P60, P80, D3 Series

DC Power Supplies
Operation Manual

Elgar Electronics Corporation

9250 Brown Deer Road
San Diego, CA 92121-2294

1-800-73ELGAR (1-800-733-5427)
Tel: (858) 450-0085 www.elgar.com
Fax: (858) 458-0267
Email: sales@elgar.com

©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 written permission from Elgar Electronics Corporation.

November 2, 2007 Document No. M550001-01 Rev F

 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.

i
 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.

ii M550001-01
 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.

M550001-01 iii
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

iv M550001-01
 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 v
 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

vi M550001-01
 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 19.00 in.

Depth 18.00 in
Height 3.50 in.
Weight 45 lbs max.

ELECTRICAL CHARACTERISTICS:

Input Power (Standard)

Voltage 190-253 VAC

Frequency 47 to 63 Hz
Phases Single, 2-wire plus gnd

Regulation (Line or Load)

Voltage 0.1% of max. output voltage

Current 0.2% of max. output current

Transient Response A 30% step load will recover to within 2%

of original value within 10ms.

Stability +0.05% of set point per 8 hrs. after warm-

up and at a fixed line, load and temp.

Remote Control/Monitor 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

Power Density 2.5 Watts/cubic in.

Power Factor 0.72

1-2 M550001-01
 Table 1-1
P62 Series Technical Characteristics – Continued

PARAMETERS SPECIFICATIONS

Remote Programming

Resistive:

Constant Voltage (0-100%) 0 - 5k ohms

Constant Current (0-100%) 0 - 5k ohms

Voltage:

Constant Voltage (0-100%) 0 - 5/10 VDC

Constant Current (0-100%) 0 - 5/10 VDC

Remote Sensing 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.
ENVIRONMENTAL
CHARACTERISTICS:

Temperature Coefficient 0.02%/°C of max. output voltage rating for

voltage set point.
0.03%/°C of max. output current rating for
current set point.
Ambient Temperature

Operating 0 to 50°C
Storage -20° to 70°C

Cooling Internal fans

Agency Approvals TÜV NRTL to UL1950

(excluding 600 volt models) 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:
P63, D3 P66
Width 19.00 in. 19.00 in.
Depth 22.00 in 22.00 in.
Height 5.25 in. 10.5 in.
Weight 120 lbs max. 163 lbs max.

ELECTRICAL CHARACTERISTICS
Input Power
Voltage
Standard 208-230 VAC (tested to 190-253 VAC)
Options 400 VAC (tested to 360-440 VAC)
480 VAC (tested to 432-528 VAC)

Frequency 47 to 63 Hz

Phases 3-phase, 3-wire plus ground

Regulation (Line or Load)

Voltage 0.1% of max. output voltage
Current 0.5% of max. output current

Transient Response A 30% step load will recover to within 2%

of original value within 10ms.

Stability +0.05% of set point after 8 hr. warm-up

at fixed line, load and temp.

Remote Control/Monitor 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.

Power Density 4.5 Watts/cubic in. (10 & 20 KW)

6.8 Watts/cubic in. (15 & 30 KW)

Power Factor .72 min.

Efficiency 80% minimum at full load

1-4 M550001-01
 Table 1-2
P63, P66, P83, P86, and D3 Series Technical Characteristics - Continued

PARAMETERS SPECIFICATIONS

Remote Programming

Resistive:
Constant Voltage (0-100%) 0 - 5k ohms
Constant Current (0-100%) 0 - 5k ohms

Voltage:
Constant Voltage (0-100%) 0 - 5 VDC or 0 -10 VDC
Constant Current (0-100%) 0 - 5 VDC or 0 -10 VDC

Remote Sensing 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.
ENVIRONMENTAL CHARACTERISTICS:
Temperature Coefficient 0.02%/°C of max. output voltage rating
for voltage set point.

0.03%/°C of max. output current rating

for current set point.
Ambient Temperature
Operating 0 to 50°C
Storage -40° to 75°C

Cooling Internal fans

Agency Approvals TÜV NRTL to UL1950

(excluding 600 volt models) 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: Output P-P Ripple - Typical

- Dual output supplies are available RATING *3300 * P60, P80, D3 *P60 Low Noise
in the P63 (3U) chassis with a 5-15V 30 mV RMS 50 mV 30 mV
combination of any two voltages 20-60V 30 mV RMS 75 mV 45 mV
and 3300 watts per voltage. 80V 50 mV RMS 100 mV
100V 50 mV RMS 125 mV
120V 50 mV RMS 135 mV
150V 50 mV RMS 150 mV
200V 175 mV
250-300V 200 mV
400V 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.

1-6 M550001-01
 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 Prime Power Input 190-253 VAC (Std)

FL1 - AC (Std) 47-63 Hz
FL1 - AC (with opt. 3 phase) Power Source
CHASSIS - GND
Output Power
Pos. Bus Bar <=60 volt models User load(s)
Neg. Bus Bar (see Table 2-3)

Pos. Threaded Stud >=80 volt models

Neg. Threaded Stud (see Table 2-3)

J1 Control Interface See Table 3-1 for a

description

2-2 M550001-01
 Table 2-2
5kW to 15kW and 16kW to 30kW Series Input/Output Connectors

CONNECTOR FUNCTION CONNECTS TO

FL1 - AC Prime Power Input 200-240 VAC (Std)

FL1 - AC 47-63 Hz
FL1 - AC 360-440 VAC (option)
CHASSIS - GND 432-528 VAC (option)
Output Power
Pos. Bus Bar <=60 volt models User load(s)
Neg. Bus Bar (see Table 2-3)

Pos. Threaded Stud >=80 volt models

Neg. Threaded Stud (see Table 2-3)

J1 Control Interface 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 Bus Bar with hole for 3/8” bolt

3.3kW to 15kW <=60V Bus Bar with two holes for 3/8” bolts

16kW to 30kW <=60V Bus Bar with three holes for 3/8” bolts

2kW to 3kW >=80V Terminal Block with 10-32 screws

3.3kW to 15kW >=80V 3/8” Threaded Studs

16kW to 30kW >=80V 3/8” Threaded Studs

Table 2-4
Input Connection Descriptions

INPUT PHASE P62 NON- P63, P83, D3 P66, P86

VOLTS COUNT MODULAR NON-MODULAR 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.

