KEPCO KIT 219-0548 User manual

©2015, KEPCO, INC 1
Data subject to change without notice 228-1744 REV 3
INSTRUCTION MANUAL
BOP 1000W
KEPCO
KEPCO, INC.  131-38 SANFORD AVENUE  FLUSHING, NY. 11355 U.S.A. TEL [phone]FAX [phone]
http://www.kepcopower.com email: [e-mail]
An ISO 9001 Company. Transition Circuit
KIT 219-0548
BOP 6-125MG
TRANSITION CIRCUIT KIT
1. DESCRIPTION
Kepco KIT 219-0548 contains components used for a field upgrade of BOP 6-125MG power supplies to allow
smoother transitions through zero power when driving inductive loads at low frequencies and/or at a low rate of
output power changes. This upgrade avoids possible faults under these conditions which can cause the unit to dis-
play an error and reduce output power to zero.
The Transition circuit detects when the voltage and the current at the BOP output have opposite signs, showing
that the unit is beginning to sink power. This turns on a preload placed between the Front End Module and the Out-
put Module of the BOP. If the Sink power increases to the point that the Source-Recuperation Detector is triggered,
the Front End switches to Sink-Recuperation mode at an increased level of power, as the preload is turned off by
the Source-Recuperation Detector. This permits a sharper transition towards Sink-Recuperation mode. If the Front
End switches to Source mode, the preload is activated for a predetermined period of time in order to boost the
power requested from the Front End, resulting in a sharper transition towards the Source mode.
2. APPLICABILITY
This KIT applies only to BOP 6-125MG models. Contact Kepco for kits applicable to other models. This manual
applies only to Rev 2 Transition Circuit Assemblies.
3. INSTALLATION INSTRUCTIONS
3.1 MATERIAL SUPPLIED (See Table 1.)
TABLE 1. MATERIAL SUPPLIED
MATERIAL KEPCO PART NUMBER QUANTITY
Transition Circuit assembly (A7A3)
comprised of (1) Printed Circuit Board assembly (236-
3069), (1) Heat Sink assembly (136-0481) and other related
components
300-0535 1
Screw, PHPH, 6-32 x 0.5 in. 101-0519 2
Cable Assembly, A2A5 to A7A3J1 (5-Pin connector) 118-1265 1
Cable Assembly, A4A8 to A7A3J3 (4-Pin connector) 118-1266 1
Cable Assembly, A4A8 to A7A3J4 (3-Pin connector) 118-1267 1
Resistor, 150KOhms, 1%, 1/8W (R59) 115-2597 1
Resistor 200KOhms, 1%, 1/4W (R58, R70) 115-2809 2
Cable Tie 138-0076 5
Adapter Plate 128-2412 1
Screw, FLPO, 6-32, 0.375 IN., ST 101-0332 2
Self-adhesive Plastic Mount Cable Tie 138-0089 3
Instruction Manual 228-1744 REV 3 1

2228-1744 REV 3 080515
KEPCO, INC.  131-38 SANFORD AVENUE  FLUSHING, NY. 11355 U.S.A. TEL [phone]FAX [phone]
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3.2 COVER REMOVAL PROCEDURE
WARNING: Before installing the kit, unplug the BOP from a-c input source and disconnect the output
load!
1. Turn power off and disconnect the unit from source power and remove line cord, then disconnect the output
load.
NOTE: Retain all hardware for reassembly.
2. Remove the two mounting ears from the chassis by removing three screws from each.
CAUTION: The two screws at the top of the front panel must be removed first to avoid damage to the
front panel.
3. Remove the top cover of the unit by removing 14 screws as follows: two at top of the front panel, four at each
side, (one towards the rear, three at the bottom) and four at the top of the rear panel.
3.3 PRINTED CIRCUIT BOARD AND HEAT SINK INSTALLATION PROCEDURE
The Transition Circuit Assembly (A7A3) is shipped with Printed Circuit Board (PCB) assembled to the Heatsink
with the preload-MOSFET mounted directly on the heatsink (Figure 1).
FIGURE 1. TRANSITION CIRCUIT ASSEMBLY, COMPONENT LOCATIONS
1. Attach the adapter plate provided in this kit to the Transition Circuit assembly heat sink using two flat head
screws (P/N 101-0332) provided in this kit.
2. Install the Transition Circuit assembly as shown in Figure 2 by sliding the adapter plate under the fan and
using the two screws provided in this kit at the ventilation holes identified in the figure. The screws are inserted
up through the bottom of the chassis into the adapter plate.
CAUTION: When routing cables, ensure that the cables stay clear of the Output Module (A2) Fan and
Auxiliary Power Supply (A5).
3. Cable assembly P/N 118-1267 (provided in the Kit) has a 3-pin connector with two wires, each having non-iso-
lated ring lugs. Remove the screws and lockwashers from J4M and J2M on A4A8, then add the wires from the
cable assembly to the wires already connected to J4M and J2M as follows (see Figure 2 for the location of
A4A8 in the chassis, Figure 3 for location of J4M and J2M and Figure 6 for cable routing):
• red/white wire to A4A8- J4M
• black/white wire to A4A8- J2M
!
R28
C12
Q6
1
2
Q2
!

