ha MODULAR POWER SUPPLIES A, C, AND E SERIES MODELS 62003A-62048A, 62003C-62048C, AND 62003E-62048E OPERATING AND SERVICE MANUAL FOR SERIALS 12104-00101 AND ABOVE* “For Serials Above 121000101, 2 change page may be included. Hewlett-Packard HP Part No, 5950-5969 Printed: May, 1972SECTION | GENERAL INFORMATION 1-1 DESCRIPTION 1-2 Hewlett-Packard modular power supplies are completely solid-stata, amploying high-raliability tran sistors and integrated circuits. The power supplies are packaged in three uniform height and depth cases thet are fractions of the standard 19-inch rack width. The supplies ean be bench-operated or rack-mounted indi vidually oF in any combination to full rack width or less. The modular power supplies are of the Constant Voltage/Current Limiting type, furnishing ful-ated ‘output voltage at the maximum rated outout current. ‘The output voltage can be adjusted between #05 V or 85% (whichever is greater) af nominal while providing fullrated output current. The supply and loed are fully protected from current overloads by a self-estor- ing current cutback circuit that causes the output ‘current to cutback linearly from approximately 103% to approximately 10% of rated output as the load varias from slightly above the maximum rated value to ‘ complete short citcult. The current limit (cutback) activation point is adjustable anywhere between the 103% and 10% limite 1:3 Either the positive or negative output terminal may be grounded at the rear terminals. 1-4 SCOPE 1-5 This manual provides installation procedures, ‘operating instructions, principles of operation, main: tenance data, and replacesble parts information for the thirty-three Hewlett-Packard modular power supplies listed in the following chart, Note that the last two digits in the model number indicate the nominal out- bat voltage of the supply, The ~A suffix supplies. ‘V8-rack with units while the ~C and ~E models are W4-rack width units 1-6 SCHEMATICS 1-7. The modular power supplies covered in this ‘manual are of similar design differing mainty in com: ‘ponent values rather than in cireuit operation. Hence, 1 in general, the information presented in the manual applies to all of the power supply models with any significant differences among the supplies described as toplcabla. Thus, the schema agra at he rar of the manual depict group of sila supplier wth ve pe ourruT NOMINAL Vourace | CURRENT ] MODEL (Minimum Adj. Span) AT 50°C za | eeonsa 3V 0.5V) zen woos 5A —[ eran Pa ETS AV (+0.5V) 4a 62004C_ Sa [ara 7a wa BV (+0.5V) 44 62005C sa anos TER | 620008 6V (+0.5V) 375A 62006C 78a —| e208 18A | e0108 10V (+0.5V) 3.268 ‘62070C 5A eamTOe TgA | 82079 12V (+0.60V) 3.04 62012C SoA [eae 125k 076A 15V (+0.75V} 250 ‘62015C Soa] TE 1a oT 18V (=0.90V) 2.25 62018C asa —[ eror9e TBA] e004 (24V (£1.20V) 175A, 620246 a76R | wont 7A [e008 (28V (+1.40V) 1.54 62028 26a | eae eA —[Ceaoien 48V (+2.40V) 1.04 62048C Zon] e0HeEschematics provided to ilusteate all 33 models, Each schematic, of cours, identifies the supplies for which it applies and includes notes and tables to identify the difference mainly in component values} among the supplies illustrated in the common schematic. 1-8 SPECIFICATIONS 1.9 Detailed specifications for the power supplies are given in Table 1-1. Table 1-1. Specifications [neu 115Vae £10%, single phase, 48-63 Hz. See Options 101, 102, and 103. oureur: ‘See Paragraph 15. LOAD REGULATION: Less than 0.01% or 1 mV whichever is eater for 2 {ull load to no load change in output cureent. LINE REGULATION: Less than 0.01% or 1 mV whichever is greater for a 410% change in the specified input voltage. RIPPLE AND NOISE: ‘Less then 1 mV rms and 2 mV p-p (up to 20 MHz), ‘TEMPERATURE RANGES: ‘Operating: 0 to 50°C ambient. Output current do- rated linearly for temperatures greater than 50” with 60% of maximum output current at 71°C ambient. 88°C to 488°C Convection cooled. ‘Storage: Cooling ‘TEMPERATURE COEFFICIENT: Less than 0.01% output voltage change per degree Centigrade over the operating range from 0 10 60°C. after 30 minutes warmup. ‘THERMAL PROTECTION: ‘Hest sink mounted thermostat opens ac line i supply overheats due to high ambient temperature “Thermostat automatically closes (reset) when temper ature cools to sate operating level STABILITY: ‘Less than 0.1% total drift for 8 hours after an init rmvup time of 30 minutes at constant ambient, con- stant line voltage, and constant load, ‘TRANSIENT RECOVERY TIME: Less than 50 usee for output recovery to within 16 mV of nominal output voltage following 6 food change from full to half load (or vice versa). (OVERLOAD PROTECTION: ‘A current limit circuit euts back current linearly to approximately 10% of rated output current when supply is short-circuited, Automatically resets when overload removed. Current limit activation point adjustable (screwdriver control) but preset at factory to activate at 104.21% of maximum rated output current at nominal outout voltage. ‘OUTPUT CONTROL: Screwdriver adjustment accessible through hole in front panel. Minimum adjustment range is 0.5 V or 85%, whichever fs grester ERROR SENSING: Error sensing normally accomplished focally at rear terminals. Provision included at rear terminal stip for remote sensing with correction for load lead voltage drops of up to 0.6 V total. Load protected if sensing terminals inadvertently opened. MOUNTING: "Three mounting surfaces provided for mounting in. the upright position. For mounting orientations oth than upright, adequate cooling is raquired. See Section I. DIMENSIONS: A suffix models: 1.917 W x 5.03" Hx 12.26" D (48 mm Wx 128mm