2-4 M550001-01
2.4 WIRE SIZING
Care must be taken to properly size all conductors for the input and output of the power
supply. Table 2-5 below gives minimum recommended wire size for the input. This
table is derived from the National Electrical Code and is for reference only. Local laws
and conditions may have different requirements. The table is for copper wire only.

Table 2-5
Minimum Wire SizeTable
SIZE TEMPERATURE RATING OF COPPER CONDUCTOR
60 °C 75 °C 85 °C 90 °C
TYPES TYPES TYPES TYPES
RUW, T, TW, FEPW, RH, V, MI TA, TBS, SA,
UF RHW, RUH, AVB, SIS, FEP,
AWG
THW, THWN, FEPB, RHH,
MCM
XHHW, USE, THHN, XHHW
ZW
CURRENT RATING
14 20 20 25 25
12 25 25 30 30
10 30 35 40 40
8 40 50 55 55
6 55 65 70 75
4 70 85 95 95
3 85 100 110 110
2 95 115 125 130
1 110 130 145 150
0 125 150 165 170
00 145 175 190 195
000 165 200 215 225
0000 195 230 250 260

For higher ratings wires can be paralleled or refer to the National Electrical Code.
Refer to Table 2-6 for AC input current requirements.
Table 2-6
Maximum AC Current Ratings
Input Line Current Unit of
Input V
3.3 kW 6.6 kW 10 kW 13.3 kW 16.6 kW 20 kW Measure
200-240 VAC 15 29 44 57 72 87 Amps AC
360-440 VAC 10 19 28 37 46 56 per
480 VAC 9 18 27 35 44 53 phase

M550001-01 2-5
2.5 OUTLINE DRAWINGS
The following pages (figures 2-1 through 2-6) show the outlines and overall dimensions
for the “P” product lines.

J1
J3

J2 NEG POS
DC OUTPUT PROGRAM
PROGRAM
REMOTE
IEEE ADDRESS REMOTE

VOLTAGE CURRENT

POWER

Figure 2-1
P62 Outline Drawing, 2kW to 3kW (Output Voltage <=60 V)

2-6 M550001-01
 J1
J3

J2 NEG POS
DC OUTPUT PROGRAM
PROGRAM
REMOTE
IEEE ADDRESS REMOTE

VOLTAGE CURRENT

POWER

Figure 2-2
P62 Outline Drawing, 2kW to 3kW (Output Voltage >=80 V)

M550001-01 2-7
 VOLTAGE CURRENT

POWER

VOLTAGE CURRENT

POWER

VOLTAGE CURRENT

Figure 2-3
P63 & D3 Outline Drawing, 3.3KW to 10KW (Output Voltage <=60 V)

2-8 M550001-01
 VOLTAGE CURRENT

POWER

Figure 2-4
P83 Outline Drawing, 5.0KW to 15KW (Output Voltage >=80 V)

M550001-01 2-9
 -

VOLTAGE CURRENT

POWER

Figure 2-5
P66 Outline Drawing, 13.3KW to 20kW (Output Voltage <=60 V)

2-10 M550001-01
 VOLTAGE CURRENT

POWER

Figure 2-6
P86 Outline Drawing, 20KW to 30KW (Output Voltage >=80 V)

M550001-01 2-11
 This page intentionally left blank.

2-12 M550001-01
 Chapter 3
OPERATING INSTRUCTIONS

3.1 CONTROLS AND INDICATORS

Front panel controls and indicators for the ‘P’ Series are identified in Figure 3-1.
Although different models may have different heights, the controls remain the same
across the entire series. Table 3-1 provides a description of all operator controls and
indicators.

1 2 3 5 4

11 10 9 8 6 7

Figure 3-1
P6x, P8x, and D3 Series Controls and Indicators

For the D3 Series, the Controls and Indicators for PS1 are on the top half of the front
panel, for PS2 they are on the bottom half of the panel.

M550001-01 3-1
 Table 3-1
P62, P63, P66, P83, P86, and D3 Series Controls and Indicators

FIGURE &
CONTROL/INDICATOR FUNCTION
INDEX NO.

3-1 & 3-2

1 VOLTAGE Meter Measures voltage output.

2 CURRENT Meter Measures current output.

3 Overvoltage Potentiometer Adjusts overvoltage trip level.

4 Voltage Mode Indicator Indicates the power supply is operating

in the voltage mode.

5 Current Mode Indicator Indicates the power supply is operating

in the current mode.

6 Overvoltage Indicator Indicates output voltage has exceeded

preset level, and power supply output
is turned off.

7 Fault Indicator Indicates internal fault such as bias

supply, thermal, or converter failure.

8 Readback Overvoltage Reads back the actual overvoltage trip

level on the voltage meter display.

9 Local Output Current Control Adjusts current output to a desired

level.

10 Local Output Voltage Control Adjusts voltage output to a desired

level.

11 ON/OFF Switch Applies bias power to the power

supply.

3-2 M550001-01
 Table 3-2
Connector J1 Designations and Functions

J1 SCHEMATIC FUNCTIONAL
DESIGNATOR SYMBOL DESCRIPTION

1 ISO Isolated remote on/off. Externally supplied AC/DC voltage

ON/OFF source for on/off control. A positive(+) voltage will turn on
the supply. This input control is optically isolated from the
power supply circuit up to 500 VDC.

2 ISO RTN Isolated circuit return used with isolated on/off control
J1-1 and J1-14.

3 REM OV Remote overvoltage set. A remote signal sets the

SET overvoltage trip level. 0-5 VDC = 0-100%.

4 VP RTN Voltage programming return. Used with J1-9, J1-15 or J1-

21 and must be referenced to or within ±3V of the circuit
common.

5 ON/OFF Remote on/off. Switch/relay contacts or a direct short

between this terminal and circuit common turns on the
unit.

6 COM Common Circuit.

7 I MON Output current monitor. 0-10 VDC equals 0-100% rated

current.

8 V SET 0-5 VDC local voltage control monitor.

9 VP 5V Remote voltage programming using a 0-5 VDC source.

10 IP 5V Remote current programming using a 0-5 VDC source.

11 ISET 0-5 VDC local current control monitor.

12 SENSE - Remote Sense (-) on <60 volts output units.

13 SENSE + Remote Sense (+) on <60 volts output units.

14 ISO Isolated TTL/CMOS on/off control. A high state

TTL/CMOS TTL/CMOS voltage turns on the power supply, and a low
state or open connection turns the supply off.

