factory preset mode and the power supply output V, I are controlled by the dual action volume knobs.
Push the knobs to toggle the coarse and fine tuning, notice the subtle changes in brightness of related LED. .
Adjust the knobs to your desired values by trying coarse and fine tuning.
To check the preset current level, just turn the Current Knob lightly in any direction.
The display will resume its normal brightness after few seconds to double confirm your adjustment.
6.2 Preset Mode
a. In this mode, the Rear Control Light is on to indicate panel V & I controls are de-activated.
b. There are 3 preset output P1/ P2/ P3 at the Recall Selection Switch (9)
c. The preset values are factory set as following table.
d. End user can set his own output rating, please refer to paragraph 6.3
Recall No.
Output Voltage
Output Current
P1
5V
Maximum
P2
13.8V
Maximum
P3
HCS-3200: 15V
HCS-3202: 25V
HCS-3204: 55V
Maximum
6.3 Set Mode – First enter into the Set Mode by pushing Switch (8) to Set Mode slot.
The power supply is then ready to be preset.
6.3.1 To define the preset output P1/ P2/ P3.
a. Select the Recall Switch (9) to the position P1, P2 or P3 which you want to set
b. Adjust the front panel voltage control knob to set your desired voltage value
c. Adjust the front panel current control knob to set your desired current limit value
d. Repeat the procedure for remaining recalls P1, P2, P3 if desired.
e. Move Mode Switch (8) from Set to Preset position to confirm your settings.
Remarks:
All the set values in the presets will be kept even after the power supply has been tuned off.
Always check output voltage of Presets before connect to Load
To check the preset values, move Mode Switch (8) to Preset position
Move the Recall Switch (9) to P1, P2 or P3.
The V and I settings of corresponding RECALL P1, P2, P3 will be show on the panel meters.
It is more ease to setup these preset values by using PC software. After set values in PC software and save. Use
Recall switch to use it.
6.4 Analogue Remote Control Mode
To control the output voltage and current by remote control connector (10)
Please refer to paragraph 8

7. Using the power supply
7.1 This series has 3 models. Make sure you have used the correct one.
They have different output voltage range and current as following:
Model Number
Output Voltage Range
Total Rated Current
HCS-3200
1 ~ 18V
0 ~ 20A
HCS-3202
1 ~ 36V
0 ~ 10A
HCS-3204
1 ~ 60V
0 ~ 5A
7.2 Check the rating label of the power supply and make sure it complies with your AC mains voltage.
Connect the power supply to the AC Mains using the provided power cord.
Make sure the Mode Switch (8) is at Normal Position.
Below table to show the self test sequence
Self test display and Sequence
Test contents
To show software version
Segment check
C.V. Indicator check
C.C. Indicator check
Rear control indicator check
Return to C.V.
Start to check
Over voltage protection check
Over load protection check
Over temperature protection check
Fan check
Output off (remote control mode)
7.3 The power supply will perform a series of self checks when it is switched on.
The LED and other indicators on the front panel will be on by turn. When the cooling fan is being checked, a high
speed wind noise can be heard.
After the self checks, the CV, V and A LED indicators are lit up displaying voltage and 0.0 current. To find out
about the set CC current level, just turn the current control knob one click in either direction. The current display
returns to 0.0 after a few seconds.

7.4 Using the control knobs
The rotary encoder control knobs have fine and coarse tuning with clicking movement.
Push the knobs to toggle between coarse and fine tuning, notice the subtle changes in brightness of related LED. .
Adjust the knobs to your desired values by trying coarse and fine tuning.
The display will resume its normal brightness after few seconds to confirm your adjustment.
7.5 Connect the equipment to the power supply. Red (+) is connected to the positive polarity input of the equipment
and Black (-) is connected to the negative polarity input of the equipment.
7.6 Switch on the power supply first and the panel meter & green CV Indicator should light up again.
7.7 Switch on the equipment and the panel meter & green CV Indicator should still remain in green.
7.8 You can now operate the equipment.
When an operation is finished, switch off the equipment first and then switch off the power supply.
7.9 Manually zeroing Current Meter Offset
The power supply will auto-zeroing the current meter offset when powered up. In case it is needed to reset current
meter to zero during test and you do not want to restart power supply. You can manually reset it to zero in menu
mode.
Press and hold Voltage Control Knob for 30s to enter MENU mode. It shows
Rotate Current Control Knob until the Current meter showing
Then press Current Control Knob once to confirm. The “YES”will be lighted after successful zeroing current
meter offset.
Finally, press Voltage Control Knob to exit MENU mode.

