CONTROLLED POWER 700A User manual

10KVA - 15KVA
208V, 240V, 480V or 600V INPUT
208/120V, 240/120V, 380/220V, 480/277V OR 600/346V OUTPUT
THREE PHASE, 50Hz or 60Hz
113121-Rev 3
SERIES 700A POWER PROCESSOR
OWNERS MANUAL
IMPORTANT - SAVE THESE INSTRUCTIONS - PLEASE READ THIS MANUAL
BEFORE USING EQUIPMENT
TROY, MICHIGAN

The following symbol indicates that caution should be taken when performing the
process required in this manual. Damage to the unit or personal harm could hap-
pen if proper precautions are not taken.
The following symbol indicates that there is a risk of electrical shock if proper
precautions are not followed. Only qualied personnel should perform the actions
required in this manual.
Shock Hazard
Caution

PUBLISHED JULY, 2005 - ALL RIGHTS RESERVED: REPRODUCTION WITHOUT PERMISSION IS PROHIBITED
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ABOUT THIS MANUAL
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Clicking any blue text will take you to that section of our website.
FEATURES AND SPECIFICATIONS .................................................................... 4
RECEIVING, INSPECTING AND STORING THE UNIT........................................ 5
REMOVING THE UNIT FROM THE PALLET........................................................ 6
SAFETY PRECAUTIONS...................................................................................... 7
PRELIMINARY INSTALLATION ............................................................................ 8
INSTALLATION ................................................................................................... 10
OPTION INSTALLATION..................................................................................... 12
BYPASS OPERATION AND MONITORING........................................................ 15
START UP ........................................................................................................... 16
PREVENTIVE MAINTENANCE........................................................................... 17
PERFORMANCE CHECKLIST ........................................................................... 18
GENERAL TROUBLESHOOTING ...................................................................... 19
WARRANTY ........................................................................................................ 20
CUSTOMER SUPPORT...................................................................................... 21
APPENDIX A ....................................................................................................... 22
CABINET OUTLINE........................................................................................ 23
NOTES ........................................................................................................... 25
TABLE OF CONTENTS

4
Controlled Power Company engineers and manufactures the industry’s highest quality power processors and voltage regulators,
capitalizing on 40 years of expertise. We have an enviable reputation for quality, which is reected in the design, workmanship,
and performance of our products.
Subjecting commercial and industrial electrical systems to a harsh, “polluted” electrical environment increases downtime, main-
tenance costs, and lost productivity. Maintaining steady, spike-free voltage and keeping ground noise away from the controls,
increases the reliability of electronic equipment, contributes to the overall integrity of data, and enhances workow and produc-
tivity.
Controlled Power Company’s front access Series 700A Power Processor is a solid-state, automatic voltage regulator which
guards against both high and low voltage conditions. The Series 700A easily corrects wide input voltage deviations to well within
the safe operating limits for information technology equipment as recommended by CBEMA and ITIC. The power protection that
the Series 700A delivers, meets the IEEE and ANSI standards that dene power anomalies, occurrences, and their impact on
operations.
Extended Line Voltage Regulation
Optional Extended Range for Intermittent Duty only:
Input Line Voltage: +10%, - 40%
Output Line Voltage: + 5%, - 6% typical
+13%
+10%
INPUT
Extended
Protection
- 40%
+8% +5% - 6% -9%
OUTPUT
Extended Input
Range P rotection
+8% +3% - 3% -13%
OUTPUT
Extended Input
Range P rotection
+15%
+10%
INPUT
Standard
Protection
-20%
-30%
Wide Range Protection Extended Range Protection
- 43%
Line Voltage Regulation
Input Line Voltage: +10%, - 20%
Output Line Voltage: ± 3% typical
Features & Benets
• 7-tap, microprocessor-controlled for tight voltage regu-
lation, accuracy, and stability.
• Precisely maintains correct voltage to ± 3% within
one cycle, and maintains regulation during extended
brownouts.
• Low output impedance transformer minimizes voltage
distortion and sags commonly associated with high
surge currents.
• Triple-shielded isolation transformer provides a noise-
free ground, attenuates voltage spikes and transients,
and re-establishes the N-G bond.
• Internal manual bypass option maintains system isola-
tion, voltage transformation, and power conditioning.
• Superior compatibility with dynamic loads.
• Increased surge capability, without the need for auto-
matic bypassing, provides full-time power conditioning.
• High-efciency design results in lower operating cost.
Product Specications
• Input Operating Voltage Range: +10%, - 20% from nomi-
nal (Extended regulation range options available.)
• Input Frequency: 60 Hz, ± 3 Hz
• Input Power Factor: > .99 PF with resistive load
• Reected Harmonics: Triplen harmonics are not reect-
ed to the utility under non-linear loads
• Output Line Voltage Regulation: ± 3% from nominal
• Response Time: < 1/2 cycle
• Correction Time: 1 cycle
• Load Regulation: 2.5% typical, no load to full load
• Overload Rating: 200% for 10 seconds; 1000% for 1
cycle
• Noise Attenuation:
Common Mode: 146 dB
Transverse Mode: 3 dB down at 1 kHz; 40 dB down
per decade to below 50 dB with a resistive load
• Transient Voltage Suppression: Meets ANSI C62.41
Category B-3
• Efciency: 96% - 97% typical, model and load depen-
dant
FEATURES AND SPECIFICATIONS