M550001-01 3-3
 Table 3-3
D-Shell Connector J1 Designations and functions – Continued

J1 SCHEMATIC FUNCTIONAL
DESIGNATOR SYMBOL DESCRIPTION

15 VP 10V Remote voltage programming using a 0-10 VDC source.

16 IP 10V Remote current programming using a 0-10 VDC source.

17 FAULT Fault state. A high state indicates a converter,

temperature or bias supply fault, and the LED on the front
panel will illuminate.

18 S/D FAULT Shutdown fault. This terminal goes to high state in the
event of converter, temperature, overvoltage or bias
supply fault.

19 V MON Output voltage monitor. 0-10 VDC equals to 0-100%

rated voltage.

20 VP RTN Voltage programming return. Used with J1-9, J1-15 or

J1-21 and must be referenced to or within ±3V of the
circuit common.

21 VP RES 1 milliamp current source for remote voltage

programming using resistance. 0-5k ohm resistor
referenced to common will program the output voltage
from 0-100%.

22 IP RES 1 milliamp current source for remote current programming

using resistance. 0-5k ohm resistor referenced to
common will program the output from 0-100%.

Current programming return. Used with J1-10, J1-16 or

23 IP RTN J1-22 and must be referenced to or within ±3V of the
circuit common.

Circuit common.
24 COM
Current programming return. Used with J1-10, J1-16 or
25 IP RTN J1-22 for remote current programming and must be
referenced to or within ±3V of the circuit common.

Note: This interface is not usable on units equipped with digital programming
functionality, i.e., the “R” and “S” series models.

3-4 M550001-01
 The following paragraphs provide setup
and operating procedures for the P62,
1 P63, P66, P83, P86, and D3 Series.
14
The power supply may be configured via
connector J1 on the rear panel for
different operating configurations: local
and remote current programming, local
and remote voltage programming,
normal parallel, auto-parallel, normal
series, auto-series, and auto-tracking.
The use and operating requirements of
25 each configuration are provided in the
13 following paragraphs. Reference Table
3-2 for connector J1 designations and
functions. See Figure 3-2 for pin-out
diagram.
Figure 3-2
Pin-out for Connector J1

3.2 LOCAL OPERATION

Units are shipped from the factory configured for local voltage/current control and local
voltage sensing Units are shipped from the factory configured for local voltage/current
control and local voltage sensing. J1 is supplied with a mating connector with remote
on/off jumpered for ON (terminal 5 shorted to terminal 6). Prior to turning the unit on,
rotate the voltage and current potentiometers fully counterclockwise (minimum output).
Then, turn the power ON and adjust the voltage and current to the desired output.

3.3 REMOTE CURRENT PROGRAMMING

The remote current programming is used for applications that require the output
current be programmed (controlled) from a remote source. An external resistance or
external voltage source may be used as a programming device. When using remote
current programming, a shielded, twisted-pair, hookup wire is recommended to
prevent noise interference with programming signals.
a) Remote Current Programming Using Resistance. The resistance coefficient
for remote current programming is 5k ohms/100% rated output with respect to
terminal J1-23 (IP RTN). The programming current from terminal J1-22 (IP
RES) is factory set for 1 milliampere. This yields a coefficient of 1.0% of rated
output current for each 50 ohms. If multiple switches or relays are used to
program different levels, make-before-break contacts are recommended.
Note that if an external resistance is used for remote programming, the
current programming return (IP RTN), terminal J1-23, must be connected
directly to or within ±3 volts of the power supply common terminal, J1-24.
See Figure 3-3 for connection requirements.
b) Remote Current Programming Using a 0-5 VDC or 0-10 VDC Voltage
Source. A DC voltage source for remote current programming is connected
between J1-10 (IP 5V) or J1-16 (IP 10V) and the return terminal J1-23 (IP
RTN). Note that the return terminal J1-23 (IP RTN) must be referenced
directly to or within ±3V of the power supply common, J1-24. The voltage

M550001-01 3-5
 coefficient for 5V remote current programming is 50 millivolts = 1% of rated
output, i.e., for a 300 amp model, each 50 millivolts of programming voltage
equals 3 amps of output current. The voltage coefficient for 10V remote
current programming is 100 millivolts = 1% of rated output, i.e., for a 300 amp
model, each 100 millivolts of programming voltage equals 3 amps of output
current. See Figure 3-4 for connection requirements.

3.4 REMOTE VOLTAGE PROGRAMMING

The remote voltage programming configuration is used for applications that require
the output voltage be programmed (controlled) from a remote source. An external
resistance or external voltage source may be used as a programming device. When
using remote voltage programming, a shielded, twisted-pair, hookup wire is
recommended to prevent noise interference with programming signals.

1. External Voltage Programming Using Resistance. The resistance coefficient

for remote voltage programming is 5k ohms/100% of rated output voltage
with respect to the VP RTN, J1-20. The programming current from terminal
J1-21 (VP-RES) is factory set to 1 milliampere. This yields a coefficient of
1.0% of rated output voltage for each 50 ohms. If multiple switches or relays
are used to program different levels, make-before-break contacts are
recommended. Note that if an external resistance is used for remote
programming, the voltage programming return (VP RTN), terminal J1-20,
must be connected directly to or within ±3 volts of the power supply common
terminal, J1-24 See Figure 3-5 for connection requirements.
2. External Voltage Programming Using a 5 VDC or 10 VDC Voltage Source. A
DC voltage source for remote voltage programming is connected between J1-
9 (VP 5V) or J1-15 (VP 10V) and the return terminal J1-20 (VP RTN). Note
that the return terminal (VP RTN) must be referenced directly to or within ±3V
of the power supply common, J1-24. The voltage coefficient for 5V remote
voltage programming is 5 volts = 100% of rated output voltage. The voltage
coefficient for 10V remote voltage programming is 10 volts = 100% of rated
output voltage. See Figure 3-6 for connection requirements.

3.5 REMOTE SENSING

In applications where the load is located some distance from the power supply, or the
voltage drop of the power output leads significantly interferes with load regulation,
remote voltage sensing may be used. When remote sensing is used, voltage is
regulated at the load versus the power supply output terminals. To connect the power
supply for remote voltage sensing (see Figure 3-7 for connection requirements),
perform the following procedure.

3-6 M550001-01
 CAUTION
If the power supply is operated with load
power lines disconnected and sensing line
connected, internal power supply damage
may occur. (Output current then flows
through sensing terminals.)

