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MANUAL FOR HIGH VOLTAGE SERIES 102
DOCUMENT NUMBER83-486-001
Page 1 A
CONTROL SHEET
PROJECT ENGINEERDRAFTING MANAGERSALES/MARKETINGQA MANAGER
CONTROLLING DEPT.: ENGINEERING/DRAFTING
ORIGINATING DEPT.: ENGINEERING/DRAFTINGAPPROVAL SIGNATURES : JOB TITLE
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LAMBDA EMI405 ESSEX ROAD, NEPTUNE, NJ 07753
TEL: (732) 922-9300FAX: (732) 922-9334
OPERATOR MANUAL FOR
83-486-001 Revision D
MODELSERIAL NUMBER
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Table of Contents
6 - 25.5 Recommended Spare Parts List6 - 15.4 Troubleshooting6 - 15.3 Maintenance6 - 15.2 Calibration6 - 15.1 Safety Precautions6 - 15 MAINTENANCE AND TROUBLESHOOTING5 - 45.6 Operation as a DC Power Supply5 - 35.5 Determining AC Line Current5 - 35.4 Measuring High Voltages5 - 25.3 Paralleling Units5 - 25.2 Voltage Reversal5 - 15.1 Determining Capacitor Charge Time
5 - 15 APPLICATIONS4 - 34.2 Initial Check-Out Procedure4 - 14.1 Remote Control4 - 14 OPERATION3 - 33.8 Power Cord Specification3 - 33.7 Installation Requirement for IEC 601.13 - 23.6 Connecting High Voltage Output3 - 23.5 Grounding and Input AC Power3 - 13.4 Orientation3 - 13.3 Mounting and Cooling Requirements3 - 13.2 Initial Inspection3 - 13.1 Safety Precautions
3 - 13 INSTALLATION2 - 22.13 Options2 - 22.12 Weight2 - 22.11 Size2 - 22.10 HV Output Connector2 - 22.9 Cooling2 - 22.8 Protection Features2 - 22.7 Inrush Current2 - 22.6 Power Factor2 - 12.5 Input Voltage/Current2 - 12.4 Efficiency2 - 12.3 Regulation
2 - 12.2 Charge Rate2 - 12.1 Output Voltage/Current2 - 12 SPECIFICATIONS1 - 11 DESCRIPTION
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List of Figures
4 - 2Figure 4.1 Suggested Interface Circuit3 - 2
Figure 3.1 Input AC Power Connections2 - 3Figure 2.1 Mechanical Details1 - 2Figure 1.2 Output Power and Current1 - 1Figure 1.1 102 Series Block Diagram
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The 102 Series are high voltage, switching power supplies designed specifically for
charging capacitors in laser systems and other pulsed power applications. The 102 Series
provide 1,000 Watts of average power and can be paralleled indefinitely for higher total
system power. EMI also offers the 402 Series, 802 Series, and 153 Series rated at 4,000,8,000 and 15,000 Watts respectively.
The 102 Series power supply incorporates a high-frequency IGBT series-resonant inverter
for efficient generation of the output power. A high-performance control module precisely
regulates the output voltage, automatically compensating for line, load, temperature, rep
rate, and program voltage variations. Normal external fault conditions such as line dropout,
open or short circuit load, HV arc and over-temperature will not damage the unit.
CONTROL PCB
ASSY
FUSES
INRUSH LIMIT
AUX POWER
CONTROL
INPUT
POWER
REMOTE
CONTROL
LINE
RECTIFIER
INVERTER PCB ASSY
FILTER40kHZ
INVERTER
STEP-UP XFMR
HV RECTIFIER
HV FILTER
HV DIVIDER
HV TANK ASSY
HV
OUTPUT
Figure 1.1 102 Series Block Diagram
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The output voltage of the 102 power supply is fully adjustable over each range. The full
output current is available at rated voltage to supply a peak charge rate of 1250 J/sec. From
100% down to 75% of rated voltage, the usable power is constant and the current increases
according to I=2500/V. Below 75% rated voltage, the current is constant. This feature
allows the power supply to provide its full peak charge rate of 1250 J/sec over the top 25%
of the voltage range. In addition, this peak charge rate is 25% higher than the average
charge rate of 1000 J/sec. These enhanced specifications provide the full 1000 Watts ofaverage output power at only 75% of rated voltage and 80% charging duty cycle, as well as
up to 100% voltage.
