Wayne Kerr AP10030 Troubleshooting guide

Wayne Kerr
Wayne Kerr Wayne Kerr
Wayne Kerr
AP1kW Power Supplies
AP1kW Power SuppliesAP1kW Power Supplies
AP1kW Power Supplies
AP3080 AP6050 AP10030
AP3080 AP6050 AP10030AP3080 AP6050 AP10030
AP3080 AP6050 AP10030
User & Service Manual
User & Service ManualUser & Service Manual
User & Service Manual
Part Nº 9HAP1kW
Wayne Kerr Electronics Ltd
Durban Road, Bognor Regis, West Sussex, England PO22 9RL
Tel [phone] • Fax [phone]
Iss2 02/03/2009 12:08:00 PMA

2 Wayne Kerr AP 1kW Power Supplies • Issue 2


Wayne Kerr Electronics Ltd 1995
The copyright in this work is vested in Wayne Kerr Electronics Ltd and this document is issued for the purpose
only for which it is supplied. No licence is implied for the use of any patented feature. It must not be reproduced
in whole or in part, or used for tendering or manufacturing purposes except under an agreement or with the
consent in writing of and then only on the condition that this notice is included in any such reproduction.
Information furnished is believed to be accurate but no liability in respect of any use of it is accepted by Wayne
Kerr Electronics Ltd.

Wayne Kerr AP 1kW Power Supplies • Issue 2 3
CONTENTS
1. SAFETY ............................................................................................................................................................. 4
1.1 GENERAL............................................................................................................................................................ 4
1.2 A.C. POWER SUPPLY .......................................................................................................................................... 4
1.3 ADJUSTMENT,REPLACEMENT OF PARTS,MAINTENANCE AND REPAIR............................................................... 4
1.4 STATIC ELECTRICITY .......................................................................................................................................... 5
1.5 DISPOSAL HAZARDS ........................................................................................................................................... 5
1.6 LOAD INDUCTANCE ............................................................................................................................................ 5
2. SCHEDULE OF EQUIPMENT ....................................................................................................................... 6
3. INTRODUCTION ............................................................................................................................................. 7
4. SPECIFICATION ............................................................................................................................................. 8
5. INSTALLATION............................................................................................................................................. 12
5.1 SUPPLY VOLTAGE............................................................................................................................................. 12
5.2 MAINS CONNECTION ........................................................................................................................................ 13
5.3 LOCATION ........................................................................................................................................................ 13
5.4 RACK MOUNTING ............................................................................................................................................. 13
6. OPERATING INSTRUCTIONS.................................................................................................................... 15
6.1 FIRST TIME OPERATION.................................................................................................................................... 15
6.2 CONNECTING THE LOAD ................................................................................................................................... 16
6.3 PROTECTIVE CIRCUITS...................................................................................................................................... 17
6.4 OPERATING MODES .......................................................................................................................................... 20
6.5. LINE IMPEDANCE TEST.................................................................................................................................... 30
6.6. CURRENT MONITOR (IMON) ............................................................................................................................ 31
6.7. INHIBIT TERMINAL........................................................................................................................................... 31
7. CIRCUIT DESCRIPTION ............................................................................................................................. 32
8. RECALIBRATION ......................................................................................................................................... 36
8.1 EQUIPMENT NEEDED FOR RECALIBRATION ...................................................................................................... 36
8.2 RECALIBRATION PROCEDURE ........................................................................................................................... 37
8.3 OUTPUT NOISE AND RIPPLE MEASUREMENTS .................................................................................................. 40
9. MAINTENANCE ............................................................................................................................................ 42
9.1 CLEANING......................................................................................................................................................... 42
9.2 SAFETY CHECKS ............................................................................................................................................... 42
9.3 GUARANTEE ..................................................................................................................................................... 43
9.4 SERVICE ........................................................................................................................................................... 43
10. COMPONENT SCHEDULES...................................................................................................................... 44
11AP3080.............................................................................................................................................................. 45
11AP6050.............................................................................................................................................................. 50
11AP10030............................................................................................................................................................ 56
11. CIRCUIT DIAGRAMS ............................................................................................................................... 62