H x 31mm D} C~ & E~ suffix models: 3.94" W x 6.03" H 12.25" D 1100 men W x 128mm H x at tmm D} WEIGHT (not/shipping): AX sufi Mode CH suffix Models: E~ suffix Models: 6 bs (2, 7 kal/8 Ibs (3, 6 Ka 10.tbs (4, 5 kgl/12 tbs (5, 4 ko) 13 Ibs (6, 9 kgh/16 Ibs (7, 3kal 121-10 OPTIONS 103 1-11 Options are factory modifications of a standard ed by the customer. The {following options are available for the instruments ‘covered by this manual. Where necessary, detailed cover age of the options are included in the manual Instrument thar are ‘OPTION NO. DESCRIPTION on Overvoltage Protection “Crow a bar": A completely separate circuit {or protecting delicate leads against ower supply fallure or operator error. The crowbar circuit monitors the output voltage and within 10 psec imposes a virtual short-circuit (conducting SCR or triac) across the power supoly output if the preset overvoltage margin is exceeded, The crowbar circuit is contained on 3 printed wiring board that is mounted inside the power supply. The activa- tion (trip) voltage of the crowbar is adjustable (screwdriver adjustment} ‘over the following minimum range: from +0.5 Vde above minimum rated ‘output vottage to +2 Vado above maxi= ‘mum rated output voltage. 101 220 Vac, single phase input: Supply 's normaly shipped with 2 120 Vac (nominal) transformer . Option 101 replaces this transformer with @ 220 Vae (nominal) transformer and allows operation from a 190-233 Vac, 48-63 Hz single phase input. 102 240 Vac, single phase input: Supply 's normally shipped with @ 120 Vac (nominal) transformer. Option 102 raplacos this transformer with 8 240 Vac (nominal) transformar and allows operation from a 208-254 Vac, 48-63 Hz, single phase input. 120 Vee/240 Vac, single phase in- put: Supply is normelly shipped with 2.120 Vac (nominal) transform Option 103 replaces this transformer with a 120 Vae/240 Vac (nominal) ‘multitap transformer and aliows field changeable operation from 104-127 Vac or 208-254 Vc, 48-63 He single phase input. System Control: This option allows ‘the user to contro! the supply’s over- voltege protection “crowbar circuit as well vs output voltage. The 104 ‘option includes the same internal, ad- justable overvoitage protection crow- bar as provided with the 011 option. In addition, tho 104 option crowbar includes external {from a rear term- inal strip) pulse control capability that allows the crowbar to be either externally triggored or which provides, an output pulse to indicate that the crowbar has triggered. The crowbar pulse specifications are: {Input Trigger Pulse: Voltage: 8 18 V Width (between 90% point at leading edge and 10% point at falling edgel: 8 wsec — 2 msec Output Pulse: Voltsge: 2 12V Width (between 90% point at leading edge and 10% point at falling edge): 2 — 20 psec Load impedance: 1 KS (min.} In addition to the crowbar trigger external access, the 104 option also Jneludes access (from a rear terminal strip) to the summing point of the supply to enable the de output volt- age to be remotely programmed to zero (215 mVde max.) with a contact, closure,1-12 ACCESSORIES 1-13 The aceessories listed below may be ordered with the power supply or soparately from your local Hewlett: Packard field sales office (refer to list at rear of manual for address). HP Part No. 624108 Description Rack Mounting Tray for mounting any combination of supplies. 19” wide, 5-1/4" high, and 17" deep. (Refer to Section I! for details.) 62a Rack Tray Blank Front Panel, 10-1/2" wide, 5-3/16" high, 1/8" thie. 624124 Rack Tray Blank Rear Panel, mounts ‘on rear of rack mounting tray and «allows installation of custom input! ‘output connectors or other hardware 62815 Rack Tray AC Distribution Pane! mounts on rear of rack mounting tray and includes 2c input terminal strip and line card. e2a14n Rack Tray Slides provide easy access to rack mounting tray and its supplies. 624138, Rack Mounting Tray Cooting Unit provides forced air cooting of rack: mounted supplies. 14 1-14 INSTRUMENT/MANUAL IDENTIFICATION 1-18 Hewlett-Packard power supplies are identified by 1 two-part serial number. The first partis the serial umber prefix, a numberletter combination thet de notes the date of a significant design change and the country of manufacture. The first two digits indicate the year (10= 1970, 11= 1971, etc.) the second two digits indicate the week, and the letter "A designates the U.S.A. as the country of manufacture. The second part is the power supply serial number; a different sequential number is assigned to each power Supply, srarting with 00101. 1-16 If the seria! number on your instrument does not ‘agree with those on the title page of the manual, Chenge Sheets supplied with the manual or Manual Backdating Changes define the differences between your instrument and the instrument described by this manual 1-17 ORDERING ADDITIONAL MANUALS 1-18 One manual is shipped with each power supply. ‘Additional manuals may be purchased from your local Howiett-Packard field office (see list at rear ofthis rmenual for addresses). Specify the model number, serial number prefix, and HP Part number provided on. the title page.SECTION I INSTALLATION 2-1 INITIAL INSPECTION 2.2. Bofore shipment, this instrument was inspected and found to be free of mechanical and electrical de- fects. As soon as the instrument is unpacied, inspact for any damage that may have aceurrad in transit. Save alt packing materials until the inspection is completed. I damage is found, a claim should be filed with the carries immediately. Also, a Hewlett-Packard Sales and Service office should be notified. 