Connect sensing leads from the load positive to J1-13 and the load negative to J1-12.
A shielded, twisted-pair, hookup wire is recommended to avoid potential noise
interference.

3.6 REMOTE OUTPUT ON/OFF CONTROL

Remote on/off control may be accomplished by contact closure or by an isolated
external AC/DC or TTL/CMOS voltage source.

1. Remote on/off by contact closure. Output is on when contacts are closed.

See Figure 3-8 for connection requirements.

2. Remote on/off control may be accomplished by an external 12 to 240 VAC or

6 to 120 VDC or TTL/CMOS source. Application of AC/DC or high state
TTL/CMOS voltage will turn on the power supply. See Figures 3-9 and 3-10
for connection requirements.

3.7 REMOTE OVERVOLTAGE SET

A remote DC voltage source can be connected externally between terminals J1-3
(REM OV SET) and J1-6 (COM) to set the output overvoltage trip level. A 0-5 VDC
signal equals 0-100% of rated output voltage. See Figure 3-11 for connection
requirements. Do not program the remote overvoltage set point greater than 10%
(5.5V) above the power supply rated voltage as internal power supply damage
may occur.

NOTE
The following modes of operation are used
for applications requiring more current or
voltage than is available from a single
power supply. To meet the requirements for
greater output voltage or current, two
supplies may be connected in series or
parallel.

M550001-01 3-7
3.8 AUTO-PARALLEL OPERATION
In the auto-parallel mode of operation, a master/slave configuration is established.
Up to four power supplies may be paralleled using this configuration.

CAUTION
When using two supplies in parallel, damage
may occur to slave(s) crowbar circuits if slave
overvoltage level set is not higher than the
master overvoltage level set. To prevent
damage, apply a 6 VDC source between J1-3
(REM OV SET) and J1-6 (COM), or set all slave
units overvoltage setting to maximum and set
the master unit to the desired trip level. If
overvoltage protection is not desired, set to trip
at maximum rated voltage.

To set up the auto-parallel mode of operation, connect all outputs in parallel to the
load. Connect jumper from master J1-7 (I MON) to slave J1-16 (IP 10V), and the
slave J1-6 (COM) must be connected to the slave J1-25 (IP RTN). Always set the
slave overvoltage to maximum and the master to the desired trip level. Output
currents will track automatically. If tracking is not close, perform the calibration
procedures listed in Chapter 4. See Figure 3-12 for connection requirements.

3.9 AUTO-SERIES OPERATION

In the auto-series mode of operation, a master/slave configuration is established. No
more than two power supplies may be in series. With two supplies connected in
series, one is established a master and the remaining unit as a slave. The master
supply must always be the most positive unit. Connect Rx between the master
positive output and the slave J1-15 (VP 10V), and connect the slave J1-20 (VP RTN)
to the slave J1-6 (COM). When operating in the auto-series mode, current control
potentiometers of the slave units are active and should be set to maximum clockwise
position. See Figure 3-13 for connection requirements and Rx value.
Under no condition should the negative terminal of either supply be greater than 150
volts, positive or negative, from chassis potential.

3.10 AUTO-TRACKING OPERATION

In the auto-tracking mode of operation, a master/slave configuration is established.
Up to four power supplies may be connected in the auto-parallel configuration. In this
configuration, two or more supplies may be connected with common negative
outputs. The slave(s) output voltage is a percentage of the master as controlled by
the value of Rx. Individual current controls on both master and slave(s) remain
active. See Figure 3-14 for connection requirements.

3-8 M550001-01
 For equal voltage supplies with volt-per-volt tracking, Rx = 0 ohms.

For other ratios or different voltage supplies, Rx can be calculated by using the
following formulas:

Rx(kohms) = (10/SMR) - 10

SMR(Slave/Master Ratio) = SR(Slave Ratio)/MR(Master Ratio)

where SR = slave desired Vout/rated Vout
MR = master desired Vout/rated Vout

Example: It is desired to have a slave power supply

rated at 20 VDC and operated at 12 VDC,
while the master power supply rated at 10
VDC is operated at 8 VDC.

The Slave Ratio(SR) = 12V/20V = .60

The Master Ratio (MR) = 8V/10V = .80

Then; The Slave/Master Ratio(SMR) = .60/.80 = .75

And Rx(kohms) = (10/.75) - 10 = 13.33 - 10 = 3.33 kohms.

Note: The slave ratio (SR) must always be less than or

equal to the master ratio (M).

