Elgar SW5250A Service Manual

Contact Information Telephone: 800 733 5427 (toll free in North America) 858 450 0085 (direct) Fax: 858 458 0267 Em

TABLE OF CONTENTS TW SERIES viii This page intentionally left blank.

1-1 SECTION 1 – THEORY OF OPERATION 1.1 INTRODUCTION This service manual is intended to assist in the maintenance, troubleshooting, repair to the m

THEORY OF OPERATION TW SERIES 1-2 FIGURE 1-1. TW5250PWR MOD: ØARECTIFIER-OR-PFCDC/DCPWR MOD: ØBRECTIFIER-OR-PFCDC/DCPWR MOD: ØCRECTIFIER-OR-PFCDC/

SERVICE MANUAL THEORY OF OPERATION 1-3 The system shown in Figure 1-1 is a TW5250 meaning that it contains three identical output channels A, B, and

THEORY OF OPERATION TW SERIES 1-4 1.4 DIGITAL CONTROL BOARD FIGURE 1-2. DIGITAL CONTROL BOARD BLOCK DIAGRAM The Digital Control Board is

SERVICE MANUAL THEORY OF OPERATION 1-5 checked for corruption, and if no corruption is found program control is passed to the FLASH memory. The Digit

THEORY OF OPERATION TW SERIES 1-6 1.5 ANALOG PROCESSOR BOARD FIGURE 1-3. ANALOG PROCESSOR BOARD BLOCK DIAGRAM The Analog Processor Board

SERVICE MANUAL THEORY OF OPERATION 1-7 The sinewave references are fed either directly to the servo amplifiers or are AC coupled, depending on the se

THEORY OF OPERATION TW SERIES 1-8 1.7 POWER CONDITIONER MODULE FIGURE 1-7. POWER CONDITIONER MODULE BLOCK DIAGRAM The power condit

SERVICE MANUAL THEORY OF OPERATION 1-9 The PFC module is a two–board assembly consisting of a PFC Power and a PFC Control board. The single–phase AC

THEORY OF OPERATION TW SERIES 1-10 overall switching frequency of 400 kHz. This high switching frequency allows smaller filtering components to be us

2-1 SECTION 2 – MAINTENANCE AND TROUBLESHOOTING 2.1 GENERAL This section contains procedures for corrective maintenance of the TrueWave products. In

MAINTENANCE AND TROUBLESHOOTING TW SERIES 2-2 2.3 REQUIRED TEST EQUIPMENT The test equipment required to conduct performance verification procedures

SERVICE MANUAL MAINTENANCE AND TROUBLESHOOTING 2-3 2.5 FAULT SYMPTOMS/TROUBLESHOOTING The troubleshooting approach taken in this section will be at

MAINTENANCE AND TROUBLESHOOTING TW SERIES 2-4 TABLE 2-3. TROUBLESHOOTING Fault Symptom Troubleshooting/Corrective Action With unit turned on, front

SERVICE MANUAL MAINTENANCE AND TROUBLESHOOTING 2-5 Fault Symptom Troubleshooting/Corrective Action Unit comes up normally. Upon relay closure unit

MAINTENANCE AND TROUBLESHOOTING TW SERIES 2-6 2.6.1 Remove the (20) flat-head screws securing the top cover to the chassis. Note that some of the s

SERVICE MANUAL MAINTENANCE AND TROUBLESHOOTING 2-7 2.6.3 Remove the fan panel power cables from the Analog board connectors, J10 and J11, as shown

MAINTENANCE AND TROUBLESHOOTING TW SERIES 2-8 2.6.5 Disconnect fan panel power cable at J3 on the Housekeeping board mounted on the chassis floor.

SERVICE MANUAL MAINTENANCE AND TROUBLESHOOTING 2-9 2.6.7 Gently remove the retaining clip as shown above. The switch can now be slid back through

i About AMETEK AMETEK Programmable Power, Inc., a Division of AMETEK, Inc., is a global leader in the design and manufacture of precision, programm

MAINTENANCE AND TROUBLESHOOTING TW SERIES 2-10 2.6.9 To remove the Analog and Control boards from the front panel assembly, remove the (8) mountin

SERVICE MANUAL MAINTENANCE AND TROUBLESHOOTING 2-11 2.6.11 Remove the (2, 4 or 6) screws, depending on model, that secure the top bracket to the mo

MAINTENANCE AND TROUBLESHOOTING TW SERIES 2-12 2.6.13 Remove the (4) screws that secure the Signal board to the air baffle. 2.6.14 The Signal b

SERVICE MANUAL MAINTENANCE AND TROUBLESHOOTING 2-13 2.6.15 Cut all tie-wraps securing the cable assembly to the air baffle as shown above. 2.6

MAINTENANCE AND TROUBLESHOOTING TW SERIES 2-14 2.6.17 Remove the air baffle by lifting straight out as shown above. 2.6.18 Any module can now b

SERVICE MANUAL MAINTENANCE AND TROUBLESHOOTING 2-15 2.6.19 … And then lifting the module straight up and out of the chassis as shown above. 2.6.