2-3. Mechanical Check 2-4 This check should confirm that there are no ‘broken connectors and that the panel surfaces are Tree cof dents and seratches. 25 Electrical Check 2.6 The Instrument should be checked against its electrical specifications. Section V includes an “in-cab- inet” performance check to verify proper instrument operation, 2:7. INSTALLATION DATA 28 The instrument is shipped ready for bench oper- ation. Its necassary only to connect the instrument to a source of power and itis ready for operation. 2:9. Location 2410 This instrument is air cooled, Sufficient space should be allotted so that a free flow of cooling aie can reach the instrument whan it in operation. At least 1/2.inch clearance at the bottom of the unit is recom- ‘mended to permit proper airflow. The supply should bbe used in an area where the ambient temperature doo: ‘not exceed 60°C, If operated at an ambient greeter than 50°C, the supply’s output current must be linearly da- saved down to 60% at 71°C. 24 NOTE {the power supply must be operated in 2 restricted airflow environment, the supply’s ‘power consumption (and heat dissipation requirements) can be minimized by oper- ating at low line input voltage. Consult your ‘nearest HP sales engineer for more infor: ‘mation an the cooling requirements for your specitic operation 2:11 Mounting Orientation 2412 Figure 2-1 shows outline and dimension infor: mation for each modular power supply size. As shown, holes are provided on three surfaces of the supplies any ‘of which can be used to install the supply in the up- ‘ight position, If the top mounting holes are used; how- ever, be sure that a rigid top support is employed to support the weight of the units). Note that if any other crientation other than upright is required, adequate air flow must be provided: see your nearest HP sales engi- ner for additional information. 2:13 Rack Mounting 2414 The modular power supplies can be readily ‘mounted in any combination in a standerd 19-inch rack using the Hewlett-Packard Rack Mounting Tray, Model 624108. The supplies ere mounted upright an attached to the tray using the two (A~ suffix models) fo four (C~ and E~ suffix models) 10-32 threaded ‘mounting holes located in the battom af the supply case. The maximum number of supplies that can be ‘mounted in the tray depends on the types of supplies used. For example, if all 1/B.vidth (A~ suffix) supplies are employed, eight moduler power supplies can be mounted in the tray. Of course, the tay does nat have t9 be filled to capacity,AVSUFFIX MODELS. (178 WIDTH PACKAGE) ee ‘Shs Sj oo el Tats basta fe C8 E-SUFFIX MODELS (1/4-WIDTH PACKAGE) Stones Seos3e Figure 2-1. Outline Diagrams, Modular Power Supplies 222:18 INPUT POWER REQUIREMENTS 2-16 The modular power supplies may be operated from a nominal 120 Vac, 220 Vac, or 240 Vac, 48:65 He, power source. The standard supply (no options) is shipped from the factory wired for 120 Vac (nominal) operation and requires the following maxi ‘mum input current and power at high line (127 Vac} voltage input 2.17 220/240 VOLT OPERATION 248 As applicable, Options 101, 102, and 103 {in stalled at the factory) permit the supply to be operated from a 120, 220, or 240 Vac (nominal) input line. Option 101 provides for 220 Vae operation while Option 102 allows 240 Vac operation. Option 103, however, provides for sithar 120 Vac or 240 Vac oper ation at the selection of the user as described below. 23 Sie a teaee enone cinnent | ciroan erases tetera te wager | pues fea n Stes ares oe = & ot Heal aie laos hatha dees a {SS Hise rnativt iri pated tater a a a ene a ae a 62005C. “20, 79W, fe wero 62005E 71.534 T60W | 3 20088 6A, sw Ea aes eae aio 20066, “BOA Taw SP. tr sau comncorons eam fon fa PATE moeenes 20104 “398 zw 1 ce aree a om ’ ano | a ne 7 ane aaa Sex —[ om 62012E 1.898 191W 8 a8 a5 aH an ee a i a ee ra co a a a on on Sane on i ae Seen | 520244. A Sow Figure 2-2. Primary Connections For 120/240 Vac 620240. 234 ay Operation (Option 103) — A Suffix Models Only a Sea a i ia a en a 229 Onto oe rns saa 1375 | a vest meson av von 298004 520480 STA 25W Nay thr the ranformerconnetlos are changed 62048 2.008 193 at the transformer terminals shown in the illustration.3a out ramen 8 Figure 2:3. Primary Connections For 120/240 Vac Operation (option 103) =C and —E Suffix Models Only 24 2:21 REPACKAGING FOR SHIPMENT 2.22 To insure safe shipment of the instrument, itis recommended that the package designed for the instru ‘ment be used. The original packeging material is re ‘usable, [fit is not available, contact your local Hewlett Packard field office to abtain the materials. This office will also furnish the address of the nearest service office to which the instrument can be shipped. Be sure ‘0 attach a tag to the instrument which specifies the ‘owner, model number, full serial number, and service required, oF a brief description of the troubleSECTION Ill OPERATING INSTRUCTIONS 3-1 TURN-ON CHECKOUT PROCEDURE 32. The following checkout procedure describes the Uso of the voltage contral and ensures that the supply is operationel. a. Before connecting input power to unit, connect external voltmeter across +S and —S terminals at resr teerninal boord, b, Connect unit to input power souree using AG, ACC, and ground terminals at rear. (Use proper wire sizo in accordance with the input AC current rating ©. Observe output voitage of supply on external rotor. Output is factory set to nominal voltage. If de- sired, VOLTAGE ADJUST (écrevdriver contrat, 3c- cessible through cutout on front panel) potentiometer can be used to set output to any voltage within adjust: rent span (40.6 V or 25% as applicable). NOTE The current limit may require resdiust: ment if the output voltage is set away from nominal. Refer to Paragraph 38. 