7.10 Reset 3 preset output P1/ P2/ P3 to factory default value
In session 6.3, you learning how to set 3 preset output to you preferred value. In case you need to reset it to factory
default, you can do it in MENU mode.
Press and hold Voltage Control Knob for 30s to enter MENU mode.
When it is showing “CCO”, rotate Voltage Control Knob until Voltage meter showing “rPr”.
The Current meter is showing “no”at this time. Then rotate Current Control Knob until Current meter showing
“YES”.
Press Current Control Knob once to confirm. The “YES” will be lighted after preset output being reset to factory
default value.
Finally press Voltage Control Knob to exit MENU mode
7.11 Upper Voltage Limit (UVL) and Upper Current Limit (UCL)
The power supply has Upper Voltage Limit and Upper Current Limit setting. These value can ONLY be set
through PC software. The UVL and UCL settings will not be saved into power supply. These values can only be
used when HCS is controlled through PC software. Details please refer to section 11.2 of this manual.
When increasing output voltage setting and reach set UVL value. The voltage display will show
When increasing output current setting and reach set UCL value. The current display will show

8. ANALOGUE REMOTE CONTROL MODE
There are two methods for remote control of current and voltage adjustment.
Both methods require both the current remote control part and the voltage remote control part to be set up and be in
used at the same time in order for analogue remote control mode to be functional.
Otherwise unit will be in CC mode all the time and the analogue remote control will not be functional.
8.1 Method A Using two external variable DC voltage sources
Remote Socket Pin Assignment for external variable voltage source PIN FUNCTIONS
Remote Socket Pin Assignment for external variable voltage source
PIN
FUNCTIONS
REMARKS
1
Internal DC +5V
Less then 50mA
2
Voltage Adjust
0 - 5V
3
Current Adjust
0 - 5V
4
Ground
5
Output OFF
Short to Ground
6
N.A.
7
N.A.
8
N.A.
CC current setting by remote control.
Adjust the CC current using external power supply connected to Pin 3.
Output voltage setting by remote control
Check the output voltage range of the power supply by varying the external voltage source connected to Pin 2.

8.2 Method B Using two 0 – 5K Ohm variable resistors
Two variable resistors must be set up at the same time in order for the remote control to be functional.
Remark: variable resistors 5Kohm.
Remote Socket Pin Assignment for variable resistor
PIN
FUNCTIONS
REMARKS
1
Internal DC +5V
Resistor end
2
Voltage Adjust
Variable part of resistor
3
Current Adjust
Variable part of resistor
4
Ground
Another resistor end
5
Output OFF
Short to Ground
6
N.A.
7
N.A.
8
N.A.
CC current setting by remote control.
Adjust the CC current setting using the 0-5k Ohm variable resistor.
Output voltage setting by remote control
Check the output voltage range of the power supply by adjusting the 5Kohm variable resistor.
8.3 Remote Output ON/OFF Control
This remote output on/off control can be activated in any of the modes Normal, Preset, Remote and Set mode.
A. By default, Pin 5 is open and output is on.
B. Shorting Pin 5 to Pin 4 (ground) and output is off.
C. When output is off, the C.V. & C.C. LED will flash. The current output voltage and current setting will show on
the panel meter.
D. You also can adjust the output by voltage & current control knob to your desired value when output is off.
Remark: using the 8pin remote plug provided and connect with 22AWG wires.
CAUTION !
The allowable fastest switching On/Off frequency is 10 times per second.
When the On/Off frequency is over 10 times per second, the power supply may not work normally and protections may
be triggered.
Pin numbers are marked
on
the black portion.

