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

Chapter 1
DESCRIPTION OF EQUIPMENT
1.1 PURPOSE AND CAPABILITIES
The Power Ten P60, P80, and D3 Series power supplies are general purpose power
supplies designed specifically for laboratory test and systems applications requiring
variable DC sources with good ripple and regulation characteristics. The P60 power
supplies include five separate series: P62, P63, P66, P83, and P86. The D3 power
supplies are dual output supplies that can have two supplies with the same 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. The D3 Series models provide a
total combined output power of 6.6 kilowatts.
1.2 TECHNICAL CHARACTERISTICS
The physical, electrical, and environmental characteristics for the P62, P63, P66, P83,
P86, and D3 Series are listed in Tables 1-1 through 1-6.
M550001-01 1-1

Table 1-1
P62 Series Technical Characteristics
PARAMETERS SPECIFICATIONS
PHYSICAL CHARACTERISTICS:
Width
Depth
Height
Weight
ELECTRICAL CHARACTERISTICS:
Input Power (Standard)
Voltage
Frequency
Phases
Regulation (Line or Load)
Voltage
Current
Transient Response
Stability
Remote Control/Monitor
Power 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 and current monitor,
OVP limit set, and summary fault status
2.5 Watts/cubic in.
0.72
M550001-01
1-2

Table 1-1
P62 Series Technical Characteristics – Continued
PARAMETERS SPECIFICATIONS
Remote Programming
Resistive:
Constant Voltage (0-100%)
Constant Current (0-100%)
Voltage:
Constant Voltage (0-100%)
Constant Current (0-100%)
Remote Sensing
ENVIRONMENTAL
CHARACTERISTICS:
Temperature Coefficient
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°to 70°C
Internal fans
TÜV NRTL to UL1950
TÜV to IEC 950
CE mark
M550001-01 1-3

Table 1-2
P63, P66, P83, P86, and D3 Series Technical Characteristics
PARAMETERS SPECIFICATIONS
PHYSICAL CHARACTERISTICS:
Width
Depth
Height
Weight
ELECTRICAL CHARACTERISTICS
Input Power
Voltage
Standard
Options
Frequency
Phases
Regulation (Line or Load)
Voltage
Current
Transient Response
Stability
Remote Control/Monitor
Power Density
Power Factor
Efficiency
P63, D3 P66
19.00 in. 19.00 in.
22.00 in 22.00 in.
5.25 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 or 12-120 VAC, and TTL or CMOS
switch, output voltage and current
monitor, OVP limit set, summary fault
status.
4.5 Watts/cubic in. (10 & 20 KW)
6.8 Watts/cubic in. (15 & 30 KW)
.72 min.
80% minimum at full load
M550001-01
1-4

Table 1-2
P63, P66, P83, P86, and D3 Series Technical Characteristics - Continued
PARAMETERS SPECIFICATIONS
Remote Programming
Resistive:
Constant Voltage (0-100%)
Constant Current (0-100%)
Voltage:
Constant Voltage (0-100%)
Constant Current (0-100%)
Remote Sensing
ENVIRONMENTAL CHARACTERISTICS:
Temperature Coefficient
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 point.
0 to 50°C
-40°to 75°C
Internal fans
TÜV NRTL to UL1950
TÜV to IEC 950
CE mark
M550001-01 1-5

Table 1-3
Available Voltages and Currents
V Out 2KW 3KW 3.3W 6.6W 10KW 13.3W 16.6W 20KW 5KW 10KW 15KW 20KW 25KW 30KW PS1 PS2
5 325 500 1000 1500 2000 2500 3000 500 500
8 250 350 400 800 1200 1600 2000 2400 400 400
10 200 300 330 660 1000 1300 1650 2000 330 330
12.5 265 530 800 1060 1325 1600 265 265
15 130 200 220 440 660 880 1100 1320 220 220
20 100 150 166 330 500 665 830 1000 166 166
25 132 265 400 520 650 800 132 132
30 66 100 110 220 330 440 550 660 110 110
40 50 75 83 166 250 330 415 500 83 83
50 40 60 66 133 200 265 330 400 66 66
60 33 50 55 110 166 220 275 330 55 55
80 25 37 62 125 187 250 312 375
100 20 30 50 100 150 200 250 300
120 16 25
130 38 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
20-60V
80V
175 mV
200 mV
50 mV RMS
50 mV RMS
50 mV RMS 135 mV
125 mV
225 mV
* P-P noise is measured across a 1 uF capacitor at the end of a 6’ load cable with the supply
operating at full load and at nominal input line voltage.
** RMS noise is measured directly across the output terminals with the supply operating af full
load and at nominal input line voltage.
3300RATING
100 mV
50 mV RMS 75 mV
50 mV 30 mV
45 mV
60 Low Noise
400V
100V
150V
200V
250-300V
P
*
* *
M550001-01
1-6

Chapter 2
INSTALLATION
2.1 INSPECTION
Inspect the shipping carton for possible damage before unpacking the unit. Carefully unpack
the equipment. Save all packing materials until inspection is complete. Verify that all items
listed on the packing slips have been received. Visually inspect all exterior surfaces for broken
knobs, connectors, or meters. Inspect for dented or damaged exterior surfaces. External
damage may be an indication of internal damage. If any damage is evident, immediately
contact the carrier that delivered the unit and submit a damage report. Failure to do so could
invalidate future claims.
2.2 INPUT/OUTPUT CONNECTORS
Tables 2-1 and 2-2 list all external 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.
Take precautions to ensure that the concentration of ozone is limited to a safe value. The
recommended long-term exposure limit for ozone is 0.1 PPM (0.2 mg/m3).
NOTICE
For proper connection to the mains, a 100
amp or less circuit breaker or fuse is
required.
WARNING
Under no condition should the negative
output terminal exceed 300V to earth
ground. Units with output voltage in excess
of 300V must have their negative output
terminal tied to earth ground.
M550001-01 2-1

2.3 LOCATION AND MOUNTING
The “P” Series models are intended for mounting in a standard 19.0-inch equipment
rack. Four screws, two on each side of the front panel, should be used to secure the
unit in place.
NOTICE
The unit should be provided with proper
ventilation. The top, rear and both sides of
the unit should be free of 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 2-3)
Control Interface
190-253 VAC (Std)
47-63 Hz
Power Source
User load(s)
See Table 3-1 for a
description
M550001-01
2-2

Table 2-2
5kW to 15kW and 16kW to 30kW 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
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

Table 2-3
Output Connection Descriptions
SUPPLY TYPE CONNECTION DESCRIPTION
2kW to 3kW <=60V
3.3kW to 15kW <=60V
16kW to 30kW <=60V
2kW to 3kW >=80V
3.3kW to 15kW >=80V
16kW to 30kW >=80V
Bus Bar with hole for 3/8” bolt
Bus Bar with two holes 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 ¼ - 20 ¼ - 20
400 3-phase NA 10 - 32 ¼ - 20
480 3-phase NA 10 - 32 ¼ - 20
Note: Observe the maximum torque specification indicated in the housing.
M550001-01
2-4