0, To verify operation of currant limit circuit, remove voltmeter and disconnect input power. Connect short across output terminals of supply and reconnect {input power. Using clip-on miltlemmeter (HP Model 4288, or equivalent) observe that short circuit output ‘current is approximately 3% to 18% of rated output current. fe. Remove short and milliammeter. Before con- necting actual load to supply, read the following para graphs. 33 OPERATION 2-4 The supply can be operated in one of two oper- ating mades; normal or remote sensing. Auto-Series, ‘Auto-Parallel, Auto-Tracking and remote programming ‘operation are not feasible with this supply. The follow- a ing paragraphs describe both of those modes plus supplementary oporating information. More theoreti- cal descriptions regarding the operational festures of power supplies in general are given in application note 904, DC Power Supply Handbook {available at 0 charge from your local HP sales office). 3-5 Normal Operating Mode 346 The power supply is shipped with the rear werm- inal straps connected for Constant Voltage/Current Limiting, local sensing, operation. This strapping pattern is illustrated in Figure 3-1. Before connecting ‘load to the supply, check the rear terminals to ensure that the connections are correct and that the connect: ing straps are tightoned securely Tplaizig] * |=} Figure 3-1. Normal Strapping 37 Current Li 38 Figure 3-2 shows typical current limiting charac- ‘etisties for all HP modular supplies. As indicated on ‘the drawing, the currant limit point varies in accord- ance with the output voltage. As reczived from the factory, the initial curcert limit point is set to 104 =1% ‘of the current rating with the output voltage at its rominal value. This same current limit setting is recom ‘mended for all output voltages within the adjustmant span because: (1) the current limit erossover point must be at feast 3% higher than the maximum expected ‘operating current to pravent performance degradation; ‘and (2) a current limit setting of higher than 105% of, rating creates the possibility of excessive internal heat: ing as specified in the caution note of Figure 3-2. Hence, the current limit potentiometer (accassible through &cutout in the side pane!) may have to be readjusted to satisfy the above two requirements ifthe usar incends to operate at an output voltage which is above or below nominal. For exemple, if the user has a supply of 10 Volts of above and requires an output voltage of +5% above nominal, the initial current limit point would be factory set t0 approximately 109% of rating, This violates the 105% current limit constraint mentioned previously and, thus, the current limit potentiometer ‘would have to be adjusted (described in Section V) so that the current limit point is moved to 104 £1% at the upper voltage limit rather than at nominal voltage. ‘A. SUPPLIES BELOW 10V 2 | ae 8 SUPPLIES IOV AND ABOVE | 3-9 Connecting Load 3410 Each load should be connected to the proper supply output terminals using separate pairs of con necting wires. This will minimize mutual coupling offects between loads and will retin full advantage of the low output impedance of the power supply. Each peir of connecting wires should be as short es possible ‘and twisted or shielded to reduce noise pickup. (If shield is usad, connect one end to power supply ground terminal and leave the other end unconnected.) 3:11 If load considerations require that the output ‘power distribution terminals be remotely loceted from ‘the power supply, thon the power supply output term: inals should be connected to the remote distribution ‘terminals via a pair of twisted or shielded wires and ‘each load separately connected to the cemote distribu: tlon terminals. For this case, remote sensing should be used (Paragraph 3-13). 3412 Positive or negative voltages can be obtained from this supply by grounding either ane of the out put terminals or one endl of the toad, 3-13 Remote Sensing (See Figure 3-3) 3-14 Remote sensing is used to maintain good regu- lation at the load by reducing the degradation in regu- lation that would occur due to the voltage drop in the leads between the power supply and the load. Remote sensing is accomplished by utilizing the strapping pat- tera shown in Figure 33. The power supply should be ‘urned off before changing strapping patterns, The Jeads from the sensing terminals to the ioad will carry ‘much less current than the load leads and it is not re- quired that these leads be as heavy as the load leads. Howover, they must be twisted or shielded to mini- mize noise pick-up. (elelaleleleiel Figure 3-2. Typical Current Limiting Characteristics Figure 33. Remote Sensing9:15. For reasonable load lead lengths, remote sensing ‘greatly improves the performance of the supply. How: cover, if the load is located a considerable distance from the supply, added precautions must be observed to obtain satisfactory operation. Notice that the voltage ‘drop in the load leads subteacts directly from the avall- able output voltage and also reduces the amplitude of the feedback error signals that are developed within the unit. Because of these factors itis recommended that the total drop in both load leads not exceed 0.5 V. Ifa larger drop rust be tolerated, please consult your local HP sales engineer. NOTE Due to the voltage drop in the foad leads, it may be necessary to readjust the current limit. Refer to Paragraph 28. 