Key Technical Specifications
| Parameter | Specification |
|---|---|
| Output Power | 20 kW (GSW 200/500V) |
| Output Voltage | 0–500 V DC |
| Output Current | 70 A |
| Control Modes | Constant voltage, constant current, constant power |
| Output Accuracy | ±1% |
| Input Voltage | 3×400 VAC, ±10%, 50/60 Hz |
| Cooling | Water-cooled |
| Arc Handling | Automatic; response ≤6 μs, blanking 6 μs–10 ms |
| Parallel Operation | Supported; no master/slave wiring required |
| Communication Interfaces | Profibus, EtherCat, RS-232/485, 0–10 V / 4–20 mA (option-dependent) |
| Mounting | 19-inch rack, approx. 3 HU |
| Protections | Overvoltage, overcurrent, overtemperature, short circuit |
Product Introduction
If your coater trips every time the plasma arcs, the power supply is either doing its job or failing at it. The ADL GSW 200/500 sits in that middle ground where uptime depends on cooling, grounding, and whether someone changed the arc parameters without telling production. It is a 20 kW, 500 V, 70 A water-cooled DC supply built for magnetron sputtering, not a bench supply you park next to a PLC.Engineers keep these units because the arc handling actually works. The suppression response hits in microseconds, and the parallel mode does not force you into messy master/slave wiring. I have seen GSW units run for years on glass, foil, and tool-coating lines. The weak point is never the IGBTs first; it is cooling flow, dirty fittings, or a missing interlock. Treat the water circuit like part of the process, and this supply will stay quiet.
Quality SOP & Tech Pitfalls
The Lab Report (SOP)
- Visual inspection: Check nameplate, revision, connectors, coolant fittings, and arc damage on output terminals.
- Insulation check: Measure output-to-chassis and input-to-chassis resistance with a Fluke 115 or equivalent.
- Control interface test: Verify 0–10 V / 4–20 mA or bus interface response before connecting to the cathode.
- Live test on resistive load: Confirm voltage regulation, current limit, and arc blanking behavior.
- Cooling verification: Check flow, pressure, and leak integrity under operating conditions.
- Firmware/parameter logging: Record software version, arc settings, and communication configuration.
- Final packing: Anti-static bag, desiccant, and shock-safe crate for transport.
The Engineer’s Warning (Pitfalls)Do not power this unit without confirmed coolant flow. I have seen a GSW rack sit idle for months, get restarted on a weekend shift, and cook an output stage because the chiller interlock was bypassed. Water cooling is not optional here. Also, photograph every parameter screen before you touch anything. Arc blanking time, current limit, and interface mode are easy to change and hard to debug at 2 a.m. when the coating starts drifting.
Installation & Configuration Guide
- Pre-Installation
- ⚠️ Shut down the vacuum system, isolate AC mains, and wait for DC bus discharge.
- ⚠️ Verify coolant supply, return lines, flow rate, and interlock signals.
- Photograph all existing wiring, communication cables, and parameter screens.
- Removal
- Label AC input, DC output, coolant lines, and control cables.
- Disconnect communication and analog setpoint wiring.
- Release rack mounting hardware and slide the unit out carefully.
- Installation
- Copy all parameter settings from the old unit before enabling output. This prevents most startup faults.
- Seat the new supply firmly in the rack and reconnect AC, DC, coolant, and control wiring.
- Confirm Profibus/EtherCat/RS-485 addressing if the unit is integrated into a PLC or HMI.
- Power-On & Testing
- Verify 3×400 VAC input and correct phase sequence.
- Enable coolant flow and confirm interlock closure.
- Power up without load; check LED/status indicators and communication handshake.
- Test low-voltage output, current limit, and arc suppression before returning to production.
Compatible Replacement Models
| Compatibility | Model | Notes |
|---|---|---|
| ✅ Drop-in Replacement | ADL GSW 200/500 (same revision) | Match nameplate voltage, current, and interface options. |
| ⚠️ Software Compatible | ADL GSW 200/1000 | Same GSW family; different voltage/current rating. Requires parameter and cathode review. |
| ⚠️ Software Compatible | ADL GX / HX series with matching power | May require rack, cooling, and communication reconfiguration. |
| ❌ Hardware Mod Required | Non-ADL DC sputtering supplies | Different interlocks, arc handling, and communication mapping. Not recommended unless upgrading the full line. |
Frequently Asked Questions (FAQ)
Is the GSW 200/500 still in production?
ADL continues to support the GSW family, but availability for an exact 200/500 revision depends on current manufacturing. Surplus and tested used units are common replacements.Can I replace it with a GX or HX unit?
Only after checking voltage, current, cooling, rack size, and communication. The GSW 200/500 is 20 kW, 500 V, 70 A. A GX or HX replacement must match the cathode and process requirements.Does it need master/slave wiring for parallel operation?
No. GSW units support parallel operation without dedicated master/slave wiring.Can I run it without water cooling?
No. The GSW series is water-cooled. Running it without proper flow, pressure, and interlocks will cause faults or permanent damage.What communication interfaces does it support?
Depending on configuration, it can support Profibus, EtherCat, RS-232/485, and 0–10 V / 4–20 mA analog control. Confirm the installed option on the actual unit.Is hot-swapping safe?
Not recommended. Treat it as a maintained power-down replacement. You need to isolate AC mains, discharge DC output, and verify cooling interlocks before swapping.What warranty can I expect?
For surplus units, warranty depends on pre-shipment testing. A 12-month warranty is reasonable only after full electrical and cooling verification.
