Powerten P60 Series User manual

Elgar Electronics Corporation
9250 Brown Deer Road
San Diego, CA 92121-2294
1-800-73ELGAR (1-800-733-5427)
Tel: [phone]
Fax: [phone]
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 writte
n permission from Elgar Electronics Corporation.
www.elgar.com
November 2, 2007 Document No. M550001-01 Rev F

i
Safety Notice
Before applying power to the system, verify that the unit is configured properly for the
user's particular application.
CE and UL recognition status of this series of power supplies is based on rack mounted
application only. Use of the power supplies outside of a rack mount enclosure will
expose the user to high voltage and/or high current sources. Extreme caution must be
used under these circumstances.
The analog control inputs (connectors J1 and J2) on the rear panel are referenced to the
negative output of the power supply. Grounding the positive output of the power supply
or biasing the output of the supply above chassis potential will cause these inputs (along
with the output of the supply) to have a potentially hazardous offset voltage. Exercise
caution under these conditions. Under no circumstances should the negative output of
the supply be more than 150 volts, positive or negative, from chassis potential.
Installation and service must be performed only by properly trained and qualified
personnel who are aware of dealing with attendant hazards. This includes simple
tasks such as fuse verification.
Ensure that the AC power line ground is connected properly to the unit input
connector or chassis. Similarly, other power ground lines including those to
application maintenance equipment must be grounded properly for both
personnel and equipment safety.
Always ensure 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 hazardous voltages
within the chassis. However, depending on the user's application configuration, HIGH
VOLTAGES HAZARDOUS TO HUMAN SAFETY may be generated normally on the
output terminals. Ensure that the output power lines are labeled properly as to the
safety hazards and that any inadvertent contact with hazardous voltages is eliminated.
Due to filtering, the unit has high leakage current to the chassis. Therefore, it is
essential to operate this unit with a safety ground.
This unit is designed to be permanently connected to the power source and as such
must have a readily accessible disconnect device incorporated in the fixed wiring.
After the unit has been operating for some time, the metal near the rear of the unit may
be hot enough to cause injury. Let the unit cool before handling.
These operating instructions form an integral part of the equipment and must be
available to the operating personnel at all times. All the safety instructions and advice
notes are to be followed.
Neither Power Ten nor any of the subsidiary sales organizations can accept
responsibility for personal, material or consequential injury, loss or damage that results
from improper use of the equipment and accessories.

M550001-01
ii
SERVICE SAFETY NOTICES
WARNING!
HAZARDOUS VOLTAGES IN EXCESS OF
480 V RMS, 700 V PEAK MAY BE
PRESENT WHEN COVERS ARE
REMOVED. QUALIFIED PERSONNEL
MUST USE EXTREME CAUTION WHEN
SERVICING THIS EQUIPMENT. CIRCUIT
BOARDS, TEST POINTS, AND OUTPUT
VOLTAGES MAY BE FLOATING ABOVE
CHASSIS GROUND.
WARNING!
TO GUARD AGAINST RISK OF
ELECTRICAL SHOCK DURING OPEN
COVER CHECKS, DO NO TOUCH ANY
PORTION OF THE ELECTRICAL
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 VIA EXTERNAL
MEANS; ALL CIRCUITS AND/OR
TERMINALS TO BE TOUCHED MUST BE
SAFETY GROUNDED TO THE CHASSIS.
WARNING!
QUALIFIED SERVICE PERSONNEL NEED
TO BE AWARE THAT SOME HEAT SINKS
ARE NOT AT GROUND, BUT AT HIGH
POTENTIAL.

M550001-01 iii
FCC NOTICE
This equipment has been tested and found
to comply with the limits for a Class A digital
device, pursuant to part 15 of the FCC
Rules. These limits are designed to provide
reasonable protection against harmful
interference 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
correct the interference at his own expense.