5
RECEIVING, INSPECTING AND STORING THE UNIT
INSPECTING THE POWER PROCESSOR
Upon receipt of the unit, visually inspect for shipping damage. If any damage is found, the Purchaser must contact
the Carrier immediately and le a shipping damage claim.
NOTE: Be sure to remove the top and side panels, and inspect the inside of the unit for shipping damage.
If any internal damage has occurred or any external damage that could affect the operation of the unit, please contact
Controlled Power Company.
FOR ASSISTANCE CALL 1-800-521-4792 X222
STORING
If it is necessary to store the unit for a period of time before it is installed, be sure to place the unit in a clean, dry
area. To prevent excessive dust from accumulating on the unit, it is advisable to protect it by replacing it in the
original container (if possible). If the original container is not available it is recommended that all openings that lead
internally into the unit are covered so that dust, water or any other substance cannot enter the internal components
of the system. The unit must be handled at all times with the same care you would give to any piece of precision
industrial equipment.
IMPORTANT NOTICE
This shipment has been carefully inspected, checked and properly packaged at our company.
When it was delivered to the carrier it was in good condition and technically it became your property
at that time. Thus, any damage, whether obvious or hidden, must be reported to the transportation company
within FIVE days of receipt of the shipment at your premises to avoid forfeiting claims for damages.
FOR ALL SHIPMENTS DAMAGED IN TRANSIT
Leave the items, packing material and carton “AS IS”. Notify your carrier’s local ofce
and ask for immediate inspection of the carton and contents.
After inspection has been made by the carrier, and you have received acknowledgment in writing as to the
damage, notify our Customer Service Department to make any required repair arrangements.
It is your responsibility to follow the above instructions or the carrier will not honor any claims for damage.
Also, if there are any shortages or questions regarding this shipment, please notify us within FIVE days.
Please note that we cannot be responsible for any service work or back-charges unless authorized
by us in writing, before the work is performed.

6
Option ERR1040 and certain voltage selections and options may change cabinet size and weight
- see “Appendix A - Cabinet Outline” for alternate cabinet congurations.
REMOVING THE POWER PROCESSOR FROM PALLET
Please take special care when removing the unit from the pallet. Proper equipment must be used for lifting and mov-
ing, and all safety precautions should be taken. Each unit is bolted to a wooden pallet. In order to properly remove
the cabinet from the pallet, all bolts connecting the unit to the pallet must be removed completely. The unit can then
be lifted off the skid using a pallet jack or fork lift. When lifting the unit off of the pallet, be sure to take proper safety
precautions. Serious injury and/or unit damage can result otherwise.
REMOVING THE UNIT FROM THE PALLET
10-15KVA