9. FAULTS AND TROUBLE SHOOTING
9.1 OUP: Over Voltage Protection
This unit has a built-in tracking over voltage protection feature. In the event of output voltage becoming
greater than the set value (see specified range from specifications table), protection will be triggered and the
output power will be cut off and OUP warning appears as below.
To reset the warning, switch off the unit and remove all loading.
Switch the unit back on again and it should resume normal operation.
If this problem persists, please contact and consult with your agent.
9.2 OTP: Over Temperature Protection
There is a thermo sensor inside the unit to monitor and to prevent the unit to gets too hot inside. At OTP, there
is no output and the following warning will appear on the LED display.
When you get this warning, switch off the unit and remove all loading.
Check your load and output setting. Allow the unit to cool down for at least 30 minutes.
Check if any of the ventilation is blocked, check enough clearance around power supply.
Listen carefully for the short wind noise from the cooling fan when you turn on the unit again.
If you cannot hear this routine self test wind noise on switch on, the fan is fault and do not use the power
supply, contact your agent.
9.3 OLP: Over Load Protection
Normally the overload protection is sustained by the CC constant current mode.
When the CC mode fails and goes undetected, it may cause serious damage to your test piece or load .
The OLP is to minimize the extent of damage to your loads as power supplies do fail some day.
Switch off your power supply as soon as you see this warning as shown below.
To reset this warning, switch off the unit and remove all loading.
Switch the unit back on again and double check with caution ..
If this problem cannot be fixed, please contact and consult with your agent.

9.4 S1 Err or S2 Err: RECALL switch or MODE switch is not located at the correct position
In case the display shows S1 Err or S2 Err, it is indicated that the RECALL switch or the MODE switch at the
rear panel is not located at the correct position or maybe something wrong with the switches which make
them bad contact.
Please try to toggle the switches to the correct position to fix the error.
If the problem cannot be fixed, please contact and consult with your agent.

10. SPECIFICATIONS
Models
HCS-3200
HCS-3202
HCS-3204
Output
Variable Output Voltage
1 – 18VDC
1 – 36VDC
1 - 60VDC
Variable Output Current
0 - 20A
0 - 10A
0 – 5A
Voltage Regulation
Load (10-100% Load)
50mV
Line (90-264VAC Variation)
20mV
Current Regulation
Load (10-90% Rated Voltage)
100mA
100mA
100mA
Line (90-264VAC Variation)
50mA
Ripple & Noise
Ripple & Noise (r.m.s.) Voltage
5mV
Ripple & Noise (peak-peak) Voltage
50mV
50mV
50mV
Current Ripple & Noise (r.m.s.)
30mA
30mA
30mA
Meter Type & Accuracy
Voltage Meter
3 Digit LED Display ±0.2% +3 counts
Current Meter
3 Digit LED Display ±0.2% +3 counts
Other
Input Voltage
100 – 240VAC 50/60Hz~
Full Load Input Current (230/100Vac)
2.1 / 4.6A
2.1 / 4.6A
1.7 / 3.7A
Efficiency (@ 230Vac)
84.7%
85.9%
86%
Switching Frequency
100 – 120Khz~
100 – 120Khz~
100 – 120Khz~
Tracking Over Voltage Protections
O/P 1-5V: set voltage +2V
O/P 5-18V: set voltage +3V
O/P 1-5V: set voltage +2V
O/P 5-20V: set voltage +3V
O/P 20-36V: set voltage +4V
O/P 1-5V: set voltage +2V
O/P 5-20V: set voltage +3V
O/P 20-60V: set voltage +4V
Transient Response Time (50-100%Load)
1.5ms
Power Factor Control
Power factor correction >0.95 at optimal load
Cooling Method
Thermostatic Control Fan from Zero to full speed
Protections
Overload, Short Circuit by Constant Current, Output Tracking Over
Voltage, Over Temperature
Special Features
3 User defined VI preset, Remote control V, I and output on-off
Preset Cycle Programming
Max. 20 presets of V & I
Max. preset time 99min. + 59sec.
Max. preset cycle 999
Accessory
User Manual, Application Software, USB cable
Approvals
CE
Dimensions (WxHxD)
200 x 90 x 208 mm 7.9 x 3.5 x 8.2 inch
Weight
2.4 kg 5.2 lbs