M550001-01 3-9
 1 14

COM 6
22 IP RES

23 IP RTN
13 0-5 Kohms
PROGRAM

Figure 3-3
Remote Current Programming Using Resistance

1
16 IP 10V

COM 6

IP 5V 10
0-5 VDC + 23 IP RTN + 0-10 VDC
VOLTAGE 13 VOLTAGE
SOURCE - - SOURCE

Figure 3-4
Remote Current Programming Using 0-5 VDC or 0-10 VDC Voltage Source

3-10 M550001-01
 1 14

COM 6 20 VP RTN

21 VP RES

13 0-5 Kohms
PROGRAM

Figure 3-5
Remote Voltage Programming Using Resistance

1
15 VP 10V

COM 6 20 VP RTN

VP 5V 9
+ 0-10 VDC
13 VOLTAGE
0-5 VDC + - SOURCE
VOLTAGE
SOURCE -

Figure 3-6
Remote Voltage Programming Using 0-5 VDC or 0-10 VDC Voltage Source

M550001-01 3-11
 LOAD

+ − 3 2

J3
1

SUPPLY
OUTPUT
TERMINALS

Figure 3-7
Remote Sensing Operation at the Load

1 14

ON/OFF 5

25

Figure 3-8
Remote On/Off Control by Contact Closure

3-12 M550001-01
 ISO ON/OFF 1
+ 14
ISO RTN 2
-
AC OR DC
SOURCE

25

Figure 3-9
Remote On/Off Using Isolated AC or DC Voltage Source

1 14 ISO TTL/CMOS
ISO RTN 2

25

Figure 3-10
Remote On/Off Using Isolated TTL/CMOS Voltage Supply

M550001-01 3-13
 1

REM OV SET 3
0-5.5 VDC +
VOLTAGE COM 6
SOURCE -

13

Figure 3-11
Remote Overvoltage Set Using DC Voltage Source

PS1 PS2 LOAD

MASTER SLAVE

1 1
14 14
16 IP 10V
5
6
IMON 7
5
6 + −
PS1
OUTPUT

25 25 IP RTN

+ −
PS2
OUTPUT

ADDITIONAL SLAVES (UP TO

FOUR TOTAL) MAY BE CONNECTED
IN SAME MANNER AS FIRST

Figure 3-12
Auto-Parallel Operation

3-14 M550001-01
 PS1 PS2
MASTER RX LOAD
SLAVE

1 1
14 15 VP 10V

5
6
5
6 20 VP RTN + − PS1
OUTPUT

25

+ − PS2
OUTPUT

RX (K ohms) = 2(PS1 RATED Vout + PS2 RATED Vout) - 20

EXAMPLE: FOR A 20 VOLT RATED PS1 AND A 10 VOLT RATED PS2
RX = 2(20+10)-20 = 40K ohms

Figure 3-13
Auto-Series Operation

LOAD
PS1 PS2
MASTER SLAVE

1
+ −
14 VP 10V
15
PS1
OUTPUT
5 5
Rx 6
6 19
VMON 20 VP RTN

25
24 COM
+ − PS2
OUTPUT

LOAD
Figure 3-14
Auto-Tracking Operation

M550001-01 3-15
 This page intentionally left blank.

3-16 M550001-01
 Chapter 4
CALIBRATION

4.1 INTRODUCTION

This chapter contains calibration procedures for the P62, P63, P66, P83, P86 and D3
Series.

4.2 CALIBRATION AND ADJUSTMENTS

To perform the following calibration and adjustment procedures, the cover must be
removed from the power supply. Because removal of the cover allows access to
potentially hazardous power voltages (up to 253 VAC or 450 VDC) and because of the
importance of accurate readings to performance, only technically trained personnel
should perform calibration procedures.

WARNING
Hazardous voltages exist on the rear of the
supply. Great care must be taken to avoid
both the input terminals, and while the
supply is enabled, the output terminals.
Only authorized personnel should perform
this procedure.

The calibration Test Setup procedures require the following: remove prime power, then
connect the power supply to a resistive load capable of full-rated voltage and current.
Connect a precision current shunt in series with either the positive or negative output
between the power supply and the resistive load. Two digital multimeters are required to
perform the calibration procedures.

To properly calibrate the power supply first calibrate the power converter then calibrate
the control card as described in the following sections.

4.2.1 P62 Series Calibration Procedures

In this section refer to Figure 4-1 for locations of assemblies in the P62.

M550001-01 4-1
 5V Reference Calibration

The 5V reference for the front panel voltage and current control must be
calibrated first. Refer to Figure 4-7 for locations of components on the control
assembly.

a. With prime power removed, remove jumper J9 on the converter assembly.

b. Connect a digital multimeter (DMM) between E1 and E3 of the current
control potentiometer R32 on the control assembly.
c. Apply prime power to the power supply, and push the front panel switch to
the ON position.
d. Adjust potentiometer R29 until DMM across E1 and E3 indicates 5.000
VDC.
e. Remove prime power from power supply and wait 3 minutes (minimum) for
filter capacitors to discharge.

Converter Assembly Calibration

For proper results, converter assembly A2 must be calibrated prior to the

calibration of control assembly A1. Refer to Figure 4-3 for component locations
on the P62 converter assembly.

Current Limit Calibration.

1. With prime power removed, install jumper J9 on the converter
assembly.
2. Connect a load of minimum 5% heavier than full-rated power and a
DMM across external current shunt.
3. Rotate front panel voltage control fully clockwise.
4. Rotate front panel current control fully counterclockwise.
5. Apply prime power to power supply, and push the front panel switch to
the ON position.
6. Rotate front panel current control fully clockwise or until DMM across
external current shunt indicates a maximum of 5% above the
converter assembly rated output current. Adjust potentiometer R64
until the supply puts out 5% over the rated current when the front
panel current pot is fully clockwise.
If the fault light lights before the output reaches 5% over the maximum
rating, adjust the internal current limit. To adjust the internal current
limit set R73 so the fault light just goes off at 5% over maximum
rating.
7. Once the converter is delivering 105% of rated current and the current
mode indicator on the front panel is illuminated, rotate R73
counterclockwise until the current mode indicator just extinguishes.
Do not adjust beyond this point.

4-2 M550001-01
 8. Remove prime power from the power supply, and wait three minutes
(minimum) for the filter capacitors to discharge.
Current Feedback Amplifier Zero Calibration.
1. Remove jumper J9 on the converter board.
2. Connect a DMM between the output of U8, pin 1, and the common
return (on converter assembly A2).
3. Apply prime power to power supply, and push the front panel switch to
the ON position.
4. Adjust R68 for zero null (minimum voltage on DMM).
5. Remove prime power from the power supply, and wait 3 minutes
(minimum) for filter capacitors to discharge.
6. Replace jumper J9.
Current Feedback Amplifier Full-Scale Calibration.
1. Remove prime power to the power supply, and leave jumper installed
on J9.
2. Connect DMM between the output of the current feedback scaler U8,
pin 1, and the common circuit. Set DC voltage scale to read 5.0 volts.
3. Connect a second DMM across the external current shunt.
4. Rotate front panel voltage control fully clockwise.
5. Rotate front panel current control fully counterclockwise. This
changes the operation of the power supply from the voltage to the
current mode.
6. Apply prime power to power supply, and push the front panel switch to
the ON position.
7. Rotate front panel current control clockwise until DMM indicates 5.000
VDC between U8, pin 1, and common.
8. Adjust converter assembly potentiometer R64 until DMM across
external current shunt indicates full-rated output current.
9. Remove prime power from power supply and wait 3 minutes
(minimum) for filter capacitors to discharge.

4.2.2 P63, P66 and D3 Series Calibration procedures

In this section refer to Figures 4-2 and 4-6 for locations of assemblies and
potentiometers.

M550001-01 4-3
 5V Reference Calibration

The 5V reference for the front panel voltage and current control must be
calibrated first. Refer to Figure 4-6 for locations of components on the control
assembly.
a. With prime power removed, remove jumper J7 on all converter
assemblies.
b. Connect a digital multimeter (DMM) between E1 and E3 of the current
control potentiometer R32 on the control assembly.
c. Apply prime power to the power supply, and push the front panel switch to
the ON position.
d. Adjust potentiometer R29 until DMM across E1 and E3 indicates 5.000
VDC.
e. Remove prime power from power supply and wait 3 minutes (minimum) for
filter capacitors to discharge.
Converter Assembly Calibration

For proper results, the converter assemblies must be calibrated prior to the
calibration of control assembly A1. Refer to Figure 4-5 for locations of
components on the converter assembly.