100
75
50
25
25 50 75 100
% OUTPUT VOLTAGE
125
100
25 50 75 100
% USABLE
OUTPUT
POWER
% OUTPUT
CURRENT
% OUTPUT VOLTAGE
Figure 1.2 Output Power and Current
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The output voltage is fully adjustable over each range. The full output current is available
at rated voltage to supply a peak charge rate of 1250 J/sec. From 100% down to 75% ofrated voltage, the power is constant and the current increases according to I=2500/V.
Below 75% rated voltage, the current is constant. This provides the full 1000 Watts of
average output power at only 75% of rated voltage and 80% charging duty cycle, as well as
up to 100% voltage.
67 mA50 mA0-50 kV
83 mA63 mA0-40 kV
111 mA83 mA0-30 kV
167 mA125 mA0-20 kV
333 mA250 mA0-10 kV
667 mA500 mA0-5 kV
833 mA625 mA0-4 kV
1.67 A1.25 A0-2 kV
3.33 A2.5 A0-1 kV
At
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65% minimum with 180-264 V AC line.
Limited to less than 22 amps.
Short circuit and HV arc-to-ground any time during operation, and open circuit at turn-on,
will not damage the power supply. Shutdown on Overtemp, over-voltage, open interlock, and
line undervoltage. Highly buffered I/O for noise immunity in severe electrical environments.
Forced air with internal fan, -20C to 40C inlet temperature, 10% to 90% R.H.
non-condensing.
Standard EMI two-piece unshielded HV connector and 4 foot silicone HV cable.
!!!!
5.8 inches wide, 5.5 inches high, 15 inches deep. Refer to Figure. 3 for details.
17 lbs., 8 kg
Custom output voltage, 0.1% regulation, mounting brackets, EMI filter, custom length HV
cable, water cooling, DC load operation.
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Figure 2.1 Mechanical Details
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All model 102 power supplies contain hazardous voltage and energy. The power supply
must only be installed and operated by qualified authorized personnel who have read thisoperator's manual and are familiar with the operation, hazards and application of the power
supply. Proper care and judgment must always be observed. Ensure all covers are in place
and securely fastened and the required grounding and cooling is supplied before connecting
input AC power. Proper grounding from the input AC power is required to reduce the risk
of electric shock. Use extreme caution when connecting input AC power and never apply
the incorrect input power. Use extreme caution when connecting the high voltage output
cable. Ensure all load capacitors are completely discharged prior to connection and never
handle the output cable when the power supply is operating. Always replace fuses with the
same type and Volt/Amp ratings. Never attempt to operate the power supply in any manner
not described in this manual. Never remove DANGER or WARNING labels from the
power supply, and replace lost or damaged labels immediately. The power supply should
only be serviced by authorized qualified EMI personnel.
The shipping container should contain the following items: power supply, HV output cable,
male 15-pin "D" remote control connector and operator's manual. Examine the items
immediately for damage. Locate the serial number label on the side of the power supply
and verify the model number, the input voltage rating and the output voltage rating and
polarity. In the event of any damage promptly notify the transportation company and the
Lambda EMI customer service manager.
"#""#""#""#"
The power supply can be mounted by the six inserts located in on bottom of the power
supply (see Figure 2.1 for details). Chassis support brackets may be added to the sides of
the power supply for alternate mounting. The power supply can also operate on a bench or
table top. In all cases adequate clearances must be provided for proper air flow and cable
bends. Generally, at least 4 inches of clearance should be allowed at the inlet of the power
supply and 2 inches at the sides.
When operating in an enclosed system, care must be taken to ensure the ambient inlet air to
the power supply does not exceed the maximum operating temperature of 40C. This often
requires addition of a system heat exchanger.
The power supply must be operated in a level position. More than a quarter of an
inch (5.1mm) difference in height in any direction could cause an arcing condition in
the high voltage tank.
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Proper grounding from the input AC power is required to reduce the risk of electric shock.
The metal chassis of the power supply is grounded through the green earthing wire at the
input AC power terminal block. Use extreme caution when connecting input AC power
and never apply the incorrect input power. Connect the two lines of the input power to the
neutral and the proper line voltage terminal, 115V or 230V. Connect the earth ground to theterminal marked with the ground symbol. Refer to section 5.0 "Applications", to calculate
line currents for various operating conditions such as reduced power or charging very large
capacitor banks.
115V
N
L
L
30V
The fuse F1 (20A, 240V) on the neutral located on the control board should be jumpered by
a wire of minimum diameter of 1.45 mm, except for 208V application in the USA (only
the hot legs should be fused)
Figure 3.1 Input AC Power Connections
Ensure that the power supply is off and disconnected from the input power and that all load
capacitors are discharged and shorted to ground before making any connections. Never
handle the HV cable during operation.