MAINTENANCE AND TROUBLESHOOTING TW SERIES 2-16 This page intentionally left blank.

3-1 SECTION 3 – CALIBRATION 3.1 SCOPE These procedures cover the calibration of TrueWave models TW1750, TW3500, and TW5250. Calibrating the TrueWav

CALIBRATION TW SERIES 3-2 3.4 SETUP In each calibration section the appropriate setup is listed for the calibration step. WARNING If the TrueWave i

SERVICE MANUAL CALIBRATION 3-3 CAL{1,2,3}:OUTP:REMOTE:HIR:VOLT:OFFSET 0.0 CAL{1,2,3}:OUTP:REM:HIR:VOLT:FREQCAL 1.0 1.0 1.0 1.0 1.0 CAL{1,2,3}:MEAS:LO

ii This page intentionally left blank.

CALIBRATION TW SERIES 3-4 Wait for the TW to complete its coupling change to DC. Continue with the following GPIB commands: SOUR:VOLT:RANGE LOW SOUR

SERVICE MANUAL CALIBRATION 3-5 Send the following query command to the TW and record the return string as MEAS1: MEAS{1,2,3}:VOLT? Calculate the off

CALIBRATION TW SERIES 3-6 Calculate the gains and offset for the phase being calibrated: GAIN1 = (MEAS1 – MEAS2) / (RDGN1 – RDGN2) GAIN2 = (440.0

SERVICE MANUAL CALIBRATION 3-7 Measure the current offset by sending the following GPIB query and record the return string as MEAS1: MEAS{1,2,3}:CURR

CALIBRATION TW SERIES 3-8 3.9 DC REMOTE LOW RANGE CALIBRATION Both the measurement and output subsystems are calibrated at the same time. Connect t

SERVICE MANUAL CALIBRATION 3-9 Wait for the DMM to settle. Take a DMM reading and record the value as RDGN1. Query the output voltage of the TW and

CALIBRATION TW SERIES 3-10 Wait for the DMM to settle and record the value as RDGN1. Send the following query command to the TW and record the return

SERVICE MANUAL CALIBRATION 3-11 Calculate the gains and offset for the phase being calibrated: GAIN1 = (MEAS1 – MEAS2) / (RDGN1 – RDGN2) GAIN2 =

CALIBRATION TW SERIES 3-12 Set the TW to 320 Hz. SOUR:FREQ 320.0 Wait for the DMM to settle and record the voltage as MEAS4. Set the TW to 500 Hz. SO

SERVICE MANUAL CALIBRATION 3-13 Set the TW’s frequency to 160 Hz with the following GPIB command: SOUR:FREQ 160.0 Wait for the DMM reading to settle

iii Important Safety Instructions Before applying power to the system, verify that your product is configured properly for your particular applicat

CALIBRATION TW SERIES 3-14 3.12 LOCAL HIGH RANGE FREQUENCY CALIBRATION Connect the TW output to the DMM. Set the DMM up for auto–ranging AC voltage.

SERVICE MANUAL CALIBRATION 3-15 Calculate the calibration constants: VALUE1 = 240.0 / MEAS1 VALUE2 = 240.0 / MEAS2 VALUE3 = 240.0 / MEAS3 VALUE4 =

CALIBRATION TW SERIES 3-16 Wait for the DMM reading to settle and record the value as RDNG4. Query the TW’s output put voltage with the GPIB string b

SERVICE MANUAL CALIBRATION 3-17 Close the TW’s output relay: OUTPUT ON Wait for the DMM to settle and record the voltage as MEAS1. Set the TW to 80 H

CALIBRATION TW SERIES 3-18 Close the TW’s output relay: OUTPUT ON Wait for the DMM reading to settle and record the value as RDNG1. Query the TW’s ou

SERVICE MANUAL CALIBRATION 3-19 Query the TW’s output put voltage with the GPIB string below and record this value as MEAS5. MEAS{1,2,3}:VOLT? Set th

CALIBRATION TW SERIES 3-20 Set the TW to 160 Hz. SOUR:FREQ 160.0 Wait for the DMM to settle and record the voltage as MEAS3. Set the TW to 320 Hz. SO

SERVICE MANUAL CALIBRATION 3-21 Set the TW’s frequency to 80 Hz with the following GPIB command: SOUR:FREQ 80.0 Wait for the DMM reading to settle an

CALIBRATION TW SERIES 3-22 Calculate the measurement system frequency compensation values: VALUE1 = RDGN1 / MEAS1 VALUE2 = RDGN2 / MEAS2 VALUE3 = R

SERVICE MANUAL CALIBRATION 3-23 Wait for the phase angle measurement to stabilize on the counter timer. Record the phase angle as RDGN4. Set the TW

iv Product Family: Models: TW5250, TW3500, TW1750 Warranty Period: One Year WARRANTY TERMS AMETEK Programmable Power, Inc. (“AMETEK”), provides this