Current Limit Calibration

1. Remove prime power to the power supply. Remove jumper J7 from
all converter assemblies not being calibrated. Leave jumper installed
on assembly to be calibrated.
2. Connect a load of minimum 5% heavier than full-rated power and a
DMM across external current shunt.
3. Rotate front panel voltage control fully clockwise.
4. Rotate front panel current control fully counterclockwise.
5. Apply prime power to power supply, and push the front panel switch to
the ON position.
6. Rotate front panel current control fully clockwise or until DMM across
external current shunt indicates a maximum of 5% above the
converter assembly rated output current. (The converter assembly
rated output = the power supply rated output divided by the number of
converter assemblies.) For 10 kW models, there are three converter
assemblies. Adjust potentiometer R33 until the supply puts out 5%
over the rated current when the front panel current pot is fully
clockwise.
If the fault light lights before the output reaches 5% over the maximum
rating adjust the internal current limit. To adjust the internal current
limit set R54 so the fault light just goes off at 5% over maximum
rating.

4-4 M550001-01
 7. Once the converter is delivering 105% of rated current and the current
mode indicator on the front panel is illuminated, rotate R54
counterclockwise until the current mode indicator just extinguishes.
Do not adjust beyond this point.
8. Remove prime power from the power supply and wait three minutes
(minimum) for the filter capacitors to discharge.
9. Repeat steps (1) through (8) for the balance of converter assemblies
A3 through A5.
Current Feedback Amplifier Zero Calibration
1. With prime removed, remove jumper J7 from all converter assemblies.
2. Apply prime power to power supply, and push the front panel switch to
the ON position.
3. Connect DMM between TP2 (U2, pin 1) and TP1 (common return) to
the converter assembly to be calibrated.
4. Adjust R36 for zero null (minimum voltage range on DMM).
5. Repeat steps 3 and 4 for the balance of the converter assemblies A3
through A5.
6. Remove prime power from the power supply and wait three minutes
(minimum) for filter capacitors to discharge.
7. Replace jumper J7.
Current Feedback Amplifier Full-Scale Calibration.
1. Remove prime power to the power supply. Remove J7 on all
converter assemblies not being calibrated. Leave jumper installed on
assembly to be calibrated.
2. Connect DMM between TP2 (U2, pin 1) and TP1 (common return).
Set DC voltage scale to read 5.0 volts.
3. Connect a second DMM across the external current shunt.
4. Rotate front panel voltage control fully clockwise.
5. Rotate front panel current control fully counterclockwise. This
changes the operation of the power supply from the voltage to the
current mode.
6. Apply prime power to power supply, and push the front panel switch to
the ON position.
7. Rotate front panel current control clockwise until DMM between TP2
and TP1 indicates 5.000 VDC.
8. Adjust potentiometer R33 of converter assembly being calibrated until
DMM across external current shunt indicates one-third the full-rated
output current for 10 kW power supply models.
9. Remove prime power from power supply and wait 3 minutes
(minimum) for filter capacitors to discharge.
10. Repeat steps (1) through (9) for the balance of converter assemblies
A3 through A5.

M550001-01 4-5
4.2.3 P83 and P86 Series Calibration procedures
In this section refer to Figures 4-4 and 4-5 for locations of assemblies and
potentiometers.

5V Reference Calibration

The 5V reference for the front panel voltage and current control must be
calibrated first. Refer to Figure 4-3 for locations of components on the control
assembly.
a. With prime power removed, remove jumpers J11 and J12 on the surge
limit & power switch board of all converter assemblies.
b. Connect a digital multimeter (DMM) between E1 and E3 of the current
control potentiometer R32 on the control assembly.
c. Apply prime power to the power supply, and push the front panel switch to
the ON position.
d. Adjust potentiometer R29 until DMM across E1 and E3 indicates 5.000
VDC.
e. Remove prime power from power supply and wait 3 minutes (minimum) for
filter capacitors to discharge.
Converter Assembly Calibration

For proper results, the converter assemblies must be calibrated prior to the
calibration of control assembly A1. Refer to Figures 4-4 an 4-5 for locations of
components on the converter assembly.

Primary Current Limit Calibration

1. Remove prime power to the power supply. Remove jumpers J11 and
J12 on all converter assemblies not being calibrated. Leave jumpers
installed on assembly to be calibrated.
2. Connect a load of 5% heavier than full-rated power of the converter
assembly rated output power. (The converter assembly rated output
power = the power supply rated output power divided by the number
of converter assemblies.) For 15 kW models, there are three
converter assemblies.
3. Connect a DMM across external current shunt.
4. Connect a second DMM across the output terminals of the power
supply. Set DMM to read maximum rated power supply output
voltage.
5. Connect a third DMM across two of the three AC input terminals of the
power supply. Set DMM to read maximum rated power supply input
voltage.
6. Connect a variable transformer in series with the prime power of the
power supply.
7. Rotate front panel voltage control fully clockwise.

4-6 M550001-01
 8. Rotate front panel current control fully counterclockwise.
9. Apply prime power to power supply, and push the front panel switch to
the ON position. Adjust the variable transformer until the DMM
indicates the minimum rated power supply input voltage across the
AC input terminals.
10. Rotate front panel current control fully clockwise or until DMM across
external current shunt indicates a maximum of 5% above the
converter assembly rated output current. (The converter assembly
rated output equals the power supply rated output divided by the
number of converter assemblies.) For 15 kW models, there are three
converter assemblies. Adjust potentiometer R40 until the supply puts
out 5% over the rated current when the front panel current pot is fully
clockwise.
If the fault light lights before the output reaches 5% over the maximum
rating, adjust the internal current limit. To adjust the internal current
limit, set R45 so the fault light just goes off at 5% over maximum
rating.
11. Once the converter is delivering 105% of rated current, rotate R50
counterclockwise until the power supply is shut off by the primary
current limit circuit and the fault light lights. Do not adjust beyond this
point.
12. Push the front panel switch to the OFF position. Remove prime power
from the power supply and wait three minutes (minimum) for the filter
capacitors to discharge.
13. Rotate R50 three turns clockwise.
14. Repeat steps (1) through (13) for the balance of converter assemblies
A3 through A5.
Current Limit Calibration
1. Remove prime power to the power supply. Remove jumpers J11 and
J12 on all converter assemblies not being calibrated. Leave jumper
installed on assembly to be calibrated.
2. Connect a load of minimum 5% heavier than full-rated power and a
DMM across external current shunt.
3. Rotate front panel voltage control fully clockwise.
4. Rotate front panel current control fully counterclockwise.
5. Apply prime power to power supply, and push the front panel switch to
the ON position.
6. Rotate front panel current control fully clockwise or until DMM across
external current shunt indicates a maximum of 5% above the
converter assembly rated output current. (The converter assembly
rated output = the power supply rated output divided by the number of
converter assemblies.) For 15 kW models, there are three converter
assemblies. Adjust potentiometer R40 until the supply puts out 5%
over the rated current when the front panel current pot is fully
clockwise.

