TDK-Lambda Genesys Series User manual
Series
Programmable DC Power Supplies
G1.7 - 5kW in 1U 0-600V, 0-500A
PARALLEL KIT INSTRUCTION MANUAL
The manual covers kit options:
G/P-3U-10V
G/P-3U-20-40V
G/P-3U-60-100V
G/P-3U-150-600V
2
1.1
General
Parallel kit is supplied separately from the power supply packing according to order.
The usage of parallel kit is according to customer's needs.
1.2
Advanced Parallel
For parallel connection, refer to advanced parallel chapter in the series User Manual.
1.3
Product Safety Instructions
Safety approvals are valid for single unit only. These are not valid for parallel kit assembly.
When using a paralleling kit with a protective bracket, it must be correctly assembled, as described
further in this document.
1.4
Assembly Instructions
The supplied kit is used for standard and blank panel options. Follow the instructions carefully
according to power supply model.
1.4.1
G/P-3U-10V - Assembly Instructions for three 10V units in Parallel
1.4.1.1
Components List
Image Component Quantity
10‐32x5/16PanHeadScrew,StainlessSteel 12
HelicalSpring‐LockWasher,No.10,StainlessSteel 12
PlainWasher,No.10,StainlessSteel 12
ConnectionPlate3U 2
OutputShort 2
3
Image Component Quantity
M3x4CFlatHeadScrew,NickelPlated 8
ParallelingCable 2
OutputCover 1
BusBarInsulator 2
M3x8SEMSScrew,NickelPlated 6
4
1.4.1.2
Installation Steps
1. Attach connection plates, one on each side of the power supplies, using 12 pan head screws,
12 helical spring-lock washers and 12 plain washers as illustrated in Figure 1.
Figure1:Three10VUnitsConnectionPlates3UAssembly
2. Attach output short plates, one on each triple of terminals, using eight flat head screws as
illustrated in Figure 2.
Figure2:Three10VUnitsOutputShortPlatesAssembly
ConnectionPlate
3U
PlainWasher,No.10,StainlessSteel
HelicalSpring
‐
LockWasher,No.10,StainlessSteel
10‐32x5/16PanHeadScrew,StainlessSteel
Tighteningtorque:25.4‐31.7Lbf‐inch(2.87‐3.58Nm).
M3x4CFlatHeadScrew,NickelPlated
Tighteningtorque:4.7‐5.7Lbf‐inch(0.53‐0.64Nm)
OutputShort
5
3. Connect two paralleling cables from top unit M connector to bottom unit S connector as
illustrated in Figure 3.
Figure3:Three10VUnitsParallelingCableConnection
4. Insert output cover through the cables as illustrated in Figure 4.
Figure4:OutputCoverInsertion
ParallelingCable
Output
Cover
6
5. Assemble two lugs on each bus bar, one on each side, using two hexagon bolts, four plain
washers, two helical spring-lock washers and two hexagon nuts as illustrated in Figure 5.
Figure5:Three10VUnitsLugsAssembly
6. Assemble bus bar insulator prior to output cover assembly. The insulator is flexible and could
be opened in its bottom side. Open the insulator and cover the bus bar by sliding it over the
bus bar, from top to bottom, as illustrated in Figure 6. Repeat for the second bus bar.
Figure6:Three10VUnitsBusBarInsulatorAssembly
Forrecommendedlugsrefer
to seriesSafety&
InstallationManual.
Notsupplied.
HexagonNut,M10,StainlessSteel
HelicalSpring
‐
Lock
Washer,M10,StainlessSteel
PlainWasher,M10,StainlessSteel
M10x25HexagonBolt,StainlessSteel
Tighteningtorque:220‐265Lbf‐inch(24.9‐29.9Nm)