4 Wayne Kerr AP 1kW Power Supplies • Issue 2
1. SAFETY
1.1 General
This equipment has been designed to meet the requirements of EN61010 “Safety
requirements for electrical equipment for measurement, control & laboratory use”, and
has left the factory in a safe condition.
This product is not intended for use in atmospheres which are explosive, corrosive or
adversely polluted (e.g. containing conductive or excessive dust). It is not intended for
use in safety critical or medical applications.
The remainder of this section on safety provides information and warnings which must
be followed by the user to ensure safe operation and maintain the equipment in a safe
condition otherwise protection provided by the equipment may be impaired.
OPERATOR - Person who uses this equipment for its intended purpose. This person
should be suitably trained and aware of the hazards. Operators should be capable of fuse
replacement providing the normal precautions are taken.
1.2 A.C. Power Supply
1) It is necessary to fit a suitable a.c. power plug to the power cable, the user must
observe the following colour codes:
LIVE terminal to BROWN lead
NEUTRAL terminal to BLUE lead
EARTH terminal to GREEN/YELLOW lead.
The user must also ensure that the protective earth lead would be the last to break
should the cable be subject to excessive strain.
2) If the power cable electrical connection to the a.c. power plug is through screw
terminals then, to ensure reliable connections, any solder tinning of the cable wires
must be removed before fitting the plug.
3) WARNING! Any interruption of the protective earth conductor inside or outside the
equipment or disconnection of the protective earth terminal is likely to make the
equipment dangerous. Intentional interruption is prohibited.
4) Before switching on the equipment, ensure that it is set to the voltage of the local
a.c. power supply.
1.3 Adjustment, Replacement of Parts, Maintenance and Repair
1) When the equipment is connected to the local a.c. power supply internal terminals
may be live and the opening of the covers or removal of parts - including fuse
holders - (except those to which access can be gained by hand) is likely to expose
live parts. The equipment must be disconnected from all voltage sources before
it is opened for any adjustments, replacement (e.g. fuses), maintenance or
repair.
2) Capacitors inside the equipment may still be charged even if the equipment has been
disconnected from all voltage sources.

Wayne Kerr AP 1kW Power Supplies • Issue 2 5
3) Any adjustment, maintenance and repair of the opened equipment powered up must
be carried out by a skilled person who is aware of the hazards involved
4) Servicing personnel should be trained against unexpected hazards.
5) Ensure that only fuses with the required rated current and of the specified type are
used for replacement. The use of makeshift fuses and short circuiting of fuse holders
is prohibited.
1.4 Static Electricity
The unit supplied may use static sensitive devices and service personnel should be
alerted to components which require handling precautions to avoid damage by static
electrical discharge.
Before handling circuit board assemblies containing these components, personnel should
observe the following precautions:
1) The work surface should be a conductive grounded mat.
2) Soldering irons must be grounded and tools must be in contact with a conductive
surface to ground when not in use.
3) Any person handling static sensitive parts must wear a wrist strap which provides a
leaky path to ground, impedance not greater than 1 megaohm.
4) Components or circuit board assemblies must be stored in or on conductive foam or
mat while work is in progress.
5) New components should be kept in the supplier’s packaging until required for use.
1.5 Disposal Hazards
Service personnel should be aware that batteries should be disposed of intact and never
incinerated.
1.6 Load Inductance
Low voltage D.C. power supply products connected to large inductive loads can store
sufficient energy in the load to cause an electrical hazard. Extreme caution is
recommended when switching such circuits as back EMFs can reach dangerous levels.
WARNING
This equipment is intended for use by suitably trained and competent persons.
Under some conditions this product is capable of having hazardous voltages
(greater than 60V) on its terminals in normal use. Appropriate precautions should
be taken for safety.
This product can cause hazards if it is not used in accordance with these
instructions. Read them carefully and follow them in all respects. Double check
connections to the unit before use.
DO NOT USE THIS EQUIPMENT IF IT IS DAMAGED.

6 Wayne Kerr AP 1kW Power Supplies • Issue 2
2. SCHEDULE OF EQUIPMENT
The Power Supply has been carefully packed to prevent damage in transit.
The complete equipment comprises:-
Description Part Nº Qty
AP Power Supply 11AP3080 or
11AP6050 or
11AP10030
1
User & Service Manual 9HAP1kW 1
Spare Fuses 1A T Type FT1A00123 1
Rack Mounting Kit HB2529 1
Note: In the event of damage in transit or shortage in delivery, separate notices in writing
should be given to both the carriers and Wayne Kerr Electronics Limited, within three
days of receipt of the goods, followed by a complete claim within five days. All goods
which are subject of any claim for damage in transit or shortage in delivery should be
preserved intact as delivered for a period of seven days after making the claim, pending
inspection or instructions from Wayne Kerr Electronics Ltd., or an agent of this
company.

