Guildline 6623A-PCS/1000 User manual

Operation Manual
For The
6623A-PCS/1000/2000/3000
Precision Current Sources
www.guildline.com
NOTICE
The contents and information contained in this manual are proprietary to
Guildline Instruments Limited. They are to be used only as a guide to the
operation and maintenance of the equipment with which this manual was
issued and may not be duplicated or transmitted by any means, either in whole
or in part, without the written permission of Guildline Instruments Limited.
OM6623A-PCS-1_2_3000-5-00
01 September 2021

OM6623A-PCS-1_2_3000-5-00
01 September 2021
ii
TABLE OF CONTENTS
1. INTRODUCTION.......................................................................................................1-1
1.1. SCOPE................................................................................................................................................................1-1
1.2. GENERAL DESCRIPTION............................................................................................................................1-1
1.3. OVERVIEW ......................................................................................................................................................1-2
1.4. PRINCIPLE OF OPERATION ......................................................................................................................1-2
2. INSTALLATION........................................................................................................2-1
2.1. PRELIMINARIES............................................................................................................................................2-1
2.1.1. Power Voltage Selection................................................................................................................................2-2
2.1.2. Fuse Replacement...........................................................................................................................................2-2
2.1.3. Setup and Power On.......................................................................................................................................2-2
2.2. INCOMING INSPECTION.............................................................................................................................2-4
2.3. 6623A-PCS/3000 FRONT PANEL................................................................................................................2-10
2.3.1. Power............................................................................................................................................................2-11
2.3.2. Fault..............................................................................................................................................................2-11
2.4. 6623A-PCS/3000 REAR PANEL CONNECTORS AND CONTROLS...................................................2-12
2.4.1. Line Input Connectors..................................................................................................................................2-13
2.4.2. Current Output Terminals............................................................................................................................2-13
2.4.3. Input Control Connector...............................................................................................................................2-13
3. QUICK OPERATION GUIDE....................................................................................3-1
3.1. OPERATION GUIDE......................................................................................................................................3-1
3.1.1. Recommended Test Setup Procedure for the 6623A-PCS/3000 ..................................................................3-1
3.1.2. Setup Limits and Precautions for 6623A-PCS/3000.....................................................................................3-2
3.1.3. Checks and Precautions..................................................................................................................................3-2
4. VERIFICATION AND CALIBRATION......................................................................4-1
4.1. RATIO ACCURACY VERIFICATION........................................................................................................4-1
4.1.1. Purpose ...........................................................................................................................................................4-1
4.2. TEST EQUIPMENT REQUIRED..................................................................................................................4-1
4.3. PROCEDURE....................................................................................................................................................4-2
4.3.1. VERIFICATION OF THE 3 A TO 15 A RANGE.......................................................................................4-2
4.3.2. VERIFICATION OF THE 15 A to 150 A RANGE .....................................................................................4-2
4.3.3. VERIFICATION OF THE 150 A to 1000/2000/3000 A RANGE...............................................................4-3
4.3.4. VERIFICATION OF THE 2000 A AND 3000 A RANGE OF CURRENTS.............................................4-3

OM6623A-PCS-1_2_3000-5-00
01 September 2021
iii
5. TROUBLESHOOTING AND MAINTENANCE.........................................................5-1
5.1. INTRODUCTION.............................................................................................................................................5-1
5.1.1. Error Messages...............................................................................................................................................5-1
5.1.2. Model CS1000 'Fault' Indicators....................................................................................................................5-1
5.1.3. Maintenance ...................................................................................................................................................5-1
5.1.4. Maintenance Guidelines and Schedule..........................................................................................................5-1
5.1.5. Connection Problems .....................................................................................................................................5-2
5.1.6. Safety Features ...............................................................................................................................................5-2
6. APPENDICES...........................................................................................................6-1
6.1. GENERAL SPECIFICATIONS......................................................................................................................6-1
6.2. GENERAL SPECIFICATIONS (continued).................................................................................................6-2