About This Manual
This manual has been written expressly for the Power Ten “P” Series of power supplies
which have been designed and certified to meet the Low Voltage and Electromagnetic
Compatibility Directive Requirements 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 Documents
M550001-01
iv

M550001-01 v
TABLE OF CONTENTS
Chapter 1 DESCRIPTION OF EQUIPMENT............................................................1-1
1.1 PURPOSE AND CAPABILITIES..................................................................................1-1
1.2 TECHNICAL CHARACTERISTICS.............................................................................1-1
Chapter 2 INSTALLATION.........................................................................................2-1
2.1 INSPECTION..................................................................................................................2-1
2.2 INPUT/OUTPUT CONNECTORS.................................................................................2-1
2.3 LOCATION AND MOUNTING ....................................................................................2-2
2.4 WIRE SIZING.................................................................................................................2-5
2.5 OUTLINE DRAWINGS .................................................................................................2-6
Chapter 3 OPERATING INSTRUCTIONS.................................................................3-1
3.1 CONTROLS AND INDICATORS .................................................................................3-1
3.2 LOCAL OPERATION....................................................................................................3-5
3.3 REMOTE CURRENT 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 Calibration procedures...................................................................4-3
4.2.3 P83 and P86 Series Calibration procedures..........................................................................4-6
4.2.4 Control Assembly Calibration..............................................................................................4-9
Chapter 5 MAINTENANCE.........................................................................................5-1
5.1 INTRODUCTION...........................................................................................................5-1
5.2 PREVENTIVE MAINTENANCE..................................................................................5-1
5.3 FUSES............................................................................................................................5-3

M550001-01
vi
LIST OF FIGURES
Figure 2-1 P62 Outline Drawing, 2kW to 3kW (Output Voltage <=60 V)................................... 2-6
Figure 2-2 P62 Outline Drawing, 2kW to 3kW (Output Voltage >=80 V)................................... 2-7
Figure 2-3 P63 & D3 Outline Drawing, 3.3KW to 10KW (Output Voltage <=60 V).................... 2-8
Figure 2-4 P83 Outline Drawing, 5.0KW to 15KW (Output Voltage >=80 V)............................. 2-9
Figure 2-5 P66 Outline Drawing, 13.3KW to 20kW (Output Voltage <=60 V) ......................... 2-10
Figure 2-6 P86 Outline Drawing, 20KW to 30KW (Output Voltage >=80 V)............................ 2-11
Figure 3-1 P6x, P8x, and D3 Series Controls and Indicators .................................................... 3-1
Figure 3-2 Pin-out for Connector J1........................................................................................... 3-5
Figure 3-3 Remote Current Programming Using Resistance .................................................. 3-10
Figure 3-4 Remote Current Programming Using 0-5 VDC or 0-10 VDC Voltage Source ....... 3-10
Figure 3-5 Remote Voltage Programming Using Resistance.................................................. 3-11
Figure 3-6 Remote Voltage Programming Using 0-5 VDC or 0-10 VDC Voltage Source....... 3-11
Figure 3-7 Remote Sensing Operation at the Load ................................................................. 3-12
Figure 3-8 Remote On/Off Control by Contact Closure ........................................................... 3-12
Figure 3-9 Remote On/Off Using Isolated AC or DC Voltage Source...................................... 3-13
Figure 3-10 Remote On/Off Using Isolated 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 Converter Card........................................................................................ 4-16
Figure 4-6 P63 & P66 Converter Card..................................................................................... 4-17
LIST OF TABLES
Table 1-1 P62 Series Technical Characteristics.......................................................................................1-2
Table 1-2 P63, P66, P83, P86, and D3 Series Technical Characteristics................................................1-4
Table 1-3 Available Voltages and Currents..............................................................................................1-6
Table 2-1 2kW to 3kW High Series Input/Output Connectors...................................................................2-2
Table 2-2 5kW to 15kW and 16kW to 30kW Series Input/Output Connectors .......................................... 2-3
Table 2-3 Output Connection Descriptions...............................................................................................2-4
Table 2-4 Input Connection Descriptions .................................................................................................2-4
Table 2-5 Minimum Wire SizeTable.......................................................................................................... 2-5
Table 2-6 Maximum AC Current Ratings..................................................................................................2-5
Table 3-1 P62, P63, P66, P83, P86, and D3 Series Controls and Indicators ..........................................3-2
Table 3-2 Connector J1 Designations and Functions...............................................................................3-3
Table 3-3 D-Shell Connector J1 Designations and functions – Continued ...............................................3-4
Table 5-1 Preventive Maintenance Schedule ............................................................................................ 5-1
Table 5-2 Inspection and Corrective Action .............................................................................................5-2
Table 5-3 Fuse Values............................................................................................................................... 5-3