M550001-01 4-7
 If the fault light lights before the output reaches 5% over the maximum
rating adjust the internal current limit. To adjust the internal current
limit set R45 so the fault light just goes off at 5% over maximum
rating.
7. Once the converter is delivering 105% of rated current and the current
mode indicator on the front panel is illuminated, rotate R45
counterclockwise until the current mode indicator just extinguishes.
Do not adjust beyond this point.
8. Remove prime power from the power supply and wait three minutes
(minimum) for the filter capacitors to discharge.
9. Repeat steps (1) through (8) for the balance of converter assemblies
A3 through A5.
Current Feedback Amplifier Zero Calibration
1. With prime removed, remove jumpers J11 and J12 from all converter
assemblies.
2. Apply prime power to power supply, and push the front panel switch to
the ON position.
3. Connect DMM between J10-3 (U2, pin 14) and J10-10 (common
return) to the converter assembly to be calibrated.
4. Adjust R25 until DMM between J10-3 and J10-10 indicates
15.00mVDC.
5. Repeat steps 3 and 4 for the balance of the converter assemblies A3
through A5.
6. Remove prime power from the power supply and wait three minutes
(minimum) for filter capacitors to discharge.
7. Replace jumpers J11 and J12.
Current Feedback Amplifier Full-Scale Calibration.
1. Remove prime power to the power supply. Remove J11 and J12 on
all converter assemblies not being calibrated. Leave jumper installed
on assembly to be calibrated.
2. Connect DMM between J10-3 (U2, pin 14) and J10-10 (common
return). Set DC voltage scale to read 5.0 volts.
3. Connect a second DMM across the external current shunt.
4. Rotate front panel voltage control fully clockwise.
5. Rotate front panel current control fully counterclockwise. This
changes the operation of the power supply from the voltage to the
current mode.
6. Apply prime power to power supply, and push the front panel switch to
the ON position.
7. Rotate front panel current control clockwise until DMM between J10-3
and J10-10 indicates 5.000 VDC.

4-8 M550001-01
 8. Adjust potentiometer R40 of converter assembly being calibrated until
DMM across external current shunt indicates one-third the full-rated
output current for 15 kW power supply models.
9. Remove prime power from power supply and wait 3 minutes
(minimum) for filter capacitors to discharge.
10. Repeat steps (1) through (9) for the balance of converter assemblies
A3 through A5.

4.2.4 Control Assembly Calibration

In this section refer to Figure 4-6 for locations of assemblies and potentiometers.

Voltage Reference
The voltage reference is provided by an adjustable current regulator Q1
and associated components. To calibrate for the 1 mA programming
coefficient (constant voltage), the following sequence is recommended.
For J1 and J2, refer to the D-shell connectors on the rear panel.
1. Set front panel current control fully counterclockwise.
2. Connect a precision DMM to J1-21(VP RES) with reference to
J1-24(COM). Set DMM to DC milliamps and 2 milliamps range.
3. Apply power to power supply, and push the front panel switch to the
ON position.
4. Adjust R47 for 1.000 milliamps on DMM.
5. Remove power from power supply.
Current Reference
The current reference is a precision current source consisting of Q2 and
associated components. Calibration is accomplished by adjusting R50.
The following sequence is recommended. For J1 and J2, refer to the D-
shell connectors on the rear panel.
1. Set front panel voltage control fully counterclockwise.
2. Connect a precision DMM to J1-22(IP RES) with reference to
J1-24(COM). Set DMM to DC milliamps and 2 mA range.
3. Apply power to power supply, and push the front panel switch to the
ON position.
4. Adjust R50 for 1.000 milliamps on DMM.
5. Remove power from power supply.
Voltage Zero Calibration
The voltage control circuit (U11-A) zero is adjusted by R39. The following
sequence is recommended. For J1 and J2, refer to the D-shell
connectors on the rear panel.
1. Connect a jumper (short circuit) between J1-8(V SET) and J1-
6(COM).
2. Connect DMM across CR7. Set DMM to read DC volts and
approximately 200 millivolt range.

M550001-01 4-9
 3. Set front panel current control fully clockwise.
4. Set front panel voltage control fully counterclockwise.
5. Apply power to power supply, and push the front panel switch to the
ON position.
6. Adjust R39 until DMM reads zero. Do not continue adjustment once
the DMM reads zero millivolts.
7. Remove power from power supply.
8. Remove DMM from CR7 of control assemblies.
9. Remove jumper between J1-8 and J1-6.
Current Zero Calibration
The current error amplifier circuit (U10-D) zero is adjusted with R26. The
following sequence is recommended. For J1 and J2, refer to the D-shell
connectors on the rear panel.
1. Connect a jumper (short circuit) between J1-11(I SET) and J1-
6(COM).
2. Connect any resistive load and DMM across the output terminals of
the power supply. Set DMM to read DC volts and approximately 200
millivolt range.
3. Set front panel voltage control fully clockwise.
4. Set front panel current control fully counterclockwise.
5. Apply power to power supply, and push front panel switch to the ON
position.
6. Adjust R26 until the power supply output voltage starts to increase in
the normal polarity. Reverse adjustment direction of R26 until output
voltage decreases to zero reading on the DMM. Do not continue
adjustment when output reads zero volts.
7. Remove power from power supply.
8. Remove DMM from power supply output terminals.
9. Remove jumper between J1-11 and J1-6.
Voltage Full-Scale Calibration
Full-scale voltage calibration is accomplished by adjusting R37. The
following sequence is recommended. For J1 and J2, refer to the D-shell
connectors on the rear panel.
1. Connect any resistive load and DMM across the output terminals of
the power supply. Set DMM to read maximum rated power supply
output voltage.
2. Connect a second DMM between J1-8(V SET) and the common
return J1-6. Set DMM to DC volts and scale to read 5.00 volts.
3. Rotate front panel current control fully clockwise.
4. Apply power to power supply, and push front panel switch to the ON
position