OM6623A-PCS-1_2_3000-5-00
01 September 2021
iv
LIST OF FIGURES
FIGURE 1-1 : MODEL 6623A-PCS/3000 BLOCK DIAGRAM ...............................................................................1-3
FIGURE 2-1 : 6623A-PCS/3000, 15 A RANGE CONNECTIONS............................................................................2-7
FIGURE 2-2 :: 6623A-PCS/3000, 150 A RANGE CONNECTIONS ........................................................................2-8
FIGURE 2-3 : 6623A-PCS/3000, 3000 A RANGE CONNECTIONS........................................................................2-9
FIGURE 2-4 : 6623A-PCS/3000 FRONT VIEW........................................................................................................2-10
FIGURE 2-5 : 6623A-PCS/3000 REAR VIEW ..........................................................................................................2-12
FIGURE 3-1 : 6623A-PCS/3000 TEST SETUP COMPLIANCE LIMITS ..............................................................3-2

OM6623A-PCS-1_2_3000-5-00
01 September 2021
v
LIST OF TABLES
TABLE 3-1 : TEST CURRENT CABLE SIZE REQUIREMENTS.........................................................................3-3
TABLE 4-2 : 6623A-PCS/1000/2000/3000 CURRENT CALIBRATION RESULTS .............................................4-4
TABLE 5-3 : MAINTENANCE SCHEDULE..............................................................................................................5-2
TABLE 6-1 : GENERAL SPECIFICATIONS.............................................................................................................6-1
TABLE 6-2 : GENERAL SPECIFICATIONS (CONTINUED)................................................................................6-2

Section 1
OM6623A-PCS-1_2_3000-5-00
01 September 2021
1-1
1. INTRODUCTION
1.1. SCOPE
This document describes the installation, operation, specifications, maintenance and verification of
the Model 6623A-PCS/1000/2000/3000 Precision Current Sources. Precautions associated with
very high current connections are provided for purposes of user safety and current source
reliability. This manual describes mainly the 6623A-PCS/3000 Precision Current Source as this
model incorporates the full complement of features in all the models. Differences with respect to
the 6623A-PCS/1000 and the 6623A-PCS/2000 models are stated where appropriate.
1.2. GENERAL DESCRIPTION
The Model 6623A-PCS/1000/2000/3000 Precision Current Sources supply positive and negative
currents in the range of 3 A to 1000, 2000 or 3000 A depending on the model. The three models
are essentially the same except for the test current capability and the cable connection terminal
configuration. The 6623A-PCS/1000 enables test currents up to 1000 A to be realized and is
supplied with one CS1000 current source chassis. The models 6623A-PCS/2000 and 6623A-
PCS/3000 models provide for test currents up to 2000 and 3000 A and are supplied with two and
three CS1000 current source chassis’s respectively. The lower current models may be upgraded by
the addition of one or two CS1000 chassis’s.
Each CS1000 current source chassis consists of seven 150 A current source modules connected
internally in parallel. The CS1000 is controlled by the Model 66259 Control Unit included with
the 6623A-PCS Precision Current Source. The control unit provides three current ranges, selection
of positive or negative currents and correction coefficients to control the accuracy of the three
current ranges. Current ranges of 3 to 15 A, 15 to 150 A and 150 A to full scale current are
provided. The first CS1000 chassis is preconfigured as the master unit and controls the additional
units through the Model 66259 Control Unit. The 66259 Control Unit can be setup to automatically
reverse the polarity of the supplied current at a selectable rate.
The 6623A-PCS Series is pre-wired and configured in a 22U high rack cabinet designed to operate
at a nominal power line voltage of 208 to 240 VAC. The rack mount cabinet includes a bus bar
arrangement to connect the CS1000 units in parallel and provide for suitable terminal connections
to external cables. A terminal panel at the top of the cabinet provides for terminal connections for
the two lower current ranges. These lower ranges are fused to provide suitable over current
protection. All necessary interconnections of the CS1000 current sources are integrated into one
cabinet such that no hardware reconfiguration is required over the full range of operation other than
the connection of the current terminals to the correct range on the back panel. An Emergency Off
switch is provided that can be placed in a convenient place close to the 6623A-PCS current source
to allow a for the immediate interruption of the test current if an emergency should arise.
Refer to section 2-3 for front and rear views of the system and descriptions of indicators, controls
and terminals.