Wayne Kerr AP 1kW Power Supplies • Issue 2 7
3. INTRODUCTION
Autoranging - The AP series of autoranging bench\rack power supplies utilise
switching techniques to provide d.c. power up to 1kW over a wide range of voltage and
current combinations, thus obviating the need to select alternative output power supplies.
Precision - The units include full digital metering of both voltage and current. The
output of each power supply is adjustable from near zero to maximum volts and from
near zero to maximum amps by the 10 turn front panel controls. Alternatively, the
outputs can be controlled by the remote resistive or voltage programming facilities at the
rear of the unit, or, when fitted, by the IEEE488 interface.
Enable & Preview - The power supply output is enabled by the front panel ‘output
enable’ switch. When this switch is in the ‘button out’ position the front panel LED
meters and bargraphs display preview the output voltage and output current. This is done
without having to open circuit the load to set the voltage or short circuit the output to set
the current.
Displays - When in the ‘output enabled’ state, the meters and bargraphs display the
actual voltage and current being delivered to the load. The bargraph displays, in addition
to providing ‘trend’ indication, also allow the user to see at a glance, the current or
voltage availability.
Overvoltage Limit - To protect the load from the inadvertent application of an excessive
voltage, the power supply incorporates an ‘Overvoltage Limit’ (OVL). this causes the
supply to ‘down programme’ if the pre-set level has been exceeded. It can be adjusted by
rotating the ‘adjust OVL’ control through the front panel. In the local mode, this voltage
level can be monitored on the voltmeter by depressing the ‘Display OVL’ button.
Indicators - To enable the user to quickly assess the operating states, the power supply is
provided with LED indication of ‘output enabled’ and ‘CV’ or ‘CI’ operation. LED
indication is also provided of, an overtemperature condition (when any of the three heat-
sink assemblies have exceeded a safe operating temperature), an overvoltage condition
and of unregulated output (if the load demand exceeds 1kW d.c.).
Computer Control - An IEEE488 interface is available as a factory fitted option. When
fitted, this allows control of voltage and current and, in addition, provides ‘read back’ to
the controller of the actual voltage and current being delivered to the load. The IEEE488
option includes LEDs which indicate if the power supply is ‘talking’ or ‘listening’ or
whether a ‘service request’ signal has been sent.
System or Bench Use - The power supply can be used on the bench or rack mounted
using the brackets provided. All units are fan cooled.
Standards - The AP series is designed to meet generic emc standards. From 1st Jan 1997
this product will comply with Euro Norm safety standard EN61010-1.

8 Wayne Kerr AP 1kW Power Supplies • Issue 2
4. SPECIFICATION
All parameters measured with a resistive load.
Models Available Model Nº P max V range I range
AP30-80 1kW 0-30V 0-80A
AP60-50 1kW 0-60V 0-50A
AP100-30 1kW 0-100V 0-30A
A.C Input 230V±14% (198 to 263V) or 115V±14% (99 to132V) 48 to 63Hz
Internal link and selector switch to change for 115V operation.
Input Current 9A max. r.m.s. for 240V a.c. (20A peak), 20A max. r.m.s. for 115V a.c.
Inrush Current 31A max. for 240V a.c. 16A for 115V a.c.
Efficiency 80% typical at max. output power
D.C. Output See models available for voltage and current ranges.
10
20
30
20 40 60 80
34A
40A
50A
66.7A
80A
20
40
60
50
30
10
10 20 30 40 50
16.7A
20A
25A
33.5A40A 50A
100
80
60
40
20
10A
12.5A
16.7A
20A
25A
30A
10 20 30
34
Fig. 4a. AP3080 Fig. 4b AP 6050 Fig. 4c. AP10030
Output Control Three methods of control:
1. Front panel ten turn potentiometers.
2. Remote programming by resistance, voltage or current.
3. IEEE488 bus control
Resolution of Controls
0.07% typical of max. output voltage.
0.07% typical of max. output current.
Line Regulation
For a 10% change of a.c. input from
nominal
Less than 0.01% +3mV in constant voltage (CV) mode.
Less than 0.01% +5mA in constant current (CI) mode.
Load Regulation
For a zero to full load change
Less than ±0.01% ±5mV in CV mode.
Less than ±0.01% ±5mA in CI mode.