11. PC Interface Control
Support OS: Windows XP/Vista/7 (32bits/64bits)
Driver: Silicon Lab CP210x USB driver
(Included in CDROM folder “USB CP210x Drivers V6.6.1 for Win_XP_S2K3_Vista_7”)
Execute Program: run “<CDROM Drive>:\pscs\pscs.bat”
Communicating your PC with the HCS power supply
A. Make sure you have downloaded or used the right USB driver for the USB port, check the Manson download
links for the choice of right USB DRIVER. ALWAYS CHECK WITH:
https://www.manson.com.hk/product/hcs-3400-usb/
B. There are many Windows versions, make sure you download the latest PC software version which support up to
Windows 11.
Again check with the above link to get the right one for your PC version.
C. Once you have the right PC Control Software and the right USB Driver then you are set to connect your HCS
with your PC.
D. Double check on the Mode Selection Button (8) on the back is set to NORMAL.
Remark:Please refer to the Appendix "HCS USB configuration for remote programming" in the last section of this
manual.
11.1 Main Display
The Main interface divided into 7 panels.
1. Display panel – use to display real-time information of power supply.
2. Main configuration and data log display panel – use to change general setting of program and display data log.
3. Voltage and Current setting panel – use to set incident output value and output On/Off.
4. Data handling panel – use to save, load and print data.
5. External Timed Program Description input space – use to enter description of External Timed Program.
6. Program running cycle setting panel – use to set running cycle for External Timed Program.
7. Information panel – use to display Maximum voltage/ current, Sampling time, upper voltage/ current limit
and software version.

11.2 Setting of UVL, UCL, sampling time & firmware update
In the setting page, you can do general setting for the program.
The software will automatic detect power super model and COM port used
You can select language for the program
You can select the COM Port for power supply connected
You can set sampling time for data log by adjust slide bar
You can set your output voltage upper limit (UVL) value to further safeguard your low voltage applications.
You can set your output current upper limit (UCL) value to further safeguard your low current applications.
You can update power supply Firmware (Remark: Only available on system shipped with version 3.1 or above)
* Remark: The UVL and UCL settings will not be saved into power supply. These values can only be used when HCS
is controlled through PC software. Setting the UVL & UCL (Upper Voltage Limit & Upper Current Limit).
1. First go to section 11.6 Internal Preset Memory to adjust all the current limit and voltage settings of
the 3 Presets P1/ P2/ P3 (9) to minimum or less than intended UVL & UCL.
2. Slide the bar for UVL or UCL to your desired values or use the <--> keys on your PC.
3. Then confirm [OK].

11.3 Display panel
The display show following information
- Output Voltage value
- Output Current value
- Output Power value
- Output On/Off status
- C.V./ C.C. Model
- Setting values
11.4 Set output value and On/Off status
You can directly type the desired output voltage & output current and then click “Set” button to set the value. Or you
can use slide bar to adjust the value.

11.5 External Timed Program
External Timed Program is completely controlled by PC, PC counts the time and changes voltage and current of power
supply.
Select External Timed Program tab to switch to the External Timed Program tab.
- Double click on the cell that you would like to set value. For example Step 2 voltage.
- Slide the bar to configure the value.
- Set time for this step to be running. The time range is between 0 to 9hours 59 minutes 59 seconds. You can click
up/down button to change value or directly input value. If the time value is set to 0, this step will be skipped.
- Select running cycle between 0-999. You can use slide bar to select or directly input value in text box. Input 0 means
run the program forever.
- Click on button to start running cycle.
- In between program running cycle, click button to stop program.
- Click to clear the setting.