Always use the HV connector and cable provided with the power supply or an equivalent
substitute provided by EMI. Fully insert the connector end of the HV cable and tighten the
locking nut only "hand tight". When operating above 20 kV and 200 Hz rep. rate, it is
recommended that a silicone grease (such as Dow Corning DC-4) be used on the HV cable
before insertion into the HV connector. This displaces the air in the connector and reduces
long term corona effects.
A stud is provided adjacent to the HV connector and should be used as the HV return. The
unshielded silicone HV cable can contact ground, but isolating it will minimize the effects
of corona in the system. Keep the minimum HV cable bend radius greater than 4 inches to
minimize stress on the insulation. Keep the HV cable as distant as possible from the input
power and the input control signals.
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Some peak current will flow out of the power supply during discharge and return through
the HV return and system chassis. This current comes from voltage reversal in
underdamped systems and from normal discharge of filter and cable capacitance. The path
for this current should not parallel control signal returns since the resulting voltages could
interfere with normal system operation. When due to voltage reversal at high rep. rates,
this current could damage the power supply. Generally a resistor in series with the HV
output can be added to limit this current to an acceptable level. Refer to section 5.0"Applications" for more information.
The oil-filled HV assembly should not be opened unless advised by EMI. The oil and
components have been specially cleaned and vacuum impregnated at the factory and the
assembly hermetically sealed. Opening the assembly may compromise performance.
#"#"#"#"
For use only with an IEC 601 isolation transformer
RFI/EMI compliance has to be checked in the final application
The leakage current exceeds IEC 601.1 (5mA) without isolation transformer.
Use wire with minimum 1.628mm diameter and 600V insulation.
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""""
The model 102 is easily controlled through the remote connector on the input panel of the
unit. Only the ENABLE/RESET, INTERLOCK, V PROGRAM and GND signals arerequired for operation. The remaining signals are provided for status monitoring and fault
diagnosis. A schematic diagram showing the suggested interface circuit appears after the
following description of control signals.
Open collector.OUTPUTINTERLOCK LED4
Open collector.OUTPUTOVERTEMP LED3
Open collector. Indicates an
output overload, over-voltage oropen circuit condition.
OUTPUTLOAD FAULT LED2
Open collector. Indicates that the
power supply is reaching end-of-
charge, i.e. the VPROGRAM set point.
OUTPUTEOC LED13
Open collector. Indicates that the
power supply is receiving an
INHIBIT signal
OUTPUTINHIBIT LED15
Control circuit return. Also
chassis/earth ground
OUTPUTGND14
15V through 10W series resistor,20mA max.OUTPUT+15V9,11
0-10V. Analog of output voltage
waveform + 1%.
OUTPUTANALOG OUT8
0-10V. Peak detector of output
charging waveform. Can be used
to drive a meter displaying peak
charging voltage.
OUTPUTPEAK VOLTS7
15V=CLOSED, GND or open
disables the power supply and
indicated interlock loop open.
INPUTINTERLOCK12
12 to 15V inhibits the unit. Open
or GND allows operation. Use this
signal to disable charging during
HV switch recovery.
INPUTINHIBIT10
0-10VINPUTV PROGRAM5
15V = ON. GND or open = OFFINPUTENABLE/RESET1
DESCRIPTIONI/OSIGNAL NAMEPIN
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Figure 4.1 Suggested Interface Circuit
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$%$%$%$%
The power supply should have no visible damage or defects and the cover should be
securely fastened. Properly connect the input power, control connector and HV output. If
there is no load connected, the power supply will regulate the output voltage to the
programmed voltage level or sense an open circuit and immediately shut down indicating a
LOAD FAULT. If there is a short circuit or overload condition on the output, the powersupply will operate in a 90% duty cycle protection mode and indicate a LOAD FAULT.
An overload condition can occur if the INHIBIT signal is missing allowing HV switch
latch-up or the discharge rep. rate is too high to allow the capacitor to fully charge to V
PROGRAM. Double check all connections and ensure that all personnel are protected
from the HV output. With the HV adjust at zero volts, turn the power supply on in the
following sequence:
102 Remote Control:
1. Connect power supply to the HV load
2. Increase load rep. rate to prevent a full charge
3. V PROGRAM signal (pin 5) at zero volts.
4. ENABLE/RESET signal (pin 1) at zero volts.
5. Assert ENABLE/RESET signal to 15V.
6. Verify HV output is at approx. zero volts.
7. Increase HV output slowly and verify adjustability.
8. Decrease load rep rate to allow full charge
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""""""""
The 102 Series is rated at 1250 J/sec peak and 1000 J/sec average charge rate. Although
the measure of Joules/sec equates to Watts, it is more convenient when working withenergy storage capacitors. The peak charge rate determines the capacitor charge time. The
average charge rate determines the total power delivered from the power supply. It is
possible to charge a capacitor at a rate of 1250 J/sec, but to discharge it at a low rep. rate
amounting to only 100 J/sec.
From 75% to 100% of rated voltage the 102 Series delivers a constant peak charge rate of
1250 J/sec. Below 75% it delivers a constant current and the charge rate depends upon the
voltage setting.
From 75% to 100% of rated voltage, the charge time is:
TC =1/2cv2
1250
Below 75% of rated voltage, the charge time is:
TC =1/2cv2 (.75xVrated)
1250
EX. A 102 rated at 40kV charging a 90nF cap to 35kV.
TC = 1/2cv2
1250 = 1/2 (90nF
)(35kV
)
2
1250 = 44m sec
EX. A 102 rated at 40kV charging a 90nF to 25kV.
TC=1/2cv2(.75xVrated)
1250 =1/2(90nF)(25kV)(.75x40kV)
1250 = 27m sec
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When the capacitor or PFN is discharged, a high peak current may flow out of the power
supply as a result of voltage reversal. This occurs in a system which is underdamped in
order to clear the high voltage switch after each pulse. The average value of this peak
current added to the normal output current may exceed the rating of the HV diodes in the
power supply. This current can be measured with a current transformer as shown.
A series terminating resistor (or series inductor or clamp diode) must be added as shown if
the average value of the peak current exceeds 110% of the normal output current.
When choosing Rs, ensure it can withstand the full output voltage across it as well as thepower dissipation caused by discharging Co (see chart) and Cc (20pF/ft) each cycle as well
as conducting the normal output current. It's power dissipation can be calculated as,
Pd = (IO2RS) + 1/2(CO + CC )V
2(REP RATE)
230pF40-50kV
460pF10-30kV
10nF5kV
50nF1-3kV
CoOutput Voltage
The 102 power supply is designed for simple parallel operation. The input power and HV
output should be connected directly together. The REMOTE connectors on the input panel
can also be connected directly together using a "daisy chain" ribbon cable from the system
controller. Each of the power supplies operate at the same time with the total charge rate
equal to the sum of each.
Sometimes when operating several units in parallel, the high total power generates noise
which interferes with the power supply control. This is usually due to the many
interconnecting control cables acting as an antenna picking up noise. The problem usually
appears as one or more of the power supplies shuts down when the output voltage increases
beyond a certain level. Dressing the control cables as short as possible and close to ground
or using shielded cables should help. In severe cases, it is necessary to wrap the cables
several times through large ferrite cores at the input panel of each unit.
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""""
A sample of the output voltage is available in the REMOTE connector. If it desired to measure
the HV output externally, care must be taken to understand the accuracy of the measurement.
When making a DC measurement, such as when the power supply is holding voltage on a
capacitor, any HV probe and DVM combination can be used. The Fluke 80K-40 probewith any 10M input resistance DVM is adequate up to 40kV. Building a simple resistor
divider using appropriate HV resistors is also very straightforward. Keep in mind that all
HV resistors, including the one in the Fluke probe, exhibit a negative voltage coefficient,
changing by up to 4% from zero to max voltage. Derating the resistors and calibrating at
the operating point solves this problem.
Making a pulsed measurement with an oscilloscope requires a compensated HV probe
having a wide bandwidth. Simply connecting a DC probe, through the proper resistance,
into a scope yields a slow response adequate for only low rep. rate systems. As with DC
probes, the pulsed probe resistor voltage coefficient is a problem. In addition, damage to
the resistors can occur during pulsing due to high electric field gradients. Also, stray
capacitance to nearby objects can significantly alter the pulse response. The Tektronix
P6015 is a high-performance, shielded probe and a good choice up to 40kV.
Measurements accurate to better than 0.1% can be achieved using a bias technique. For
example, if a 40V signal (40kV divided by 1000) is to be measured accurately, the minus input
of the DVM would be biased up 40V. The original signal, with respect to ground, is fed to the
plus input of the DVM. The bias can be measured accurately for absolute measurements, or
relative measurements read directly as the line or load is varied. In the same manner, an
oscilloscope return can be biased for accurate peak measurements during pulsing.
DC PULSED
""""
IL = Line currentIL =P
VLPFN
P = Average output power
VL = Line voltage
PF = Power factor (.65min)
Ex. A 102 operating from 115V - 10% and delivering 1000W average
IL =1000
(.9) (115) (.65) = 14.9A
When charging very large capacitor banks requiring many seconds or minutes to reach
end-of-charge, the power supply will display a load fault and go into a 90% duty cycle
protection mode. If this feature is defeated and the power supply is allowed to charge for
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an extended period, then the peak output power rather than the average must be used to
determine line current.
The 102 Series power supply is a current source which simply turns off when the voltage
reaches end-of-charge, and may cycle on/off to maintain the charge as required. Because the
charging waveform is triangular, the average power delivered is one-half of the peak power
times the duty cycle. Thus the 102 delivers 2500W peak and 1000W average power.
The 102 can provide a regulated voltage to a DC load such as an electron beam. The output
current will be preset at the factory to one-half the usual value in order to limit the average
output power to 1000 W, while making full rated HV steady state. The voltage ripple can
be easily filtered to any desired level with an external capacitor across the load.
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"&"&"&"&
The calibration and troubleshooting steps described in this section require operation of the
power supply with the cover removed. Proceed with extreme caution as hazardousvoltages are exposed throughout the unit. Safety glasses must be worn to prevent serious
injury in the event of a component failure (e.g., power transistors readily explode during
fault conditions). Because the power supply does not receive proper cooling with the cover
removed, operation at full power should be limited to less than ten minutes.
&&&&
Calibration of the output is accomplished with trimpot located on the tank cover. This PC
board is horizontally mounted on top of the high voltage tank assembly.
Output Voltage Level: R1 (25 turns). Slowly adjust clockwise to decrease output
voltage for a given V PROGRAM level. Factory set for 10V =rated voltage.
""""
No maintenance is required under normal operating conditions. Occasional vacuum or
blowout of the chassis may be required when operated in extremely dirty environments.
The oil-filled HV assembly should not be opened unless advised by Lambda EMI for fault
diagnosis. The oil and components have been specially cleaned and vacuum impregnated at
the factory and the assembly hermetically sealed. Opening the assembly may compromise
performance.
&&&&
First check for obvious trouble such as input power, output connections, control
connections and signal levels. In particular, the interlock, the INHIBIT and the
ENABLE/RESET signals. If there is no load connected, the power supply may sense an
open circuit and immediately shut down indicating a LOAD FAULT. If there is a short
circuit or overload condition on the output, the power supply will operate in a 90% duty
cycle protection mode and indicate a LOAD FAULT. An overload condition can occur if
the INHIBIT signal is missing allowing HV switch latch-up or the discharge rep. rate is
too high to allow the capacitor to fully charge to V PROGRAM.
If the power supply is making high voltage but does not appear to be functioning
properly in a specific application, the problem may be application related. Consult theLambda EMI customer service department.
If the power supply is not making full voltage, the problem is usually either failed HV
output diodes or a problem on a pc board. Refer to the schematics provided in this manual.
Check the +15V and -3V on the Control Board.
Check the +30V unregulated at the cathode of D23. If reading zero, check F4 and
F5 on the control board.
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Check the line sense at the tab of Q5 on the control card, it should be less than one
volt.
Check F1-F3 on the control card.
Check for failed power transistors or diodes on the Power Board.
Check the output and inputs of the main OR-gate U11-1,2,3,4,5,9,10,11,12. A highlevel will disable the power supply.
Check the V PROGRAM input at U2-7 with the power supply enabled.
Check the clock for a sawtooth waveform at the tab of Q2 on the control card with
the power supply enabled and the V PROGRAM input above ground.
Check the transistor gate drives at D10, D11 anode.
""""""""
IC CD40106BE RCA 64-003-066
IC ULN20004A SPRAGUE 64-006-049IC MC7815UC MOTOROLA 64-010-002
IC LM339N MOTOROLA 64-003-017
IC LM324N MOTOROLA 64-003-016
IC MC1458P1 MOTOROLA 64-002-009
DIODE 1N914 MOTOROLA 60-004-007
DIODE MUR3060PT MOTOROLA 60-048-006
XSTR 2N2907 GE 62-001-001
XSTR IRFD113 IR 63-009-020
XSTR IXGH40N60 IXYS 101-0500
RES 12, 11w, 5% OHMITE 67-114-001
CAP LPK2D102MHSC NICHICON 67-006-109
OPTO-ISO CNY65 GI 64-009-010THERMOST 67F085 AIRPAX 68-055-004
VARISTOR V420LA20A GE 53-002-019
FUSE 314020 LITTLEFUS 58-002-018
FUSE GDC500mA BUSSMANN 58-022-004
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