BusBarInsulator
7
7. Fix output cover to the power supplies using six SEMS screws as illustrated in Figure 7.
Figure7:Three10VUnitsOutputCoverAssembly
M3x8SEMSScrew,NickelPlated
Tighteningtorque:4.7
‐
5.7Lbf
‐
inch(0.53
‐
0.64Nm)
8
1.4.2
G/P-3U-20-40V - Assembly Instructions for three 20V-40V units in Parallel
1.4.2.1
Components List
Image Component Quantity
10‐32x5/16PanHeadScrew,StainlessSteel 12
HelicalSpring‐LockWasher,No.10,StainlessSteel 12
PlainWasher,No.10,StainlessSteel 12
ConnectionPlate3U 2
OutputShort 2
M3x4CFlatHeadScrew,NickelPlated 8
ParallelingCable 2
OutputCover 1
9
Image Component Quantity
BusBarInsulator 2
Protection
Insulator
1
M3x8SEMSScrew,NickelPlated 8
10
1.4.2.2
Installation Steps
1. Attach connection plates, one on each side of the power supplies, using 12 pan head screws,
12 helical spring-lock washers and 12 plain washers as illustrated in Figure 8.
Figure8:Three20V‐40VUnitsConnectionPlates3UAssembly
2. Attach output short plates, one on each triple of terminals, using eight flat head screws as
illustrated in Figure 9.
Figure9:Three20V‐40VUnitsOutputShortPlatesAssembly
ConnectionPlate
3U
PlainWasher,No.10,StainlessSteel
HelicalSpring‐LockWasher,No.10,StainlessSteel
10‐32x5/16PanHeadScrew,StainlessSteel
Tighteningtorque:25.4‐31.7Lbf‐inch(2.87‐3.58Nm).
M3x4CFlatHeadScrew,NickelPlated
Tighteningtorque:4.7‐5.7Lbf‐inch(0.53‐0.64Nm)
OutputShort
11
3. Connect two paralleling cables from top unit M connector to bottom unit S connector as
illustrated in Figure 10.
Figure10:Three20V‐40VUnitsParallelingCableConnection
4. Insert output cover through the cables as illustrated in Figure 11.
Figure11:OutputCoverInsertion
OutputCover
ParallelingCable
12
5. Assemble one lug on each bus bar using two hexagon bolts, four plain washers, two helical
spring-lock washers and two hexagon nuts as illustrated in Figure 12.
Figure12:Three20V‐40VUnitsLugsAssembly
6. Assemble bus bar insulator prior to output cover assembly. The insulator is flexible and could
be opened in its bottom side. Open the insulator and cover the bus bar by sliding it over the
bus bar, from top to bottom, as illustrated in Figure 13. Repeat for the second bus bar.
Figure13:Three20V‐40VUnitsBusBarInsulatorAssembly
Forrecommendedlugsrefer
to seriesSafety&
InstallationManual.
Notsupplied.
HexagonNut,M10,StainlessSteel
HelicalSpring
‐
LockWasher,M10,StainlessSteel
PlainWasher,M10,StainlessSteel
M10x25HexagonBolt,StainlessSteel
Tighteningtorque:220‐265Lbf‐inch(24.9‐29.9Nm)
BusBarInsulator
13
7. Fix output cover to the power supplies using six SEMS screws as illustrated in Figure 14.
Figure14:Three20V‐40VUnitsOutputCoverAssembly
8. Fix protection insulator to the output cover using two SEMS screw as illustrated in Figure 15.
Figure15:Three20V‐40VUnitsProtectionInsulatorAssembly
M3x8SEMSScrew,NickelPlated
Tighteningtorque:4.7‐5.7Lbf‐inch(0.53‐0.64Nm)
ProtectionInsulator
M3x8SEMSScrew,NickelPlated
Tighteningtorque:4.7‐5.7Lbf‐inch(0.53‐0.64Nm)
14
1.4.3
G/P-3U-60-100V - Assembly Instructions for three 60V-100V units in Parallel
1.4.3.1
Components List
Image Component Quantity
10‐32x5/16PanHeadScrew,StainlessSteel 12
HelicalSpring‐LockWasher,No.10,StainlessSteel 12
PlainWasher,No.10,StainlessSteel 12
ConnectionPlate3U 2
OutputShort 2
M3x4CFlatHeadScrew,NickelPlated 6
ParallelingCable 2
OutputCover 1
15
Image Component Quantity
BusBarProtectionBracket 1
BusBarCoverPlug 6
M3x8SEMSScrew,NickelPlated 8
16
1.4.3.2
Installation Steps
1. Attach connection plates, one on each side of the power supplies, using 12 pan head screws,
12 helical spring-lock washers and 12 plain washers as illustrated in Figure 16.