Wayne Kerr AP 1kW Power Supplies • Issue 2 9
Ripple and Noise
∆f = 20Hz to 20MHz
Typical 4mV r.m.s./40mV p-p
Max 7mV r.m.s./70mV p-p.(CV)
Typical 25mA r.m.s. Max 40mA r.m.s. (CI)
.
Temperature
Coefficient
Typical after 30 min. warm up
0.01% + 2mV per °C (CV)
0.01% + 4mA per °C (CI)
Stability Typical drift in output over an 8 hour interval (assuming constant line,
load and ambient temperature) after a 30 min. warm up
±0.03% of output ±5mV (CV)
±0.03% of output ±5mA (CI)
Output Impedance 0.2mΩat d.c., typical.
Load Inductance When using the power supply close to short circuit it is
recommended that all possible precautions are taken to maintain a low
load inductance. (Load leads should be short and where possible
twisted together.)
Response Time to
Transient Loads
Less than 2ms typical for output to recover within 100mV of nominal
(CV mode) following a change in output current of from 90-100% or
100-90% of maximum current.
Programming
Response Time
Maximum time for output voltage to change from 2 volts to maximum or
from maximum to 2V and settle within 200mV band:
UP Full load (3.4Ω) 120ms
No load 120ms
DOWN Full load (3.4Ω) 400ms
No load 1.2s
Overvoltage Limit
(OVL)
Front panel adjustable multiturn potentiometer. Trip level adjustable
from approx. 2V to a level above rated output voltage. Accuracy of trip
setting 1% approx. +1.5V.
Current Monitor 0-5V amplified current monitor output for zero to full output current.
accuracy 1% +10mV. Output impedance 5kΩnominal.
Remote Programming Resistance 0 to 4k7Ωprovides zero to full output voltage or current.
Common terminal connected to negative sense terminal.
Accuracy at 23°C 0.2% +60mV (CV) 1.1% +50mA (CI).
Voltage 0 to 5V provides zero to full output voltage or current.
Accuracy at 23°C 0.1% +60mV (CV) 1% +50mA (CI).
Remote Inhibit Input of a voltage between approx 2 and 60 volts to rear panel terminal
will shut down output.
Remote Sensing Maintains nominal voltage at load by correcting for up to 0.5V drop in
each output lead.

10 Wayne Kerr AP 1kW Power Supplies • Issue 2
E.M.C. Complies with EN50081-1 & EN50082-1 generic emissions and
immunity standards.
Note: This unit may exhibit deviance of up to 1% (CV mode) or 2% (CI
mode) in a 3V/m field.
Safety Standards Designed to comply with BS4743/IEC348.
After Jan 1st 1997 all units will be compliant with EN61010-1.
Metering And Status Twin 3 digit panel meters on front panel
Indication 12.5mm character height. High efficiency, red LED, digital display of
voltage and current output. Overvoltage limit (OVL trip point) can also
be displayed.
Twin bargraphs of 20 segments each give approximate indication of
voltage and current availability and will show trends.
Status flags give LED indication of CV and CI within panel meters.
Central status window indicates unregulated condition (UNREG),
overtemperature trip (OT), overvoltage limit (OVL). In addition, if the
IEEE488 bus option is fitted BUS indicates the unit is under bus control;
LSN indicates receiving data from the bus; TLK indicates transmitting
data on the bus; and SRQ indicates that a ‘service request’ has been
initiated
Meter Accuracy
Resolution & F.S.D
VOLTAGE
Accuracy at 23°C: ±0.2% rdg ±1 digit
Resolution: 100mV f.s.d 99.9V
CURRENT
Accuracy at 23°C: ±1% rdg ±1 digit
Resolution: 100mA f.s.d. 99.9A
IEEE (488) Interface
(When Fitted)
Refer to supplementary handbook (part no 9HAPHIBUS).
Float Voltage These units are designed for either terminal to be floated up to 120V
d.c. from earth, including the output voltage. The float sources must
be impulse free (see IEC 664) i.e. do not float the output on an
unisolated a.c. supply.
Environmental Operating temperature 0-40°C
Storage temperature -20 to +60°C
Cooling: Fan cooled. Air intake on front panel.
Overtemperature trip protection is featured.
RH <80% Non-condensing
Altitude <2000m
Pollution degree 2 - Normally non-conductive pollution.
Non-corrosive, non-explosive atmosphere.
Installation category 2 - Connected via a plug and socket to the supply.
For indoor use only.