4-10 M550001-01
 5. Rotate front panel voltage control clockwise until DMM indicates 5.000
VDC between J1-6 and J1-8.
6. Adjust R37 until output voltage reading is 100% of rated output
voltage DC between the output terminals of the power supply.
7. Remove power from power supply.
8. Remove DMM from power supply terminals.
Meter Calibration
1. Meter Zero Calibration. If zero calibrations in the converter and
control assemblies are set properly, the zero set for both voltage and
current front panel meters is automatic.
(a) If meters do not read zero, check the output voltage. If there
is some voltage present across output bus bars, turn R26 on the
control assembly until output voltage is zero.
(b) If meters do not read zero even though no voltage is present on
the output bus bars, turn R36 on the converter assemblies for
current meter and R39 on control assemblies for the voltage
meter until both meters read zero.
2. Meter Full-Scale Calibration. The full-scale adjustment for the digital
panel meters U1 and U4 is adjusted by R6 and R11, respectively. R6
is for full-scale voltage meter calibration, and R11 is for full-scale
current meter calibration. Both resistors are accessible from inside
the power supply with the cover removed.
To calibrate for full-scale voltage or current, adjust the power supply
to maximum rated output voltage (or current) using external calibrated
meters and adjust the appropriate meter to correspond to the rated
output voltage or current.
Overvoltage Trip Level Calibration
The overvoltage trip level is calibrated by adjusting potentiometer R43 on
the control assembly A1. This setting can be viewed on the voltage
display monitor by pressing the front panel switch S1. The factory setting
for the overvoltage trip level is approximately 10% above the rated output
voltage.

M550001-01 4-11
 ASSEMBLY
CONTROL
CONVERTER
ASSEMBLY
FILTER
INPUT

Figure 4-1
P62 Internal Layout

4-12 M550001-01
 CONVERTER
CONTROL ASSEMBLIES BIAS
ASSEMBLY ASSEMBLY
AC
DISTRIBUTION
BOARD

POWER POWER POWER

SWITCH SWITCH SWITCH
BOARD BOARD BOARD

INPUT FILTER

Figure 4-2
P63, P66, D3 Internal Layout

M550001-01 4-13
4-14
GROUND CURRENT
RETURN FULL CURRENT CONVERTER CURRENT
POINT SCALE ZERO ENABLE LIMIT

R64 R73

J7 R68
Q1 Q17 U9
T1 F2
R31
J3 J9
J1
Q15
J2
U8 Q16
T2 U7
Q13
U6 Q14

F4 F3 R2
Q12
Q7
C31
C10 R26
BR3 BR2

Figure 4-3
C3 J4 J5 J6

U2 Q3 R19
C4 CR4 Q8 CR9 CR8 Q9 Q11 CR10 CR11 Q10
Q6

P63, P66, D3 Converter Card

J10
BR1

M550001-01
 Figure 4-4
P83, P86 Internal Layout

M550001-01 4-15
 Figure 4-5
P83, P86 Converter Card

4-16 M550001-01
 Figure 4-6
P63 & P66 Converter Card

M550001-01 4-17
 This page intentionally left blank.

4-18 M550001-01
 Chapter 5
MAINTENANCE

5.1 INTRODUCTION
This chapter contains preventive maintenance for the power supplies.

WARNING

All maintenance that requires removal of the

cover of the unit should only be done by
properly trained and qualified personnel.
Hazardous voltages exist inside the unit.
Disconnect the supply from the input power
before performing any maintenance.
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.

5.2 PREVENTIVE MAINTENANCE

Preventive maintenance for the “P” and “D” series consists of scheduled inspection and
cleaning.

1. Schedule. Table 5-1 lists the preventive maintenance routines and the
recommended performance intervals.

2. Inspection. Table 5-2 lists the visual inspection checks to be performed. It

also indicates the corrective action to be taken.

Table 5-1
Preventive Maintenance Schedule

PREVENTIVE MAINTENANCE RECOMMENDED PERFORMANCE

ROUTINE INTERVAL

Inspection Annual

Cleaning As Required

M550001-01 5-1
 Table 5-2
Inspection and Corrective Action

ITEM INSPECT FOR CORRECTIVE ACTION

External Connector Looseness, bent or corroded Clean contacts with solvent

plugs and jacks contacts, damage or improper moistened cloth, soft bristle brush,
seating in mating connector small vacuum or low compressed
air.

Replace connectors damaged,

deeply corroded, or improperly
seated in mating connector.

Chassis, fan & Dirt and Corrosion Clean with cloth moistened with
extruded heatsinks soapy water.

External Electrical Broken, burned or pinched Repair or replace defective wires.

Wiring wire; frayed, worn or missing
insulation

External Solder Corrosion, loose, cracked, or Clean and resolder connections.

Connections dirty connections

Dirt and moisture Short circuits, arcing, corrosion, Clean as required.

buildup overheating

Front panel controls Dirt and corrosion Clean with cloth moistened with
and meters soapy water.

Use a Kimwipe tissue and GTC

glass cleaning compound to clean
the meter faces.

5-2 M550001-01
5.3 FUSES
There are no user replaceable components in the power supply.

WARNING

Only proper trained and qualified personnel

should remove the cover from the power
supply. 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.

Replacement fuses are in Table 5-3.

Table 5-3
Fuse Values
Power Supply PCB Part Number Reference Value Mfr. Part No.
P62 series 10-010-154-00 F1 250 Volt, 3/8 Amp Littlefuse 263.375
10-010-154-00 F2, F3, F4 600 Volt, 30 Amp Littlefuse KLKD30
10-010-214-00 F1 600 Volt, 30 Amp Littlefuse KLKD30
P63 & P66 series 10-010-156-00 F1 600 Volt, 30 Amp Littlefuse KLKD30
10-010-156-00 F2, F3, F4 250 Volt, 20 Amp Bussman MDA20
10-010-163-00 F1, F2, F3 250 Volt, 1/2 Amp Littlefuse 2AG230.500
P83 & P86 SERIES 10-010-197-00 F1, F2, F3 600 Volt, 30 Amp Littlefuse KLKD30
10-010-219-00 F1 600 Volt, 30 Amp Littlefuse KLKD30

M550001-01 5-3