Figure16:Three
60V‐100V
UnitsConnectionPlates3UAssembly
2. Attach output short plates, one on each pair of terminals, using six flat head screws as
illustrated in Figure 17.
Figure17:Three
60V‐100V
UnitsOutputShortPlatesAssembly
ConnectionPlate
3U
PlainWasher,No.10,StainlessSteel
HelicalSpring‐LockWasher,No.10,StainlessSteel
10‐32x5/16PanHeadScrew,StainlessSteel
Tighteningtorque:25.4‐31.7Lbf‐inch(2.87‐3.58Nm).
M3x4CFlatHeadScrew,NickelPlated
Tighteningtorque:4.7‐5.7Lbf‐inch(0.53‐0.64Nm)
OutputShort
17
3. Connect two paralleling cables from top unit M connector to bottom unit S connector as
illustrated in Figure 18.
Figure18:Three60V‐100VUnitsParallelingCableConnection
4. For load wires with a diameter smaller than or equal to 11 millimeter insert six bus bar cover
plugs into the bus bar protection bracket and fix it to the output cover using two SEMS screw.
Insert output cover assembly through the cables as illustrated in Figure 19.
Figure19:Three60V‐100VUnits,WireDiameter≤11mm,OutputCoverAssembly
ParallelingCable
OutputCover
Assembly
BusBar
Cover
Plug
BusBarProtectionBracket
M3x8SEMSScrew,NickelPlated
Tighteningtorque:4.7‐5.7Lbf‐inch(0.53‐0.64Nm)
OutputCover
18
5. For load wires with a diameter greater than 11 millimeter divide each bus bar cover plug into
two separate parts by bending and breaking it along its separate grooves, as illustrated in
Figure 20. Insert only the rounded parts into the bus bar protection bracket and fix it to the
output cover using two SEMS screw. Insert output cover assembly through the cables as
illustrated in Figure 20.
Figure20:Three60V‐100VUnits,WireDiameter>11mm,OutputCoverAssembly
6. Assemble one lug on each bus bar using one hexagon bolt, two plain washers, one helical
spring-lock washer and one hexagon nut as illustrated in Figure 21.
Figure21:Three60V‐100VUnitsLugsAssembly
SeparateGrooves
BusBarProtection
Bracket
BusBar
CoverPlug
M3x8SEMSScrew,NickelPlated
Tighteningtorque:4.7‐5.7Lbf‐inch(0.53‐0.64Nm)
OutputCover
OutputCover
Assembly
Forrecommendedlugsrefer
to seriesSafety&
InstallationManual.
Notsupplied.
HexagonNut,M8,StainlessSteel
HelicalSpring
‐
LockWasher,M
8
,StainlessSteel
PlainWasher,M
8
,StainlessSteel
M8x25HexagonBolt,StainlessSteel
Tighteningtorque:106‐132Lbf‐inch(12‐14.9Nm)
19
7. Fix output cover to the power supplies using six SEMS screws as illustrated in Figure 22.
Figure22:Three60V‐100VUnitsOutputCoverAssembly
1.4.4
G/P-3U-150-600V - Assembly Instructions for three 150V-600V units in
Parallel
1.4.4.1
Components List
Image Component Quantity
10‐32x5/16PanHeadScrew,StainlessSteel 12
HelicalSpring‐LockWasher,No.10,StainlessSteel 12
PlainWasher,No.10,StainlessSteel 12
ConnectionPlate3U 2
M3x8SEMSScrew,NickelPlated
Tighteningtorque:4.7
‐
5.7Lbf
‐
inch(0.53
‐
0.64Nm)
20
Image Component Quantity
ParallelingCable 2
FixingBracket 1
M3x8SEMSScrew,NickelPlated 6
OutputBracketG+15KW 1
M3x10SEMSScrew,NickelPlated 4
OutputBracket 1
M3x6GFlatHeadScrew,NickelPlated 2
OutputPlug 1
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