Section 1
OM6623A-PCS-1_2_3000-5-00
01 September 2021
1-2
1.3. OVERVIEW
The Model 6623A-PCS/1000/2000/3000 Precision Current Sources are precision sources of both
positive and negative currents up to a full scale of 3000 A. Figure 1-1 illustrates the instrument
circuits in block diagram form with the connections to the load. A Model 66259 Control Unit
provided with the system is programmable and allows for selection of range and polarity of the test
current. The Model 66259 Control Unit is provided with a control cable to allow the unit to be
hand held or placed on a bench near the 6623A-PCS current source.
There are no adjustments within the 6623A-PCS current source that are required for proper
operation, but the Model 66259 Control Unit must be set up with a specific range profile and test
current calibration coefficients. The Model 66259 Control Unit is generally configured at the
factory for the 6623A-PCS current source. A Summary of Coefficients for later reference as may
be needed is provided with each 6623A-PCS current source.
A complete description of the Model 66259 Control Unit including calibration and control features
is provided in a separate Operation Manual, (OM66259), with each 6623A-PCS current source.
1.4. PRINCIPLE OF OPERATION
The Model 6623A-PCS/1000/2000/3000 Precision Current Sources are modular in design. The
base module consists of a fully integrated line operated 150 A direct current source printed circuit
board. Seven of the 150 A modules are assembled in a single 5U rack mountable chassis. The
direct current outputs are connected in parallel to a pair of bus bars. The control inputs of the
CS1000 chassis’s are connected in series such that the same input control current passes through
all the 150 A modules. The control signals also provide for the selection of one of three available
ranges.
The 150 A modules are designed such that if a fault is detected the outputs of the module are
isolated from the main bus bar. In this way the remaining 150 A modules will continue to operate.
Fault indicators are provided for each 150 A module in each chassis assembly so that the module at
fault can be quickly identified.

Section 1
OM6623A-PCS-1_2_3000-5-00
01 September 2021
1-3
Figure 1-1 : Model 6623A-PCS/3000 Block Diagram
CS1000 Current Sources
CS1000
CS1000
CS1000
P1
P2
C1
C2
66259 Extender
Control Unit
Emergency Stop
Control
Output Current Buss
Load

Section 1
OM6623A-PCS-1_2_3000-5-00
01 September 2021
1-4

Section 2
OM6623A-PCS-1_2_3000-5-00
01 September 2021
2-1
2. INSTALLATION
2.1. PRELIMINARIES
Note that the Model 6623A-PCS/3000 Precision Current Source will include a separate Model
66259 Control Unit and Model 66236 Emergency Off Switch. The Model 66259 Control Unit is
provided with a separate Operation Manual. The Model 6623A-PCS/3000 current source is
shipped assembled in a 22U rack cabinet fully configured for 220 Volt, 50/60 Hz operation with a
power requirement of two 30 A, 220 Volt circuits. The 6623A-PCS/1000 and 6623A-PCS/2000
models are assembled in the same 22U also fully configured for 220 Volt, 50/60 Hz operation with
a power requirement of one 30 A, 220 Volt circuit.
Unpacking Procedure:
a. Remove the 6623A-PCS/3000 Current Range Extender and the other items from
the shipping container to a suitable location (refer to the drawing attached in back
of manual).
b. The following items are included with each new unit.
i. Operation Manual (OM6623A-PCS-1_2_3000)
ii. Spare 200 A Fuses, (GPN 099-32200), 2 per CS1000 and 2 for fly out panel
iii. Two Spare Fuse Cable Assemblies, 20 A, (GPN 31486-01-21)
iv. One 20 A, 1.5 m Red Connection Cable (GPN 996-00105)
v. One 20 A, 1.5 m Black Connection Cable (GPN 996-00104)
vi. One 150 A, 1.5 m Red Connection Cable (GPN 20239.03.02)
vii. One 150 A, 1.5 m Black Connection Cable (GPN 20239.04.02)
viii. 500 A, 2 m Red Connection Cables (GPN 20241.03.02) see Note 1
ix. 500A, 2 m Black Connection Cables (GPN 20241.04.02) see Note 1
x. One Emergency Stop Cable (GPN 31375-01-21)
xi. One Model 66236, Emergency Off Box Assy (GPN 31362-01-11)
xii. One Model 66259, Extender Control Unit with connection cable and power
supply (31151-01-05)
xiii. One 9/16” wrench (GPN 953-00916)
xiv. One per 500 A Cable Assy, 3/8-16 x 1-1/2” bolt (GPN 817-01203)
see Note 1
xv. One per 500 A Cable Assy + Twelve, 3/8” lock washer (GPN 841-01389)
see Notes 1 and 2