3-16, It should be noted that a problem ean occur in obtaining maximura rated output voltage (nominal 405 V) from lower voltage supply (below 10 V) ven if the total voltage drop in both Toad leads is maintained at 0.5 Volt. This problem is most likely to occur when the input ac is at low fine, To counter act this effect, the user can maintain the ac input at a higher line voltage or reduce the voltage drop in the Joad leads by using larger diameter wires, 33 3-17 SPECIAL OPERATING PRECAUTIONS. 3-18 Temperature 3.19 The normal operating temperature for this supply is from 0 to 50°C, ambient. Beyond 50°C, the output current is linearly derated to 50% at 71°C. Additions} information on temparature is given in Section I NOTE During normal operation of the supply, the case of the unit may become hot to the touch, This is @ normal occurrence and N0 cause for alarm. 3-20 Mounting Orientation 321. The supply should be mounted and operated in the upright position as instructed in Section UI, If the supply must be operated in an orientation other than ‘upright, an adequate flow of cooting air must be main ‘tained, Contact your nearest HP soles engineer for details.SECTION IV PRINCIPLES OF OPERATION 41 OVERALL DESCRIPTION 42. Figure 4-1 isa simplified schematic of the power ‘supply indicating ait of its major circuits. Except for ‘minor variations (discussed later in Section IV) the Hewlett-Packard modular supplies covered by this ‘manual areas shown in Figure 4-1. Notice that each stage of the supply has been designated according to function. These functional designations also appear on the applicable schematic at the rear of the manual so ‘that both diagrams can be correlated. 43 Theas input voltage is reduced to the proper lovel by the power transformer and fed to the rectifis filter whore itis converted to raw (unregulated) de. The raw de voltage is adjusted by the series regulator so that 4 regulated, constant voltage is available across the out put terminals of the supely. 44 The series regulator, part of a feedback loop, alters its conduction in accordance with the feedback control signals obtained from the driver. The driver, in turn, is controlled by feedback signals originated in |e pees Es, | as a jer om Ta cenores vouTase FEEDEHCK Pari a cenares cursenr reesmace ATH Figure 4-1. Typical Modular Power Supply, Simplified Schematicthe vottage comparison amplifier, during constant volt: ‘age operation, or the current limiting amplifier during current limit operation. 45 The reference supply provides regulated bias voltages which are used by the internal circuitry throughout the main power supply. 46 DETAILED DESCRIPTION 4-7 The following paragraphs describe in detailed terms, the operation of each of the supply's major circuits. Throughout this discussion, refer to both the simplified schematic of Figure 4-1 and the appropriate sohematie diagram at the rear of the manuel 48 Feedback Loop 49. The voltage comparison amplifier, together with ‘the driver and series regulator, comprises the constant, voltage feedback loop. This feedback loop maintains ‘a constant output voltage during normal (constant voltage) operation. To accomplish this, the voltage ‘comparison amplifier continuously monitors the out- put voltage of the supply. It detects instantaneous changes in the output and applies an amplified error signal to the series regulator (via the driver} which is fof the correct phase and amplitude to counteract the ‘change. 4-10 The feedback loop also prevents the output current from exceeding a preset current limit value. Current limiting operation is initiated by the current Timit comparizon amplifier which conducts ifthe out- put current that flows through the current sampling resistance excoads 2 value established by the current limit-adjust potentiometer. When conducting, this am- plifier sends a turn-down signal to the series regulator, via the driver. 411. An output capacitor, Co, connected across the output of the supply, helps to stabilize the feedback loop regatdless of the type of load that is imposed. 4-12 Constant Voltage Comparison Amplifier 413 This circuit consists of the VOLTAGE ADJUST potentiometer RY and a differantial amplifier stage (U2 and aseociatad components). An integrated circuit is used for the differential amplifier for inereased reliability and to minimize differential voltages dus to mismatched transistors and thermal differentials. a2 414 The voltage comparison amplifier continuously compares the output voltage of the supply with the voltage drop between the ~S terminal and the circuit's summing point (junetion at voltage divider 5, R7. and RB}, If these two voltages are momenterily unequal, an error voltage is ganerated whose amplitude is propor tional to the difference. The error signal ultimately alters the conduction of the series regulator which, in turn, alters the output current so that the output volt- ‘age becomes equal to the voltage at the summing point. Hence, through feedback action, the difference between the two inputs to U2 is held at nearly zero volts. 415 The inverting input of the comparison amplifier (pin 2 of U2) is connected, through jumper WI to the ‘constant valtage summing point. (As indicated on NOTE 7 of each schematic, W1 is connected either 10 the junction of RB, R7 for supplies below 10 V oF to the junction of R7, RB for supplies 10 V and above.) ‘The non-inverting input to the comparison amplifier {pin 3 of U2) is connected directly to the output vott- age sensing terminal (+S) of the supply. Instantaneous ‘changes in the output voltage, or changes at the sum- ring point due to rotation of the voltage pot, produce a difference voltage between the two inputs of the comparison amplifier. This differance voltage is ar plified and appears at the output of the amplifier, pin 6. 4416 Capacitor C12 and resistor R10 couple rapid out- put voltage variations to the input of U2 while siower Ide) changes are coupled to U2 via resistor AB, Diodes CAI and CR12 prevent excessive voltage excursions from oversdriving the comparison amplifier; RC net work R12,C13 provide degenerative feedback to help stabilize the foodback loop. 4.17 Driver 4-18 The driver amplifies the error signl from the ‘constant voltage or current limit comparison amplifiers 10 a level sufficient to drive the series regulating tran- sistor(s). Inverting stage Q2 receives its input signal from the OR-gate diode (C13 or CR14) that is con: ducting at the time, During normal {constant voltage) operation, CR13 is forward bissed and CR 14 is reverse biased, The reverse is true during current limiting ‘operation.4.49 Stage O2 provides mainly voltage amplification ‘of the fosdback signal while ernitter follower 3 pro- vides mast of the current gain, Some models ag. 62048, contain only one driver stage (02) instead of wwe. 420 Feedback capacitor C18 provides degenerative feadtuack ta 03 t0 prevent oscillation and C19 helps shape the high frequency rolloft of che feedback loop response curve, R2B provides « leakage current path for ‘ansistor Q3. 4-21 Series Regulator 422. The series regulator, or series control element, acts asa variable resistance connected in series with the load, Its conduction is controlled by the feedback signals from the driver so that the output voltage is ‘maintained constant or the current limit is not &x- ceeded. A diode (CRg on Figure 4-1) connected across ‘the regulator, protects the series element(s) from possible damage by a reverse current flow. 4-23. Many modular power supplies employ one series ‘uansistor as indicated on Figure 4-1. However, higher power units (such @s Models 62003E thru 620486) use wo regulating transistors, connected in parallel to ‘minimize power dissipation. Approximately hai of the output current flows through each transistor. 4-24 Current Limit Comparison Amplifier 4.25 This circuit consists of current limit adjust po tentiometer R18 and a differential amplifier stage (UBand associated components). Stage U3 is simi in appearance and operation to the constant voltage ‘comparison ampiifer, U2. 426 The current limit comparison amplifier effect ively monitors the output current of the supply by ‘monitoring the IR drop across current sampling resis- tor R15, The voltage drop across R16 is compared with a reference voltage established by the setting of current limit potentiometer R18, During constant voltage operation, the output of U3is not positive enough to forward bias OR gate diode CR14, However, if the out- put current increases to approximately 104% of the ‘ated value, the input to pin 2 of U3 is driven momen tarily less positive, If this occurs, @ positive going out put signal from U3 forward biases CR14 and reverse biases CR13. This Feedback signal then decreases the ‘conduction of the series regulator. 43 4.27 The current limiting circuit contains a current “cutback” feature which protects the series regulating ‘ransistor(s) against excessive overloads. As the load resistance decreases, the output current is cut back linearly, from the initial current limit point, to approxi rmatoly 10% of the rated current under short circuit conditions (soe Figure 4-2). Cutback action is made possible by RIB and R19, which are connected across the output of the supply. If the load resistance de- creases after the initial current limiting point, the resultant drop in output voltoge causes a decrease in the current flowing through R¥8 and R19. This, in ‘urn, causes U3 to conduct even harder further redue- ing the conduction of the series regulator. |. SUPPLIES BELOW I0v vowna 4 rd | 1 | BD four | i 8. SUPPLIES OV ANO ABOVE en een \ SENT Figure 4-2. Typical Current Limiting Characteristics 428 As described in Section Ill, the cutback point for the supply ean vary from approximately 3% to 16% of the rated output current. Resistors R20 and R21 determine the actual cutback point.4.29 Reference Supply 4-30 The reference supply iso small regulated bias source which is similar to the main power supply. It contains @ series regulator (Q11) and a comparison am- plifier (U1). The three reference voltages ae al derived from raw de obtained from a fullavave rectifier (CRY ‘and CR2) and filter capacitor C1. The +6.2V and =1.5V outputs are developed across Zener diodes RI and VR2. The reference Zener diode (VRQ) is temperature compensated. Resistor Fé limits the cur- rent through V2 to establish an optimum bias level. 4-31. The regulating circuit consists of U1, Q1, and associated components. The voltage across the reference zener {$6.2 V with respect to +8) and the voltage at the junction of divider R2 and R3 are compared and any differences are detected by U1. The error voltage is then amplified and applied to series regulator Qt t0 ‘counteract the difference and maintain the +12.4 V ‘output constant. Output capacitor C3 stabilizes the reference regulator feedback loop to prevent oscillation. 432 Zener diode VR1 provides an additional reference voltage of ~7.5 V. This voltago is not as tightly requ lated es the other two reference voltages since itis not controlled by the regulator circuit, The unregulated 423, taken directly from the rectifier, is used only bby Option 011 oF 104 crowbar circuits 44 433 Additional Protection Features 4-34 The supaty contains several "special purpose” components which protect the supply in the event of Unusual circumstances. One of these isthe output diode (CRS or US; refer to applicable schematic). Con- nected across the output terminals, this diode prevents internat damage from reverse voltages that might be apalied during system operation when ane power sup- ply is turned on before another. The output diode can \withstand currents equal to the maximum current rating of the supply for time periods af short duration (approximately 3 minutes); or up to half the current rating of the supply for longer time periods. 435 The series regulator diode (CR8 or US) protects the regulating transistor(s) from the effects of a raverse current which would occur if an external voltage were applied 2eross an unenergized supply, 4-36 Sensing protection resistors R32 and R33 pre- vent the load from receiving full rectifier voltage if the connections between the output terminals and the sensing terminals (*S and —$) are removed inadvertently. 437 Thermal switch TC1 opens if the heat sink tem= perature exceeds a safe value. With TC! open, the ac input path to the supply is broken, shutting down the supply. The switch automatically resets after the sup- ply has cooled to a temperature below that at which it originally opened. The opening and closing tempera {ures for the switch are given in the individual ports list for each supely.SECTION V MAINTENANCE 5-1 INTRODUCTION 5:2 Upon receipt of the power supply, the perfor mance check of Paragraph 6-6 can be made. This check is suitable for incoming inspection. Section Ith contains a quick but lass comprehensive checkout procedure which can be used in leu of the performance cheek, if desired. 5:3. Ife fault ls detected in the power supply while ‘making the performance cheek or during normal aper~ ation, procead to the troubleshooting procedures (Paragraph 5-37), After troubleshooting and repair (Paragraph 5-54) repeat the performance check to ‘ensure that the fault has been properly corrected and that no other faults exist, Before performing any main tenance checks, turn on the power supply and allow fal-hour warm-up. 5-4 TEST EQUIPMENT REQUIRED 55 Table 6-1 lists the test equipment required to perform the various procedures described in this section. Table 6-1, Test Equipment Required Voltmeter REQUIRED CHARACTERISTICS ‘Sensitivity: 1OOKV full sale {rmin,). Input impedane 10 magohims (min.) use = DC. calibration procedures RECOMMENDED MODEL HP 34500 Veriabie Voltage ‘Transformer Range: 90-190Vac. Equipped with voltmeter accurate within 1 Voit Vary AC input Oscilloscope Sensitivity: 1000V/er, Display transient re. sponse and ripple/ noise waveforms; ccurrent limit adjust- ment. HP 1408 plus 14008 plugin, 14024 plugin for noige measurements. Repetitive Load Sw. Rate: GOH2, 2usec. rige and fall time. Measure transient response, See Figure 5-4, Resistive Loed Value: See Paragraph 5-11. Tolerance: +5% Power supply load resistor. (Fixed re- sistor or Bheostat) lames G. Biddle “Lubri- Tact!” Rheostat 411G23CS or 411G85CS. Current Sampling Fesistor (Shunt) Value: See Paragraph 8-13. Accuracy: 1% (minimum) Measure output cut ‘Simoton Portable Shunt, 06704. Bt5-6 PERFORMANCE TEST 5-7 The following test can be used as an incoming inspection check and appropriate portions of the test ‘can be repested to check the operation of the instru: ment after repairs. The tests are performed using the ‘nominal 120VAC, 60H2, input power for the unit If the correct result is not obtained for a particular check, proceed to troubleshooting (Paragraph 8-37) 5-8 Measurement Techniques 52 Connecting Monitoring Device. For the following Constant Voltage measurements, the measuring device ‘must be connected across the rear sensing terminals of the supply in order to achieve valid indications. A mea surement made across the load includes the impedance Of the leads to the load and such lead lengths can easily hhave an impedance that is greater than the supply im- Pedance, thus invalidating the messurement, To avoid ‘mutual coupling effacts, each monitoring device must bbe connected directly to the sensing terminals by separate pairs of leads 5:10 Avoid Current Limiting. When measuring the ‘constant voltage performance specifications, the current limit point should be set at least 3% above the maxi mum output current which the supply will draw, sinee the onset of current limiting action will cause a drop. in output voltage, increased ripple, and other changes ot properly ascribed to the constant voltage operation ‘of the supply. The current limit potentiometer is fac ‘ory set to its proper value when the supply i¢ provid ing nominal output voltage. If an output voltege other than nominal is selected, read Paragraph 3-8 and then proceed to the current limit adjustment procedure, Paragraph 5-72, 5-11 Salecting A Load Resistor, Constant voltege specifications are checked with a “ful” load resistance ‘connected across the supply. The resistance and wattage of the load resistor, therefore, must permit ‘operation of the supply at its rated output voltage and current. For example, a supply that is rated at 4 0.5, volts and 4 amperes would require a load resistance of 1 om at the nominal ouxput voltage (4V), If the out put voltage were set to one of the adjustment limits (4.5V or 35V}, the load resistance would have to in- crease or decrease accordingly, to allow the unit to provide its rated current of 4 ampores. The wettage rating of the 1 ohm resistor would be 4 watts, minimum. 52 5-12 Either a fixed or variable resistor (rheostat) can be used as the load resistance. A rheostat is very useful when measuring the output current of the supply and also is @ convenience ifthe user is testing a number of ‘modular power supplies of different ratings. A rheostat of the type recommended in Figure 5-1 is adequate for any supply covered by this manual, If a fixed resistor is used for output current measurements its tolerance ‘ust be accounted for in evaluating the test results. 5-13 Output Current Measurements, For accurate out DUE current measurements 8 current sampling resistor should be inserted between the load resistor and the ‘output of the eupply. An accurate voltmeter is then Placed across the sampling resistance and the output ‘current at any time can be caleulated by dividing the voltage across the sampling resistor by its ohmic value, ‘The total resistance of the series combination (sampling resistor and load resistor) should be equal to the full load resistance as determined in the precoding para- graphs. OF course, it the value of the sempling resistance is very tow when compared to the full load resistance, the value of the sampling resistance may be ignored. ‘The meter shunt recommended in Table 1-1, for example, has a resistence of only § milliohms and can be neglected when calculating the load resistance of the supply. 5-14 Figure 6-1 shows ¢ four terminal meter shunt. ‘The load current is fed to the extremes of the wire lead: ing to the resistor while the sampling terminals are lo- cated as close as possible to the resistance portion itself Figure 5-1. Current Sampling Resistor Connections 6-15 Rated Output 5-16 Voltage, To ensure that the supply will furnish ‘the maximum rated output voltage, proceed as follows: 8. Connect digital voltmeter across +S and —S terminals of supply observing correct polarity.b. Apply input power to supply. . With no load connected, set output voltage of supply to any value desired within adjustment span. This output voltage cen be used for all rameining con- stant voltage tests. With supply off, connect full load resistance across + and — output terminals of supply (see Para sgrah 8-11). Reconnect input power to supoly. Voltmeter should read output voltage set in Stop ¢ (within tol- frances of loed resistor and meter) 5.17 Current, To ensure that the supply will furnish the maximum rated output current, proceed es follows: ‘a, Connect test setup shown in Figure 6-2, Select load and current sampling resistor values according to Paragraphs 5-11 and 5-13. b. Apply input powor to supply and adjust Ry. until digital voltmeter indicates a voltage drop which is proportional to the maximum rated output current. wosoaran) sire Resision Figure 5-2, Output Current, Test Setup 5-18 Load Regulation Definition: The change AE our inthe static, value of DC output voltage resulting from a change in load resistance from open circuit to a value which yialds maximum rated output current {or vice versa) 5:19 To check the constant voltage load regulation, proceed as follows: ‘a. Connect full load resistance across rear output terminals {Paragraph 5-11). 53 ‘b. Connect digital voltmeter across 2S terminals, . sTurn on supply and obtain desired output voltage. Record voltage read on voltmeter. 4d, Disconnect load resistance. a. Reading on digital voltmeter should not vary from reading recorded in step ¢ by more than 0.01% oF ‘mV, whichever is greater 6-20Line Regulation Definition: The change, AE our , in the static value of DC output voltage resulting from a chenge in AC input voltage over the specified range from tow ling (usually 104 Volts) to high fine (ususlly 4127 Volts), oF from high line to low line, 6:21 To test the line regulation, proceed as follows: a. Connect variable auto transiormer between input power source and power supply power input terminals. bb. Connect load resistance and digital voltmeter across output of suppl. ce Adjust variable auto transformer for low line input. &. Turn on setup. Read and record output voit: ‘ag¢ on digital voltmeter. juto transformer for high tine 4. Reading on digital voltmeter should not vary from reading recorded in step d by more than 0.01% or ‘mV, whichever is greater. 5-22 Ripple and Noise Definition: The residual AC voltage which is superimposed on the DC output of a regulated power supply, Ripple and noise may be specified and measured in terms of its RMS peek-to-pesk value, 6.23. Ripple and noise measurement can be made at ‘any input AC line voltage combined with any DC out- ‘put voltage and load current within rating, 5.24 Figure 6-3A shows an incorrect method of mea suring p- ripple, Note that a continuous ground loop ‘exists from the third wire of the input power cord ofthe supply to the third wire of the input power cord ‘of the oscilloscope via the grounded power supply case, the wire between the negative output terminal of the power supply and the vertical input of the scope, and ‘the grounded scope case. Any ground current circulat- ing in this loop as a resut of the difference in potential Eg between the two ground points causes an IR drop which is in series with the scope input. This 1R drop, normally having a 60H line frequency fundamental, plus any pickup on the unshielded ieads interconnecting the power supply and scope, appears on the face of the CRT. The magnitude of this resulting signal can easily bbe much greater than the truo ripple developed between ‘the plus and minus output terminals of the power supply, land ean completely invalidate the measurement. atu [ ete oat cask eu 7 | unh* Figure 5-3. Ripple and Noise, