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Elgar Electronics Corporation
9250 Brown Deer Road
San Diego, CA 92121-2294

1-800-73ELGAR (1-800-733-5427)
Tel: (858) 450-0085
Fax: (858) 458-0267
Email: [email protected]

P60, P80, D3 Series

DC Power Supplies

Operation Manual

©2007 by Elgar Electronics Corporation

This document contains information proprietary to Elgar Electronics Corporation. The information contained herein is
not to be duplicated or transferred in any manner without prior written permission from Elgar Electronics Corporation.

www.elgar.com

November 2, 2007

Document No. M550001-01 Rev F

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Summary of Contents for D3 Series

Page 1: ...Series DC Power Supplies Operation Manual 2007 by Elgar Electronics Corporation This document contains information proprietary to Elgar Electronics Corporation The information contained herein is not to be duplicated or transferred in any manner without prior written permission from Elgar Electronics Corporation www elgar com November 2 2007 Document No M550001 01 Rev F ...

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Page 5: ... that facility AC input power is de energized prior to connecting or disconnecting the input output power cables Warning Lethal voltages may be present inside the power supply even when the AC input voltage is disconnected Only properly trained and qualified personnel should remove covers and access the inside of the power supply During normal operation the operator does not have access to hazardo...

Page 6: ... CIRCUITS EVEN WHEN THE POWER IS OFF CAPACITORS CAN RETAIN AN ELECTRICAL CHARGE USE SAFETY GLASSES DURING OPEN COVER CHECKS TO AVOID PERSONAL INJURY BY ANY SUDDEN FAILURE OF A COMPONENT WARNING SOME CIRCUITS ARE LIVE EVEN WITH THE FRONT PANEL SWITCH TURNED OFF SERVICE FUSE VERIFICATION AND CONNECTION OF WIRING TO THE CHASSIS MUST BE ACCOMPLISHED AT LEAST FIVE MINUTES AFTER POWER HAS BEEN REMOVED V...

Page 7: ...rference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to cor...

Page 8: ...ents of the European Community Since the Low Voltage Directive is to ensure the safety of the equipment operator universal graphic symbols see below have been used both on the unit itself and in this manual to warn the operator of potentially hazardous situations SAFETY SYMBOLS CAUTION Protective Conductor Terminal Risk of Electrical Shock CAUTION Alternating Current AC Refer to Accompanying Docum...

Page 9: ... PROGRAMMING 3 5 3 4 REMOTE VOLTAGE PROGRAMMING 3 6 3 5 REMOTE SENSING 3 6 3 6 REMOTE OUTPUT ON OFF CONTROL 3 7 3 7 REMOTE OVERVOLTAGE SET 3 7 3 8 AUTO PARALLEL OPERATION 3 8 3 9 AUTO SERIES OPERATION 3 8 3 10 AUTO TRACKING OPERATION 3 8 Chapter 4 CALIBRATION 4 1 4 1 INTRODUCTION 4 1 4 2 CALIBRATION AND ADJUSTMENTS 4 1 4 2 1 P62 Series Calibration Procedures 4 1 4 2 2 P63 P66 and D3 Series Calibra...

Page 10: ...TTL CMOS Voltage Supply 3 13 Figure 3 11 Remote Overvoltage Set Using DC Voltage Source 3 14 Figure 3 12 Auto Parallel Operation 3 14 Figure 3 13 Auto Series Operation 3 15 Figure 3 14 Auto Tracking Operation 3 15 Figure 4 1 P62 Internal Layout 4 12 Figure 4 2 P63 P66 D3 Internal Layout 4 13 Figure 4 3 P63 P66 D3 Converter Card 4 14 Figure 4 4 P83 P86 Internal Layout 4 15 Figure 4 5 P83 P86 Conver...

Page 11: ...ame output voltage or two with different output voltages The power supplies of each series are constant current constant voltage supplies with an automatic crossover feature The P62 Series models provide up to 3000 watts the P63 models up to10 kilowatts the P83 up to 15 kilowatts the P66 models up to 20 kilowatts and the P86 up to 30 kilowatts each over a wide range of voltage and current levels T...

Page 12: ...Density Power Factor 19 00 in 18 00 in 3 50 in 45 lbs max 190 253 VAC 47 to 63 Hz Single 2 wire plus gnd 0 1 of max output voltage 0 2 of max output current A 30 step load will recover to within 2 of original value within 10ms 0 05 of set point per 8 hrs after warm up and at a fixed line load and temp On Off control via contact closure 6 120 VDC or 12 240 VAC and TTL or CMOS switch output voltage ...

Page 13: ...ient Ambient Temperature Operating Storage Cooling Agency Approvals excluding 600 volt models 0 5k ohms 0 5k ohms 0 5 10 VDC 0 5 10 VDC Terminals are provided to sense output voltage at point of load Maximum line drop 3 of rated voltage per line or 3V whichever is less 0 02 C of max output voltage rating for voltage set point 0 03 C of max output current rating for current set point 0 to 50 C 20 t...

Page 14: ...in 10 5 in 120 lbs max 163 lbs max 208 230 VAC tested to 190 253 VAC 400 VAC tested to 360 440 VAC 480 VAC tested to 432 528 VAC 47 to 63 Hz 3 phase 3 wire plus ground 0 1 of max output voltage 0 5 of max output current A 30 step load will recover to within 2 of original value within 10ms 0 05 of set point after 8 hr warm up at fixed line load and temp On Off control via contact closure 6 120 VDC ...

Page 15: ...cient Ambient Temperature Operating Storage Cooling Agency Approvals excluding 600 volt models 0 5k ohms 0 5k ohms 0 5 VDC or 0 10 VDC 0 5 VDC or 0 10 VDC Terminals are provided to sense output voltage at point of load Maximum line drop 3 of rated voltage per line or 3V whichever is less 0 02 C of max output voltage rating for voltage set point 0 03 C of max output current rating for current set p...

Page 16: ... 76 115 153 192 230 150 13 20 33 66 100 133 166 200 200 10 15 25 50 75 100 125 150 250 8 12 20 40 60 80 100 120 300 6 6 10 16 33 50 66 83 100 400 5 7 5 12 15 37 50 62 75 600 5 5 11 16 22 27 33 Note Dual output supplies are available in the P63 3U chassis with a combination of any two voltages and 3300 watts per voltage 150 mV P60 P80 D3 120V 5 15V 30 mV RMS 30 mV RMS Output P P Ripple Typical 20 6...

Page 17: ...xternal connections for the P62 P63 P66 P83 P86 and D3 Series models respectively Tables 2 3 and 2 4 provide input and output connection descriptions by power supply type For permanently connected equipment a readily accessible disconnect device shall be incorporated in the fixed wiring For pluggable equipment the socket outlet shall be installed near the equipment and shall be easily accessible T...

Page 18: ...f obstructions Follow the instructions in paragraphs 3 2 through 3 10 for setup and operation of the equipment Table 2 1 2kW to 3kW High Series Input Output Connectors CONNECTOR FUNCTION CONNECTS TO FL1 AC FL1 AC FL1 AC CHASSIS GND Pos Bus Bar Neg Bus Bar Pos Threaded Stud Neg Threaded Stud J1 Prime Power Input Std with opt 3 phase Output Power 60 volt models see Table 2 3 80 volt models see Table...

Page 19: ...AC FL1 AC CHASSIS GND Pos Bus Bar Neg Bus Bar Pos Threaded Stud Neg Threaded Stud J1 Prime Power Input Output Power 60 volt models see Table 2 3 80 volt models see Table 2 3 Control Interface 200 240 VAC Std 47 63 Hz 360 440 VAC option 432 528 VAC option User load s See Table 3 1 for a Description M550001 01 2 3 ...

Page 20: ...es for 3 8 bolts Bus Bar with three holes for 3 8 bolts Terminal Block with 10 32 screws 3 8 Threaded Studs 3 8 Threaded Studs Table 2 4 Input Connection Descriptions INPUT VOLTS PHASE COUNT P62 NON MODULAR P63 P83 D3 NON MODULAR P66 P86 MODULAR 220 230 1 phase 8 32 NA NA 208 3 phase 8 32 20 20 400 3 phase NA 10 32 20 480 3 phase NA 10 32 20 Note Observe the maximum torque specification indicated ...

Page 21: ...V MI TA TBS SA AVB SIS FEP FEPB RHH THHN XHHW 14 20 20 25 25 12 25 25 30 30 10 30 35 40 40 8 40 50 55 55 6 55 65 70 75 4 70 85 95 95 3 85 100 110 110 2 95 115 125 130 1 110 130 145 150 0 125 150 165 170 00 145 175 190 195 000 165 200 215 225 0000 195 230 250 260 TEMPERATURE RATING OF COPPER CONDUCTOR CURRENT RATING For higher ratings wires can be paralleled or refer to the National Electrical Code...

Page 22: ... 2 1 through 2 6 show the outlines and overall dimensions for the P product lines Figure 2 1 P62 Outline Drawing 2kW to 3kW Output Voltage 60 V POWER VOLTAGE CURRENT PROGRAM REMOTE PROGRAM REMOTE J1 DC OUTPUT POS NEG J3 IEEE ADDRESS J2 M550001 01 2 6 ...

Page 23: ...Figure 2 2 P62 Outline Drawing 2kW to 3kW Output Voltage 80 V POWER VOLTAGE CURRENT DC OUTPUT NEG POS IEEE ADDRESS J2 J3 PROGRAM REMOTE REMOTE PROGRAM J1 M550001 01 2 7 ...

Page 24: ...Figure 2 3 P63 D3 Outline Drawing 3 3KW to 10KW Output Voltage 60 V POWER POWER VOLTAGE VOLTAGE CURRENT CURRENT VOLTAGE CURRENT M550001 01 2 8 ...

Page 25: ...Figure 2 4 P83 Outline Drawing 5 0KW to 15KW Output Voltage 80 V POWER VOLTAGE CURRENT M550001 01 2 9 ...

Page 26: ...Figure 2 5 P66 Outline Drawing 13 3KW to 20kW Output Voltage 60 V M550001 01 2 10 POWER VOLTAGE CURRENT ...

Page 27: ...Figure 2 6 P86 Outline Drawing 20KW to 30KW Output Voltage 80 V M550001 01 2 11 POWER VOLTAGE CURRENT ...

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Page 29: ...ifferent heights the controls remain the same across the entire series Table 3 1 provides a description of all operator controls and indicators 1 2 3 4 5 6 7 8 9 10 11 Figure 3 1 P6x P8x and D3 Series Controls and Indicators For the D3 Series the Controls and Indicators for PS1 are on the top half of the front panel for PS2 they are on the bottom half of the panel M550001 01 3 1 ...

Page 30: ... Measures voltage output Measures current output Adjusts overvoltage trip level Indicates the power supply is operating in the voltage mode Indicates the power supply is operating in the current mode Indicates output voltage has exceeded preset level and power supply output is turned off Indicates internal fault such as bias supply thermal or converter failure Reads back the actual overvoltage tri...

Page 31: ... sets the overvoltage trip level 0 5 VDC 0 100 Voltage programming return Used with J1 9 J1 15 or J1 21 and must be referenced to or within 3V of the circuit common Remote on off Switch relay contacts or a direct short between this terminal and circuit common turns on the unit Common Circuit Output current monitor 0 10 VDC equals 0 100 rated current 0 5 VDC local voltage control monitor Remote vol...

Page 32: ...Voltage programming return Used with J1 9 J1 15 or J1 21 and must be referenced to or within 3V of the circuit common 1 milliamp current source for remote voltage programming using resistance 0 5k ohm resistor referenced to common will program the output voltage from 0 100 1 milliamp current source for remote current programming using resistance 0 5k ohm resistor referenced to common will program ...

Page 33: ...rogramming is used for applications that require the output current be programmed controlled from a remote source An external resistance or external voltage source may be used as a programming device When using remote current programming a shielded twisted pair hookup wire is recommended to prevent noise interference with programming signals a Remote Current Programming Using Resistance The resist...

Page 34: ...ches or relays are used to program different levels make before break contacts are recommended Note that if an external resistance is used for remote programming the voltage programming return VP RTN terminal J1 20 must be connected directly to or within 3 volts of the power supply common terminal J1 24 See Figure 3 5 for connection requirements 2 External Voltage Programming Using a 5 VDC or 10 V...

Page 35: ... an external 12 to 240 VAC or 6 to 120 VDC or TTL CMOS source Application of AC DC or high state TTL CMOS voltage will turn on the power supply See Figures 3 9 and 3 10 for connection requirements 3 7 REMOTE OVERVOLTAGE SET A remote DC voltage source can be connected externally between terminals J1 3 REM OV SET and J1 6 COM to set the output overvoltage trip level A 0 5 VDC signal equals 0 100 of ...

Page 36: ...3 9 AUTO SERIES OPERATION In the auto series mode of operation a master slave configuration is established No more than two power supplies may be in series With two supplies connected in series one is established a master and the remaining unit as a slave The master supply must always be the most positive unit Connect Rx between the master positive output and the slave J1 15 VP 10V and connect the...

Page 37: ... desired Vout rated Vout MR master desired Vout rated Vout Example It is desired to have a slave power supply rated at 20 VDC and operated at 12 VDC while the master power supply rated at 10 VDC is operated at 8 VDC The Slave Ratio SR 12V 20V 60 The Master Ratio MR 8V 10V 80 Then The Slave Master Ratio SMR 60 80 75 And Rx kohms 10 75 10 13 33 10 3 33 kohms Note The slave ratio SR must always be le...

Page 38: ... PROGRAM Figure 3 3 Remote Current Programming Using Resistance 1 13 23 IP RTN COM 6 16 IP 10V IP 5V 10 0 5 VDC VOLTAGE SOURCE 0 10 VDC VOLTAGE SOURCE Figure 3 4 Remote Current Programming Using 0 5 VDC or 0 10 VDC Voltage Source M550001 01 3 10 ...

Page 39: ... PROGRAM Figure 3 5 Remote Voltage Programming Using Resistance 1 13 20 VP RTN COM 6 15 VP 10V VP 5V 9 0 5 VDC VOLTAGE SOURCE 0 10 VDC VOLTAGE SOURCE Figure 3 6 Remote Voltage Programming Using 0 5 VDC or 0 10 VDC Voltage Source M550001 01 3 11 ...

Page 40: ...SUPPLY OUTPUT TERMINALS 1 2 3 J3 LOAD Figure 3 7 Remote Sensing Operation at the Load 1 25 14 6 ON OFF 5 Figure 3 8 Remote On Off Control by Contact Closure M550001 01 3 12 ...

Page 41: ... ON OFF 1 AC OR DC SOURCE ISO RTN 2 Figure 3 9 Remote On Off Using Isolated AC or DC Voltage Source 25 14 ISO TTL CMOS 1 ISO RTN 2 Figure 3 10 Remote On Off Using Isolated TTL CMOS Voltage Supply M550001 01 3 13 ...

Page 42: ...ote Overvoltage Set Using DC Voltage Source LOAD PS1 OUTPUT 1 25 14 5 6 1 5 6 25 IP RTN 14 16 IP 10V IMON 7 PS1 MASTER PS2 SLAVE PS2 OUTPUT ADDITIONAL SLAVES UP TO FOUR TOTAL MAY BE CONNECTED IN SAME MANNER AS FIRST Figure 3 12 Auto Parallel Operation M550001 01 3 14 ...

Page 43: ...PS1 RATED Vout PS2 RATED Vout 20 EXAMPLE FOR A 20 VOLT RATED PS1 AND A 10 VOLT RATED PS2 RX 2 20 10 20 40K ohms Figure 3 13 Auto Series Operation LOAD PS1 OUTPUT 1 25 14 5 6 5 6 24 COM 15 PS1 MASTER PS2 SLAVE PS2 OUTPUT LOAD 20 VP RTN Rx 19 VMON VP 10V Figure 3 14 Auto Tracking Operation M550001 01 3 15 ...

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Page 45: ... to avoid both the input terminals and while the supply is enabled the output terminals Only authorized personnel should perform this procedure The calibration Test Setup procedures require the following remove prime power then connect the power supply to a resistive load capable of full rated voltage and current Connect a precision current shunt in series with either the positive or negative outp...

Page 46: ...d install jumper J9 on the converter assembly 2 Connect a load of minimum 5 heavier than full rated power and a DMM across external current shunt 3 Rotate front panel voltage control fully clockwise 4 Rotate front panel current control fully counterclockwise 5 Apply prime power to power supply and push the front panel switch to the ON position 6 Rotate front panel current control fully clockwise o...

Page 47: ...current feedback scaler U8 pin 1 and the common circuit Set DC voltage scale to read 5 0 volts 3 Connect a second DMM across the external current shunt 4 Rotate front panel voltage control fully clockwise 5 Rotate front panel current control fully counterclockwise This changes the operation of the power supply from the voltage to the current mode 6 Apply prime power to power supply and push the fr...

Page 48: ...supply Remove jumper J7 from all converter assemblies not being calibrated Leave jumper installed on assembly to be calibrated 2 Connect a load of minimum 5 heavier than full rated power and a DMM across external current shunt 3 Rotate front panel voltage control fully clockwise 4 Rotate front panel current control fully counterclockwise 5 Apply prime power to power supply and push the front panel...

Page 49: ...ors to discharge 7 Replace jumper J7 Current Feedback Amplifier Full Scale Calibration 1 Remove prime power to the power supply Remove J7 on all converter assemblies not being calibrated Leave jumper installed on assembly to be calibrated 2 Connect DMM between TP2 U2 pin 1 and TP1 common return Set DC voltage scale to read 5 0 volts 3 Connect a second DMM across the external current shunt 4 Rotate...

Page 50: ...blies must be calibrated prior to the calibration of control assembly A1 Refer to Figures 4 4 an 4 5 for locations of components on the converter assembly Primary Current Limit Calibration 1 Remove prime power to the power supply Remove jumpers J11 and J12 on all converter assemblies not being calibrated Leave jumpers installed on assembly to be calibrated 2 Connect a load of 5 heavier than full r...

Page 51: ...cuit and the fault light lights Do not adjust beyond this point 12 Push the front panel switch to the OFF position Remove prime power from the power supply and wait three minutes minimum for the filter capacitors to discharge 13 Rotate R50 three turns clockwise 14 Repeat steps 1 through 13 for the balance of converter assemblies A3 through A5 Current Limit Calibration 1 Remove prime power to the p...

Page 52: ...return to the converter assembly to be calibrated 4 Adjust R25 until DMM between J10 3 and J10 10 indicates 15 00mVDC 5 Repeat steps 3 and 4 for the balance of the converter assemblies A3 through A5 6 Remove prime power from the power supply and wait three minutes minimum for filter capacitors to discharge 7 Replace jumpers J11 and J12 Current Feedback Amplifier Full Scale Calibration 1 Remove pri...

Page 53: ...lliamps and 2 milliamps range 3 Apply power to power supply and push the front panel switch to the ON position 4 Adjust R47 for 1 000 milliamps on DMM 5 Remove power from power supply Current Reference The current reference is a precision current source consisting of Q2 and associated components Calibration is accomplished by adjusting R50 The following sequence is recommended For J1 and J2 refer ...

Page 54: ...rrent control fully counterclockwise 5 Apply power to power supply and push front panel switch to the ON position 6 Adjust R26 until the power supply output voltage starts to increase in the normal polarity Reverse adjustment direction of R26 until output voltage decreases to zero reading on the DMM Do not continue adjustment when output reads zero volts 7 Remove power from power supply 8 Remove D...

Page 55: ...r current meter and R39 on control assemblies for the voltage meter until both meters read zero 2 Meter Full Scale Calibration The full scale adjustment for the digital panel meters U1 and U4 is adjusted by R6 and R11 respectively R6 is for full scale voltage meter calibration and R11 is for full scale current meter calibration Both resistors are accessible from inside the power supply with the co...

Page 56: ...INPUT FILTER CONVERTER ASSEMBLY CONTROL ASSEMBLY Figure 4 1 P62 Internal Layout M550001 01 4 12 ...

Page 57: ...CONTROL ASSEMBLY BIAS ASSEMBLY CONVERTER ASSEMBLIES INPUT FILTER AC DISTRIBUTION BOARD POWER SWITCH BOARD POWER SWITCH BOARD POWER SWITCH BOARD Figure 4 2 P63 P66 D3 Internal Layout M550001 01 4 13 ...

Page 58: ...3 R19 Q6 R2 CR4 Q8 CR9 CR8 Q9 C31 U6 Q11 CR10 CR11 Q10 R26 U7 U9 R73 R68 T2 R64 J7 J4 J5 J6 J9 Q15 Q14 Q13 Q16 Q7 Q12 U8 CURRENT FULL SCALE CURRENT LIMIT CURRENT ZERO CONVERTER ENABLE GROUND RETURN POINT R31 Figure 4 3 P63 P66 D3 Converter Card M550001 01 4 14 ...

Page 59: ...Figure 4 4 P83 P86 Internal Layout M550001 01 4 15 ...

Page 60: ...Figure 4 5 P83 P86 Converter Card M550001 01 4 16 ...

Page 61: ...Figure 4 6 P63 P66 Converter Card M550001 01 4 17 ...

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Page 63: ...t five minutes after power has been removed via external means all circuits and or terminals to be touched must be safety grounded to the chassis 5 2 PREVENTIVE MAINTENANCE Preventive maintenance for the P and D series consists of scheduled inspection and cleaning 1 Schedule Table 5 1 lists the preventive maintenance routines and the recommended performance intervals 2 Inspection Table 5 2 lists t...

Page 64: ...e frayed worn or missing insulation Corrosion loose cracked or dirty connections Short circuits arcing corrosion overheating Dirt and corrosion Clean contacts with solvent moistened cloth soft bristle brush small vacuum or low compressed air Replace connectors damaged deeply corroded or improperly seated in mating connector Clean with cloth moistened with soapy water Repair or replace defective wi...

Page 65: ...is Replacement fuses are in Table 5 3 Table 5 3 Fuse Values Power Supply PCB Part Number Reference Value Mfr Part No P62 series 10 010 154 00 F1 250 Volt 3 8 Amp Littlefuse 263 375 10 010 154 00 F2 F3 F4 600 Volt 30 Amp Littlefuse KLKD30 10 010 214 00 F1 600 Volt 30 Amp Littlefuse KLKD30 P63 P66 series 10 010 156 00 F1 600 Volt 30 Amp Littlefuse KLKD30 10 010 156 00 F2 F3 F4 250 Volt 20 Amp Bussma...

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