11.6 Internal Preset Memory
The PC interface remote mode really eliminates the tedious process in keying in groups of entries on the power supply.
Because all the data are displayed together in the monitor, possibility of wrong entry is greatly reduced. Data of
different groups can be classified, stored, exported and retrieved for use at any time.
Furthermore, retrieved data will be in red color if they exceed the present preset limits of voltage in upper voltage level
or current limiting value.
Clear Table ----- Delete all data on the Display Table to ready for new data entry.
Read for PS ----- Get data from the Power Supply.

11.7 Data Log
Data Log window
Data log window is used to display output Voltage, Current and Power against time in graphical view.
You can move the diagram left and right by adjust “Move:” slide bar.
You can zoom in/out the diagram by adjust “Zoom:” slide bar.
You can save the data in CSV file for analysis later.
- Click to save Data log to CSV file.
- Click to open and load data from CSV file to program for analysis.
- Click to print the setting to print.

11.8 Save, Load and print setting
In previous session, the above 3 buttons are used to save, load and print log data. In addition, these buttons can used to
save, load and print setting for External Timed Program and Internal Preset Memory.
First, select tab in Main configure and data log display panel.
When “External Timed Program” tab is being selected, the buttons are used to save and load the setting of External
Timed Program.
- Click to save External Timed Program setting to CSV file.
- Click to open and load setting from CSV file to program.
- Click to print the setting to print.
- If you want to add description for your setting. Input the description in following “External Timed Program
Description:” space to before save.
When “Internal Preset Memory” tab is being selected, the buttons are used to save and load the setting of Internal Preset
Memory.
- Click to save Internal Preset Memory setting to CSV file.
- Click to open and load setting from CSV file to program.
- Click to print the setting to print

11.9 Power Supply Calibration (Only available on Firmware 3.1 or above)
* WARNING: IT IS HIGHLY RECOMMENDED THAT THE CALIBRATION IS DONE BY EXPERIENCE
TECHNICAL PERSON
HCS can be calibrated by using Manson PC control software. Digital Multi-meter and Electronic load are required for
calibration.
Please connect as follow for Voltage and Current Calibration.
Click on the calibration page
It need password to entry calibration, the default password is password. After login, you can change password by click
to enter you new password.
You can recovery to default factory shipped calibration by click on button.

Click to run calibration process.
There are total 8 steps for calibration. 4 steps for Voltage and 4 steps for Current. You only need to follow step by step
to finish calibration.
It start from Voltage calibration first. DO NOT CONNECT LOAD for Voltage calibration. As show in the above figure,
the power supply will automatic set output voltage for each step. You need to measure actual output by Digital multi-
meter and input actual Voltage then click to continuous for next step.
After 4 steps of Voltage calibration, it will switch to Current calibration. It need to CONNECT TO ELECTIONIC
LOAD for current calibration. The calibration steps in similar as voltage calibration.
You can click to cancel calibration anytime.
11.10 Command Set
Command line format
COMMAND<parameter1><parameter2>... [CR]
Remark:
One decimal place for current value: HCS-3100, 3150, 3200, 3202
Two decimal places for current value: HCS-3102, 3014, 3204
Command code & return value
Function
Example
Input Command:
GMAX[CR]
Return value:
<voltage><current>[CR]
OK[CR]
Get PS maximum Voltage & Current value
<voltage>=???
<current>=???
Input command:
GMAX[CR]
Return value:
180200[CR]
OK[CR]
Meaning:
Maximum Voltage is 18.0V
Maximum Current is 20.0A
Input Command:
SOUT<status>[CR]
Return value:
OK[CR]
Switch on/off the output of PS
<status>=0/1 (0=ON, 1=OFF)
Input command:
SOUT0[CR]
Return value:
OK[CR]
Meaning:
Switch on the output of PS