CALIBRATION TW SERIES 3-24 Query the TW for the phase angle with the following command and record the value as MEAS1. MEAS2:PHASE? Set the TW frequen

SERVICE MANUAL CALIBRATION 3-25 Set the TW frequency to 60 Hz and open the output via the GPIB: SOUR:FREQ 60.0 OUTP OFF Calculate the phase offset ca

CALIBRATION TW SERIES 3-26 Wait for the counter timer to settle and record the phase angle as RDNG1. Query the TW for the phase angle with the follow

SERVICE MANUAL CALIBRATION 3-27 Set the TW frequency to 60 Hz and open the output via the GPIB: SOUR:FREQ 60.0 OUTP OFF Calculate the phase offset ca

CALIBRATION TW SERIES 3-28 Wait for the DMM to settle and record the value as RDNG2. Calculate the gain and offset for the external input: GAIN = 6

SERVICE MANUAL CALIBRATION 3-29 Reset the TW back to AC coupling mode, output off. SOUR{1,2,3}:VOLT:OFFSET 0.0 OUTP OFF OUTP:COUP AC Calculate th

CALIBRATION TW SERIES 3-30 Query the TW’s watts using the GPIB string below, and record this value as MEAS2. MEAS{1,2,3}:POW? Turn the TW’s output o

SERVICE MANUAL CALIBRATION 3-31 Turn the TW’s output off via the GPIB: OUTP OFF Calculate the gain and offset values for updating the TW: GAIN =

CALIBRATION TW SERIES 3-32 Program the TW to 160 Hz using the string below: SOUR{1,2,3}:FREQ 160 Wait until the power analyzer has stabilized and rec

SERVICE MANUAL CALIBRATION 3-33 3.23 LOCAL LOW RANGE WATTS FREQUENCY CALIBRATION Connect the 12 ohm resistor to the output of the TW through the powe

v TABLE OF CONTENTS Warranty...

CALIBRATION TW SERIES 3-34 Query the TW’s watts using the GPIB string below, and record this value as MEAS4. MEAS{1,2,3}:POW? Program the TW to 500 H

SERVICE MANUAL CALIBRATION 3-35 Query the TW’s watts using the GPIB string below, and record this value as MEAS1. MEAS{1,2,3}:POW? Program the TW to

CALIBRATION TW SERIES 3-36 Calculate the calibration constants: VALUE1 = RDGN1/MEAS1 VALUE2 = RDGN2/MEAS2 VALUE3 = RDGN3/MEAS3 VALUE4 = RDGN4

SERVICE MANUAL CALIBRATION 3-37 Calculate the gain from the collected data: GAIN = (RDGN2 – RDNG1) / (MEAS2 – MEAS1) Update the TW’s gain setting u

CALIBRATION TW SERIES 3-38 Update the TW’s gain and offset calibration values with the following GPIB strings: CAL{1,2,3}:MEAS:LOC:HIR:WATT:GAIN GAIN

SERVICE MANUAL CALIBRATION 3-39 3.28 HIGH RANGE CURRENT FREQUENCY CALIBRATION Connect the 48 ohm resistor to the output of the TW through the power a

CALIBRATION TW SERIES 3-40 Query the TW’s current using the GPIB string below, and record this value as MEAS4. MEAS{1,2,3}:CURR? Program the TW to 50

SERVICE MANUAL CALIBRATION 3-41 Wait until the power analyzer has stabilized and record the watts reading as RDNG1. Query the TW’s watts using the GP

CALIBRATION TW SERIES 3-42 Calculate the calibration constants: VALUE1 = RDGN1/MEAS1 VALUE2 = RDGN2/MEAS2 VALUE3 = RDGN3/MEAS3 VALUE4 = RDGN4

SERVICE MANUAL CALIBRATION 3-43 Wait until the power analyzer has stabilized and record the watts reading as RDNG3. Query the TW’s watts using the GP

TABLE OF CONTENTS TW SERIES viSECTION 3 – CALIBRATION 3.1 SCOPE...

CALIBRATION TW SERIES 3-44 This page intentionally left blank.

4-1 SECTION 4 – PARTS LIST 4.1 GENERAL This section contains the top assembly parts list for the TrueWave products. The parts lists below directly c

PARTS LIST TW SERIES 4-2 4.3 ORDERING SPARE PARTS Contact Elgar Electronics Corporation to order spare parts or assemblies. Please specify the asse

5-1 SECTION 5 – DIAGRAMS 5.1 GENERAL This section contains the interconnect diagrams and top assembly diagrams for the TrueWave series. The intercon

DIAGRAMS TW SERIES 5-2 This page intentionally left blank.

SERVICE MANUAL TABLE OF CONTENTS viiSECTION 4 – PARTS LIST 4.1 GENERAL ...................