Section 2
OM6623A-PCS-1_2_3000-5-00
01 September 2021
2-2
xvi. One per 500 A Cable Assy + Twelve, 3/8” flat washer (GPN 839-06666)
see Notes 1 and 2
xvii. Two Break Out Plates (GPN 31372-01-11)
xviii. Twelve 3/8-16 x 1-3/4” bolt (GPN 817-01205) see Note 2
Note 1: the number of 500 A connection cables (and associated hardware) is
two, four, and six of each for the 6623A-PCS/1000, the 6623A-PCS/2000, and
the 6623A-PCS/3000 respectively.
Note 2: to be used with breakout plate.
2.1.1. Power Voltage Selection
There is no line input selection as the main assembly and CS1000 Chassis’s are pre-set for
220 Volts operation. The 6623A-PCS/3000 is designed for universal use of AC power
sources from nominal 208 Volts to 240 Volts in a frequency range of 50 Hz to 60 Hz.
Two 30 A, 220 Volt line cords with NEMA L6-30P molded plugs are supplied with the
6623CS-3000 current source. The 6623A-PCS/1000 and 6623A-PCS/2000 are supplied
with one line cord. Where the molded plugs, NEMA L6-30P, on the line cords do not
match the local power outlet sockets; the plugs can be removed and replaced with one that
does fit the local service. The plug should be re-wired as follows:
Black wire - Line 1 input
White wire - Neutral or Line 2 input
Green wire - Ground (safety)
2.1.2. Fuse Replacement
Spare 200 A and 20 A fuses are supplied for replacement in the 15 A and 150 A terminal
panel should the current rating be exceeded on these ranges. The fuses can be accessed by
removing the fly out panel at the top of the rack cabinet.
NOTE: care should be taken when replacing fuses such that they are installed in the
same mechanical fit as before and that the fuse leads are NOT bent.
2.1.3. Setup and Power On
Refer to section 2-3 for front and rear views of the system and descriptions of indicators,
controls and terminals.
a. Verify that the power switches are off inside the 6623A-PCS/3000 cabinet.
b. Remove any excess packing material from around the front and back panels that are
provided for shipping purposes only. Verify that the Line Voltage to be used
matches the Line Voltage setting marked on the back panel of the 6623A-
PCS/3000. If the Line Voltage to be used does not match, contact Guildline
Instruments Limited for instructions before proceeding.

Section 2
OM6623A-PCS-1_2_3000-5-00
01 September 2021
2-3
c. Connect the Model 66259 Control Unit using the 7 conductor cable, (GPN 31168-
01-21) provided. One end with smaller circular connector is to be connected to the
mating connector on the top panel of the 66259 marked 'EXTENDER' and the other
end with the larger diameter connector to the connector on the back panel of the
lowest CS1000 unit marked 'INPUT'.
d. Verify that the other CS1000 units are interconnected with short cables, the
'OUTPUT' of the lowest unit to the 'INPUT' of the next higher unit.
e. Install the Model 66236 Emergency Off Switch by connecting the cable, (GPN
31375-01-21) to the top 7 pin circular connector on the last CS1000 Current Source
inside the 6623A-PCS/3000 cabinet. Note that the Terminator Plug will need to be
removed. One or the other must be installed to allow proper operation of the
6623A-PCS units.
Note: A termination plug, GPN 31061-01-09, must be connected to the last CS1000
unit in the 6623A-PCS/3000 if the Emergency Off Switch is removed.
f. Connect the input power cords from the 6623A-PCS/3000 rack cabinet to the 208-
240 VAC power outlets rated at 30 A each.
g. Turn on the power switches of the two 30 A power bars at the back of the rack
cabinet. Each power bar has two 15 A sections with circuit breaker protection. You
should see the green 'POWER' indicator on each 15 A section of the power bars
light up. Note that the 6623A-PCS/1000 and 6623A-PCS/2000 models will have
only one power bar installed.
h. Plug the model 66259 power supply to a suitable 120 to 240 VAC, 50/60 Hz source
and connect the power supply output to the 66259 connector marked 'POWER'.
Turn on the power switch to the 66259 Control Unit. You should see the touch
screen and red 'POWER' indicator on the front panel light up.
i. Turn on the power switch to the bottom CS1000 unit in the 6623A-PCS and then
the next units above. You should see the red 'POWER' indicator on the front panels
light up. The yellow fault indicators on the CS1000 modules will light 'ON' for
about 6 seconds then remain off.
j. There should not be any yellow 'Fault' indicators remaining on. There are a set of 6
yellow indicators visible within the front grill which indicate when a fault is
experienced in any of the 6 internal 150 A slave current source modules. If some of
these should remain on, the power can be re-cycled off and on a number of times to
clear the fault.
Note: Do not turn the CS1000 Current Sources off or on while a current is being
requested unless an emergency occurs.