7
SAFETY PRECAUTIONS
**** WARNING ****
THERE ARE DANGEROUSLY HIGH VOLTAGES PRESENT WITHIN THE
ENCLOSURE OF THE POWER SUPPLY SYSTEM.
CAUTION MUST BE TAKEN WHEN WORKING WITH THE SYSTEM.
IT IS RECOMMENDED THAT ALL WORK BE PERFORMED BY QUALIFIED
ELECTRICAL PERSONNEL ONLY.
**** CAUTION ****
RISK OF ELECTRICAL SHOCK AND HIGH SHORT CIRCUIT CURRENT.
THE FOLLOWING PRECAUTIONS SHOULD BE OBSERVED
WHEN WORKING ON THE UNIT:
1) REMOVE WATCHES, RINGS, OR OTHER METAL OBJECTS.
2) USE TOOLS WITH INSULATED HANDLES.
3) WEAR RUBBER GLOVES AND BOOTS.
**** CAUTION ****
- FOLLOW ALL STANDARD AND LOCAL ELECTRICAL CODES.
- DO NOT ALLOW WATER OR FOREIGN OBJECTS TO GET INSIDE THE UNIT.
- DO NOT PLACE OBJECTS OR LIQUIDS ON TOP OF THE UNIT.
- DO NOT LOCATE THE UNIT NEAR RUNNING WATER.

8
PRELIMINARY INSTALLATION
INSTALLATION CONSIDERATIONS
Prior to installing the Series 700A, be sure to take into consideration the site you have selected. Power Processor
produce heat and therefore require ventilation as well as accessibility. Consider these factors.
- Ventilation - Input Source Voltage
- Size of the Power Processor - Receiving Facilities
- Weight Load - Distribution of Power
- Audible Noise Requirements - Room Temperature
- Remote Emergency Power Off (Repo) - Clearances
- Monitors - Accessibility
- Options - Excessively Long Power Runs
- Clean Environment - Proper Ground Techniques
CHOICE OF LOCATION
The unit has been completely inspected and extensively tested under various load conditions prior to shipment.
Care to install it at a proper location will assure long trouble-free operation.
The unit is air cooled with the air intake at the bottom and exhausts at the top, front or at the sides. Therefore, it
should be installed in a clean, dry place with enough clearance to allow a free ow of air. Allow enough space for
maintenance on all four sides of the unit. See illustration below.
24.00
Option ERR1040 and certain voltage selections and options may change cabinet size and weight
- see “Appendix A - Cabinet Outline” for alternate cabinet congurations.

9
The unit is constructed using an isolation transformer and is considered to be a
“separately derived system” It should be grounded in accordance with the NFPA 70
article 250.20 “Alternating-Current Circuits and Systems to Be Grounded”, article
250.20(D) “Separately Derived Systems” and article 250.30 “Grounding Separately
Derived Alternating-Current Systems”
REFER TO THE LATEST EDITION OF THE NATIONAL ELECTRIC CODE
REQUIREMENTS FOR OVER-CURRENT PROTECTION AND WIRE SIZING.
*** CAUTION ***
To reduce the risk of re, use only on circuits provided with ampere
branch circuit protection, in accordance with the National Electric Code,
ANSI/NFPA 70.
WEIGHT, DIMENSIONS AND BTU’s
MODEL CONTINUOUS KVA FULL LOAD
BTU’s / HR DIMENSIONS * WEIGHT (LBS.) *
10KVA 10 1,025 21.5”W X 29”D X 30”H 440
15KVA 15 1,540 21.5”W X 29”D X 30”H 520
Stated BTU’s / Hr. is at 100% rated load, 100% duty cycle.
* Option ERR1040 and certain voltage selections and options may change cabinet size and weight - see “Appendix A - Cabinet Outline” for alternate cabinet
congurations.
NOMINAL OUTPUT CURRENT AT VARIOUS OUTPUT VOLTAGES
MODEL OUTPUT VOLTAGE
208/120V 380/220V 480/277V 600/346V
10KVA 28A 15A 12A 10A
15KVA 42A 23A 18A 14A
If unit is provide with no output circuit breaker option, output over-current protection and a disconnect device (circuit breaker) shall be provided by others.
NOMINAL INPUT CURRENT AT VARIOUS INPUT VOLTAGES
MODEL
INPUT VOLTAGE
208V
208V
INPUT
BREAK-
ER SIZE
220V
220V
INPUT
BREAK-
ER SIZE
240V
240V
INPUT
BREAK-
ER SIZE
380V
380V
INPUT
BREAK-
ER SIZE
480V
480V
INPUT
BREAK-
ER SIZE
600V
600V
INPUT
BREAK-
ER SIZE
10KVA 29A 40A 27A 35A 25A 35A 16A 20A 13A 15A 10A 15A
15KVA 44A 60A 41A 60A 38A 50A 24A 30A 19A 25A 15A 20A
If unit is provide with no input circuit breaker option, input over-current protection and a disconnect device (circuit breaker) shall be provided by others.
PRELIMINARY INSTALLATION CONTINUED

10
INSTALLATION
The unit is constructed using an isolation transformer and is considered to be a
“separately derived system” It should be grounded in accordance with the NFPA 70
article 250.20 “Alternating-Current Circuits and Systems to Be Grounded”, article
250.20(D) “Separately Derived Systems” and article 250.30 “Grounding Separately
Derived Alternating-Current Systems”
OPTION WIRING SHOULD BE DONE PRIOR TO CONNECTING
PRIMARY INPUT AND OUTPUT POWER LINES
Before installing the Power Processor make sure that the input
voltage and the output voltages match the unit’s specication plate.
INPUT WIRE SIZE, GROUNDING AND OUTPUT WIRING
A. Conduit should be used for both input and output wiring.
B. Input wire ampacity is specied in NEC table 310.15(B)(16). Specifying not more than 3 connections in a raceway
based on an ambient of 30°C and wire rated for 90°C (Note: amperages will need to be adjusted for 40° C
ambient applications). Ground wire sizing is specied in NEC table 250.122.
C. Input phase conductors are terminated to the input terminals provided. (See Figure A).
Input terminal wire range: #12 AWG. - #1/0 AWG.
D. Input Ground - An ILSCO TA-2/0 terminal allows wire sizes from #14AWG - #2/0AWG.
E. Output is a 4 wire (5 including ground). If four (4) current carrying conductors are used in a raceway the neutral
is assumed to be current carrying and the wire must be de-rated as indicated in the 2011 NEC table 310.15(B)
(16).
Example: 1. Assume #10 wire max current = 25 Amps.
2. Multiply 25 x .8 = 20
3. 20 Amps is max current for #10 wire in a raceway with 4 conductors.
F. Output connections are made directly to the output bus and/or to the load side (bottom) of the optional output
circuit breakers provided (refer to the units output breakers for proper lug wire range sizes). Output neutral and
ground bus are also provided. See Figure A. The load current is not to exceed 80% of the output breaker(s)
rating, and not to exceed the rated total current.
Output terminals consist of PK9 grounding bar. Wire range: #14AWG - #4AWG.
G. Output neutral to ground bonded during manufacturing of the Power Processor. Output neutral is already grounded
by the factory.
H. Installation is subject to local codes. Verify with a local electrical inspector.

11
INSTALLATION CONTINUED
FIGURE A
“
“
Option ERR1040 and certain voltage selections and options may change cabinet size and weight
- see “Appendix A - Cabinet Outline” for alternate cabinet congurations.

12
OPTION INSTALLATION
OPTION WIRING SHOULD BE DONE PRIOR TO CONNECTING
PRIMARY INPUT AND OUTPUT POWER LINES
RBS2020 REGULATOR BYPASS SWITCH
The Power Processor has a main isolation transformer and regulator. This option bypasses the regulator portion
of the Power Processor. The bypassing is done by manually setting the switch when the power is OFF. Factory
installed, there is no external wiring or set up required for this option. See “Bypass Operation and Monitoring” for
proper use.
ERR1040 EXTENDED REGULATION RANGE 1040
Provides +10% -40% voltage regulation range for intermittent duty only. Output Regulation +5%, -6%. Note: Extended
operation at voltages below -20% may cause the main input circuit breaker to trip on the thermal overload. Factory
installed, there is no external wiring or set up required for this option.
ERR2020 EXTENDED REGULATION RANGE 2020
Provides +20% -20% voltage regulation range for intermittent duty only. Output Regulation +/- 5%. Note: Extended
operation at voltages below -20% may cause the main input circuit breaker to trip on the thermal overload. Factory
installed, there is no external wiring or set up required for this option.
ERR2030 EXTENDED REGULATION RANGE 2030
Provides +20% -30% voltage regulation range for intermittent duty only. Output Regulation +5, -6%. Note: Extended
operation main input circuit at voltages below -20% may cause the breaker to trip on the thermal overload. Factory
installed, there is no external wiring or set up required for this option.
ERR1525 EXTENDED REGULATION RANGE 1525
Provides +15% -25% voltage regulation range for intermittent duty only. Output Regulation +5%, -6%. Note: Extended
operation at voltages below -20% may cause the main input circuit breaker to trip on the thermal overload. Factory
installed, there is no external wiring or set up required for this option.
UOV2020 UNDER/OVER VOLTAGE SHUTOFF
When the output voltage goes above or below the preset value, the unit electronically shuts off. The preset voltages
can be set from 75% of nominal up to 115% of nominal. It does not trip the main breaker; however, the system is
reset by cycling the input breaker. The under/over ranges can be adjusted as required. Factory installed and set,
there is no external wiring or set up required for this option.
PSO2020 UNDER/OVER VOLTAGE AND LOSS OF POWER TRIP
When the output voltage goes above or below the preset value or detects a loss of power, the shunt trip coil is
energized, which in turn shuts off the main breaker. The preset voltages can be set from 75% of nominal up to
115% of nominal. The circuit breaker must be reset manually. Includes shunt trip breaker. The under/over ranges
can be adjusted as required. Factory installed and set, there is no external wiring or set up required for this option.

13
OPTION INSTALLATION CONTINUED
REP2020 REMOTE EMERGENCY POWER OFF (REPO)
Consists of a guarded “Emergency OFF” button which when depressed, will shunt trip the input circuit breaker of
the Power Processor. The REPO station can be remotely located. Supplied with 50 ft. cable and 24VDC shunt trip
breaker. The main circuit breaker must be manually reset to re-energize the system. Connect the REPO assembly
to the provided connector as shown below. Option ERR1040 and certain voltage selections and options may change
cabinet size and weight - see “Appendix A - Cabinet Outline” for alternate cabinet congurations.
STC2020-120 SHUNT TRIP
Adds to the main input circuit breaker; consisting of 120VAC shunt trip coil solenoid. When the shunt trip coil is
energized, the main input circuit breaker is de-energized. A manual reset is required. 120VAC supplied by customer.
Refer to the circuit diagram supplied with the unit for wiring instructions. Option ERR1040 and certain voltage
selections and options may change cabinet size and weight - see “Appendix A - Cabinet Outline” for alternate cabinet
congurations.
OPTION WIRING SHOULD BE DONE PRIOR TO CONNECTING
PRIMARY INPUT AND OUTPUT POWER LINES
REAR VIEW
OPTIONAL REPO STATION CONNECTION
50FT CORD FROM BELL BOX
SHUNT TRIP TERMINALS
CONSISTS OF A-B TERMINAL
BLOCKS, 300V, 25A MAX
WIRE RANGE 22AWG-14AWG.
120VAC SUPPLIED BY CUSTOMER
OPTIONAL
SHUNT TRIP
TERMINALS

14
OPTION INSTALLATION CONTINUED
SHARK100V1 - 0 THREE PHASE METER (30KVA and above)
Digitally displays the output voltages L-L, L-N,and output currents. Factory installed and set, there is no external wiring
or set up required for this option. For function and use, see the monitor manual supplied with the Power Processor.
SHARK100V4 - 0 THREE PHASE METER
Digitally displays Voltage, Current, kVA, kVAh, kW, kWh, kVARs, kVARh, power factor frequency, % THD, % Load
bar, with limits exceeded alarm. Includes RS485 communication using MODBUS or DNP 3.0 protocols. Factory
installed and set, there is no external wiring or set up required for this option. For function and use, see the monitor
manual supplied with the Power Processor.
SHARK200V4 - 0 ADVANCED THREE PHASE METER
Digitally displays Voltage, Current, kVA, kVAh, kW, kWh, kVARs, kVARh, power factor, frequency, % THD, % Load
bar, plus data-logging with time stamp and programmable limit alarms on all measured parameters. Features a
waveform scope to view the real-time waveform for voltage and current. Includes RS485 communication using
MODBUS or DNP 3.0 protocols. Factory installed and set, there is no external wiring or set up required for this
option. For function and use, see the monitor manual supplied with the Power Processor.
SHARK200V6 - 0 ADVANCED THREE PHASE METER WITH POWER QUALITY MONITORING
Same features as the Shark200V4, plus power quality monitoring with event logging, advanced harmonic analysis,
and a 512 samples per cycle waveform recorder. Factory installed and set, there is no external wiring or set up
required for this option. For function and use, see the monitor manual supplied with the Power Processor.
OPTIONAL COMMUNICATIONS CAPABILITY ON SHARK200V4 AND SHARK200V6 (SELECT UP TO 2)
INP100S - Ethernet TCP / IP and MODBUS TCP Web Card
RO1S - Form C Relay Contacts Board, 2 inputs/outputs
20mAOS - 4 channel 4-20mA Current Outputs
For function and use, see the monitor manual supplied with the Power Processor.
OPTION WIRING SHOULD BE DONE PRIOR TO CONNECTING
PRIMARY INPUT AND OUTPUT POWER LINES

15
*** CAUTION ***
PRIOR TO SWITCHING FROM ONE POSITION TO ANOTHER -
TURN OFF THE AC INPUT BREAKER. FAILURE TO DO SO WILL
RESULT IN SERIOUS DAMAGE TO THE POWER PROCESSOR.
BYPASS SWITCH (RBS2020)
The manual by-pass switch is a break before make switch located on the rear of the Model 700A. The manual
bypass switch is used to bypass all power electronics in case of failure.
NORMAL MODE
With the switch in the normal position, the Model 700A will provide clean and regulated power to the critical loads.
The Model 700A should have the switch in the normal position unless a failure has occurred.
BYPASS MODE
A manually operated rotary bypass switch bypasses the regulator portion of the system. The transformer and
suppression circuitry remains in the circuit when in the bypass mode. In the bypass position, the unit will not
regulate the incoming voltage. The Model 700A should be placed in the bypass position if a failure of the system
has occurred. This provides the loads with some protection until a service technician arrives.
STANDARD MONITORING
Overtemp sensing devices are mounted at critical points on the SCR regulating assembly and the main transformer.
If an overtemp condition exists the unit will electronically shut off, however, the cooling fans will continue to operate.
The “ALERT” light will illuminate and hold until the overtemp is corrected. The main AC input breaker must be turned
off in order to reset the “ALERT” light.
ALERT LIGHT - An indicator light indicates if the output has been disabled by one of the following conditions:
(1) Transformer over-temperature (2) SCR thermal over-temperature
INDICATING LAMPS - Output ON indicating lamps are provided for each phase.
3 PHASE MONITORING OPTIONS
POWER PROCESSOR - Shark100V1-0 (30KVA and above only), AOM2020 (30KVA and above only), Shark100V4-0
(30KVA and above only), Shark200V4-0 (30KVA and above only), Shark200V6-0 (30KVA and above only).
All monitoring options available on the Power Processor are either mounted on the front or the back of the cabinet.
For function and use, see the monitor manual supplied with the Power Processor.
Contact the Customer Support Department if you wish to add this option.1-800-521-4792.
REMOTE EMERGENCY POWER OFF (REPO) OPTION
The REPO is operated by a remote push button that when depressed will shunt trip the Series 700A input breaker
and disable the unit. This option may be added to units in the eld.
BYPASS OPERATION AND MONITORING

16
START UP
*** WARNING ***
THERE ARE DANGEROUSLY HIGH VOLTAGES PRESENT WITHIN THE ENCLOSURE OF THE POWER
SUPPLY SYSTEM. CAUTION MUST BE TAKEN WHEN WORKING WITH THE ENCLOSURE. IT IS
RECOMMENDED THAT ALL WORK BE PERFORMED BY QUALIFIED ELECTRICAL PERSONNEL ONLY.
NOTE: INITIAL START-UP SHOULD BE PERFORMED WITH NO LOAD ON SYSTEM.
1. Re-install all panels that may have been removed during installation.
2. Make sure the input circuit breaker is in the off position.
3. Energize the primary building power.
4. Turn on the main AC input breaker.
5. Verify that the output voltage is within the specied range.
6. Verify output phase rotation is correct.
7. Turn the system off.
8. Connect the loads one at a time and repeat Step 4.

17
PREVENTIVE MAINTENANCE
*** WARNING ***
DANGER OF ELECTRICAL SHOCK, TURN OFF ALL POWER SUPPLYING THIS EQUIPMENT
PRIOR TO MAINTENANCE.
*** WARNING ***
THERE ARE DANGEROUSLY HIGH VOLTAGES PRESENT WITHIN THE ENCLOSURE OF THE POWER
SUPPLY SYSTEM. CAUTION MUST BE TAKEN WHEN WORKING WITH THE ENCLOSURE. IT IS
RECOMMENDED THAT ALL WORK BE PERFORMED BY QUALIFIED ELECTRICAL PERSONNEL ONLY.
To ensure longer component life and trouble-free operation, minor preventive maintenance procedures should be
performed at regular intervals, for example once every year. More frequent inspection intervals would be needed
for more severe operating conditions and larger number of hours of continuous operation.
1. Remove the required panels and at each service inspection any accumulated dust, dirt or foreign particles should
be carefully removed. Special care should be exercised in cleaning the SCR’s (power mods), heatsinks and
the control assembly.
2. A simple performance checklist has been developed for use in maintenance. See “Performance Checklist” and
check off items 1-7.
3. After items 1-7 have been checked on the “Performance Checklist”, the next step is to check the operation of
the system.
4. Replace any panels that were previously removed. Turn the unit on with no load. Check item 8 on the performance
checklist.
5. Turn on loads and check items 9-10 of the “Performance Checklist”.
6. Check to make sure all fans are operational.
NOTE: Preventive Maintenance Plans are available. Please contact the Customer Support Group for
information.
Call 1-800-521-4792.

18
PERFORMANCE CHECKLIST
Company______________________________________________________________
Model #____________________________Serial #__________________
1. Customer Comments or Problems____________________________________
2. Power Processor Environment Clean and Dust Free Yes_______ No________
3. Phase Rotation Correct (ABC) Yes_______ No________
4. Electrically wired properly ie...Conductor Sizing, Breakers, Grounding
5. Verify Input Voltage (See specication tag)
6. Check Tightness of Electrical Connections:
______Input Connections______Output Connections______Heatsink Connections (SCR’s)
______Circuit Board Connections______By-Pass Switch______Fuse Connections
______Fan Connections______Transformer Connections
7. Exercise all circuit breakers-
______Input Breaker______Output Breakers
8. Input/Output Voltage Checks.
No Load Input No Load Output
H1-H2__________VAC__________ L1-N__________VAC L1-L2__________VAC
H2-H3__________VAC__________ L2-N__________VAC L2-L3__________VAC
H1-H3__________VAC__________ L3-N__________VAC L1-L3__________VAC
9. Available Load Input Available Load Output
H1-H2__________VAC__________ L1-N__________VAC L1-L2__________VAC
H2-H3__________VAC__________ L2-N__________VAC L2-L3__________VAC
H1-H3__________VAC__________ L3-N__________VAC L1-L3__________VAC
10. Input/Output Current Checks (Balance as Needed).
Input Output
H1__________Amps L1__________Amps
H2__________Amps L2__________Amps
H3__________Amps L3__________Amps
N__________Amps
G__________Amps
11. Fans Operational_________________________________________________________

19
GENERAL TROUBLESHOOTING
*** WARNING ***
THERE ARE DANGEROUSLY HIGH VOLTAGES PRESENT WITHIN THE ENCLOSURE OF THE POWER
SUPPLY SYSTEM. CAUTION MUST BE TAKEN WHEN WORKING WITH THE ENCLOSURE. IT IS
RECOMMENDED THAT ALL WORK BE PERFORMED BY QUALIFIED ELECTRICAL PERSONNEL ONLY.
SYMPTOM PROBABLE CAUSES
1. No Output on One or More Phases. A. No Input.
B. Blown Fuse.
C. Defective SCR or Power Mod.
D. Defective Control Card.
E. Defective Sense Card.
F. Defective Over/Under Output Detection (Optional)
2. Output is too High or too Low. A. Input Out of Range.
B. Control Card Adjustment.
C. Defective Control Card.
D. Defective Sense Card.
E. Defective SCR or Power Mod.
3. Input Breaker Tripping Off. A. System Overloaded.
B. Defective Breaker.
C. Shorted Taps.
4. Blowing Semi-Conductor Fuses A. Shorted SCR’s or Power Modules.
B. Output Loads Shorted.

20
WARRANTY
This Warranty applies only to the original purchaser who must properly
register the product within thirty (30) days of receipt.
Register on-line at http://www.controlledpwr.com/csupport-warranty.php
Register on-line at http://www.controlledpwr.com/csupport-warranty.php
Controlled Power Company warrants that our products and their components will remain free from defects in material
and workmanship for the duration of the respective warranty period* from the date of shipment and agrees to replace,
F. O. B. its factory, any parts which fault through defect in material or workmanship during such period. Non payment
for the product to either the reseller, rep, distributor or the factory direct will result in revocation of warranty, technical
support and service contracts. Warranty begins from date of shipment unless a factory start-up is purchased,
then the warranty begins from date of Start Up or 90 days from ship date; whichever comes rst.
If a Start-Up is purchased with the unit(s) or within 30 days from original ship date, the 1st year warranty is upgraded
to include onsite labor and expenses during normal business hours (Monday - Friday, 8AM - 4PM). Start up includes
all travel and living expenses. Start up description: Testing all emergency circuitry - Calibration - Inspection - Exercising
all circuit breakers - Cooling fan check - Input and output parameter check - Air intake / exhaust check - Re-torque
all high current terminals - Input/Output verication - Written report. User training to be done at time of start up (no
return visits). Product installation is required to be complete before start up can be scheduled.
Products:
• Power Processor (700A) / 1 Year parts only.*
* From original shipment date / Excludes on site labor and expenses unless otherwise noted.
1. This Warranty shall be effective only if and so long as the system is installed and operated in the manner specied
in the manual which accompanied the product, and is operated within the ratings on the nameplate of the system.
2. This Warranty shall be effective provided the purchaser pays the cost of transporting the faulty component(s) to
and from Controlled Power Company’s factory at the purchaser’s own expense, unless the item covered under
service contract with Controlled Power Company. There is no cost for installation of the replacement component(s)
when done at the factory. Otherwise installation of the replacement component(s) are the responsibility of the
purchaser, unless the item is covered under service contract with Controlled Power Company. If after inspection
the faulty component has been caused by misuse or abnormal conditions in the judgment of Controlled Power
Company, the purchaser will be charged for repairs based on parts and labor required. This Warranty does not
cover fuses, light bulbs, and other normally expendable items. Controlled Power Company service personnel
are not included in this warranty unless covered by a Controlled Power Company service contract.
3. This Warranty shall be void if any alteration is made to the system, or any of its components are altered by
anyone other than an authorized Controlled Power Company service person, without the written permission of
Controlled Power Company.
4. This Warranty is in lieu of all other warranties, expressed or implied. Controlled Power Company neither assumes,
nor authorizes any person to assume for it, any liability other than that specically set forth in this Warranty. Except
for its obligations, Controlled Power Company assumes no liability or responsibility for personal injury, loss of
life, consequential or other damages resulting from defects in, or failure of, the system or any of its components.