080515 228-1744 REV 3 3
KEPCO, INC.  131-38 SANFORD AVENUE  FLUSHING, NY. 11355 U.S.A. TEL [phone]FAX [phone]
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FIGURE 2. BOP 1KW COMPONENT LOCATIONS
4. Install the 4-pin cable assembly (P/N 118-1266) on Transition Circuit A7A3J3 of the PCB (see Figure 1). Route
the cables as shown by Figure 6. This cable has three (3) unterminated wires. Determine the needed length,
cut the wire and remove the insulated sleeving (approximately 0.15"), then solder each wire to the indicated
point (see Figure 3 for A4A8 component locations and Figure 6 for cable routing):
• red wire to A4A8D1 Cathode
• black wire to A4A8D1 Anode
• white wire to A4A8TP2
3043897
CHASSIS GROUND CONNECTION
SCREW (QTY 2), PHPH,
6-32 X 0.5 IN., ST
KEPCO P/N 101-0519
TRANSITION CIRCUIT
ASSEMBLY A7A3
A2A5 ASSEMBLY
(SEE FIGURE 4.)
A4A3 ASSEMBLY
(SEE FIGURE 3.) A1 ASSEMBLY
(SEE FIGURE 2.)
OUTPUT MODULE
(A2) FAN
NOTE:
TO MOUNT TRANSITION
CIRCUIT ASSEMBLY A7A3
INSERT ONE SCREW IN
VENTILATION HOLE A, THE
OTHER IN HOLE B. IF THE
CHASSIS BOTTOM MUST
BE FLUSH TO A FLAT
SURFACE, THE CHASSIS
HOLES A AND B MUST BE
COUNTERSUNK. (PARTIAL TOP VIEW)
B
(SEE NOTE.)
FAN MOUNTING
SCREW
A
(SEE NOTE.)
FRONT
PANEL

4228-1744 REV 3 080515
KEPCO, INC.  131-38 SANFORD AVENUE  FLUSHING, NY. 11355 U.S.A. TEL [phone]FAX [phone]
http://www.kepcopower.com email: [e-mail]
FIGURE 3. A4A8 COMPONENT LOCATION/WIRING
5. Install the 5-pin cable assembly (P/N 118-1265) on Transition Circuit A7A3J1 (see Figure 1) of the PCB. Route
the cables as shown by Figure 6. This cable assembly has a 5-pin connector with five (5) unterminated wires.
Determine the needed length, cut the wire and remove the insulated sleeving (approximately 0.15"), then sol-
der each wire to the indicated point of assembly A2A5 (see Figure 4 for location of wire attachment points and
Figure 6 for cable routing):
• white/yellow wire to A2A5D26 Anode
• white/blue wire to junction of A2A5R40 and J3, pin 6
• black wire to A2A5TP1
• red wire to A2A5TP7
• white wire to A2A5TP8
FIGURE 4. A2A5 COMPONENT LOCATION

080515 228-1744 REV 3 5
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6. To gain access to the components of A4A3 in order to replace R58, R59 and R70, first remove A4A3 from the
chassis as follows:
a. At top of A4A3 disconnect nine cables from J1 through J9 of A4A3 (Figure 5).
b. Remove four screws attaching A4 assembly to the chassis.
c. Remove five screws and five washers attaching A4A3 board to A4A1 board and remove A4A3 board.
7. Unsolder and remove the following three resistors from A4A3 and replace with the resistors supplied as fol-
lows (see Figure 5 for location of A4A3 components):
• Install and solder replacement R59 supplied: P/N 115-2597 (150K Ohms, 1%, 0.125W)
• Install and solder replacement R58 and R70 supplied: P/N 115-2809 (200K Ohms, 1%, 0.25W)
FIGURE 5. A4A3 COMPONENT LOCATIONS
8. Reinstall A4A3 by following the reverse of step 6 above.
9. Perform visual inspection of transition circuit installation.
CAUTION: After installing all components and wiring as described above, perform the following
checklist to verify that installation has been done correctly.
• Verify that cable wires are connected properly and to the correct termination
• Check for unintentional short-circuits between the wire connections and adjacent components, pads and
traces.
• Use an ohmmeter to verify that the Transition Circuit heatsink is isolated (more than 1Megohm resistance)
from the BOP chassis.
• Verify that the Transition Circuit is securely attached to the BOP chassis.
• Verify that the Transition circuit cables are clear of the Output Module (A2) Fan and Auxiliary Power Supply
(A5).
!