Section 2
OM6623A-PCS-1_2_3000-5-00
01 September 2021
2-4
2.2. INCOMING INSPECTION
If no errors are displayed during power up of the individual CS1000 units then the 6623A-PCS
Precision Current Source is ready to be used once the load is connected to either the main bus bar
or one of the two lower current range terminals. Refer to the 66259 Operation Manual for
information on setting up and using the Control Unit to source current.
Use the following set up procedure to verify the functional performance of the 6623A-PCS
Precision Current Source.
Note 1: A proper range profile must have been created in the non-volatile memory of the
66259 Control Unit before proceeding. Refer to the 66259 Operation Manual
Note 2: Do not connect a load to more than one of the range terminals at any one time. It
is essential that only one set of C1 and C2 current terminals be connected at any
one time and shunt current leads of sufficient size are connected to the correct C1
and C2 range terminals for a specific measurement current. Ensure that the
correct output terminals are connected for the selected range.
Initially the measurement of the potential across a 0.01 ohm shunt of known resistance value on the
15 A range terminals is tested to ensure that the 15 A range is functional. Then the potential across
a known 0.001 ohm shunt on the 150 A range terminals is tested to ensure that the 150 A range is
functional. Finally, the potential across a known 0.0001 ohm shunt on the main bus terminals is
tested to ensure that the highest range is functional. A high resolution DVM is needed to verify that
the correct test current is provided. If the shunt standards used are not known to be within ±0.03%
of nominal ohms value then some variation in the measured results can be expected.
The following is a step by step procedure for connecting the resistors and for setting up the 6623A-
PCS properly to make the measurements.
Note:
To start the system, turn on the following equipment in specified order. Turn
on Bridge or 66259 Controller. Turn on each of the 1000 A Current Sources
Connect the load (e.g. shunt) to the correct output terminals. Only have one
load connected to the output terminals at any one time. Start measurement as
described below. Do not disconnect the load, or connect a load, while the
measurement is running. Do not turn off the 1000 A Current Sources while the
measurement is running.
To stop the system, turn off the following equipment in specified order. Stop
the measurement. Disconnect the load (e.g. shunt). Turn off each of the 1000 A
Current sources. Turn off the Bridge or 66259 Controller.

Section 2
OM6623A-PCS-1_2_3000-5-00
01 September 2021
2-5
Step 1) Connect a 0.01 ohm shunt standard to the 30 A terminals of the 6623A-PCS fly out
panel at the top of the cabinet and connect the DVM to the potential terminals of the
shunt standard. Use the 10 AWG, 30 A, test leads for the current connections. The
SCW Lead supplied should be used for the potential terminal connections. See
Figure 2-1.
- From the front panel of the model 66259 Control Unit set to stage 1 by
increasing or decreasing the value at the upper right hand section of the
display of the opening screen. Normally the 66259 will power on in stage 1.
- From the main menu, configure the current setup as follows:
- Select 'Current' function key and enter 10 for a test current value of 10 A.
- Toggle if necessary the '+ve' function key at the top left of the display to
change the polarity to a positive polarity and press the 'OK' menu function
and see that the main menu returns showing a +10 A selection.
- Press 'Start' function key to initiate a positive current of 10 A. Note that once
the 'Start' function key is pressed it will revert to show 'Stop'.
- Reference the DVM to verify that a potential of + 0.1000 volts ± 0.0005 volt
is displayed. Note that the DVM should be suitably zeroed with no current
being sourced before making measurements.
- A negative test current can be selected by toggling the '-ve' function key at
the top left of the main display window.
- Press the 'Stop' function key to return the test current to the off state.
Step 4) Record the voltage values displayed on the DVM.
Step 5) Disconnect a 0.01 ohm shunt standard from the 15 A terminals of the 6623A-PCS
fly out panel at the top of the cabinet and connect a 0.001 ohm shunt standard to the
150 A terminals of the fly out panel. Connect the DVM to the potential terminals of
the shunt standard. Use the 150 A cables supplied to make the current connections.
See Figure 2-2.
- From the front panel of the model 66259 Control unit set to stage 2 by
pressing the 'Setup' function key and increasing or decreasing the value at the
upper right hand section of the display of the opening screen then press the
'Exit' function key to revert back to the main menu.
- From the main menu, configure the current setup as follows:
- Select 'Current' function key and enter 100 for a test current value of 100 A.
- Toggle if necessary the '+ve' function key at the top left of the display to
change the polarity to a positive polarity and press the 'OK' menu function
and see that the main menu returns showing a +100 A selection.
- Press 'Start' function key to initiate a positive current of 100 A. Note that
once the 'Start' function key is pressed it will revert to show 'Stop'.

Section 2
OM6623A-PCS-1_2_3000-5-00
01 September 2021
2-6
- Reference the DVM to verify that a potential of + 0.1000 volts ± 0.0005 volt
is displayed. Note that the DVM should be suitably zeroed with no current
being sourced.
- A negative test current can be selected by toggling the '-ve' function key at
the top left of the main display window.
- Press the 'Stop' function key to return the test current to the off state.
Step 6) Record the voltage values displayed on the DVM.
Step 7) Disconnect a 0.001 ohm shunt standard from the 150 A terminals of the 6623A-PCS
fly out panel at the top of the cabinet and connect a 0.0001 ohm shunt standard to the
main bus terminals. Connect the DVM to the potential terminals of the shunt
standard. Use at least two of the 500 A cables supplied for each of the positive and
negative current connections. See Figure 2-3.
- From the front panel of the model 66259 Control unit set to stage 3 by
pressing the 'Setup' function key and increasing or decreasing the value at the
upper right hand section of the display of the opening screen then press the
'Exit' function key to revert back to the main menu.
- From the main menu, configure the current setup as follows:
- Select 'Current' function key and enter 1000 for a test current value of 1000
A.
- Toggle if necessary the '+ve' function key at the top left of the display to
change the polarity to a positive polarity and press the 'OK' menu function
and see that the main menu returns showing a +1000 A selection.
- Press 'Start' function key to initiate a positive current of 1000 A. Note that
once the 'Start' function key is pressed it will revert to show 'Stop'.
- Reference the DVM to verify that a potential of + 0.1000 volts ± 0.0006 volt
is displayed. Note that the DVM should be suitably zeroed with no current
being sourced.
- A negative test current can be selected by toggling the '-ve' function key at
the top left of the main display window.
- Press the 'Stop' function key to return the test current to the off state.
Step 8) Record the voltage values displayed on the DVM.
Note: The tests should execute with no errors indicated and should indicate a voltage value
approximating the actual resistance values of the shunt standards times the test current
values. This is not the 6623A-PCS full rated accuracy but serves a functional test for the
purposes of determining the instrument has been received in proper working order. Refer to
section 4 for a full verification procedure.

Section 2
OM6623A-PCS-1_2_3000-5-00
01 September 2021
2-7
Figure 2-1 : 6623A-PCS/3000, 15 A Range Connections

Section 2
OM6623A-PCS-1_2_3000-5-00
01 September 2021
2-8
Figure 2-2 :: 6623A-PCS/3000, 150 A Range Connections

Section 2
OM6623A-PCS-1_2_3000-5-00
01 September 2021
2-9
Figure 2-3 : 6623A-PCS/3000, 3000 A Range Connections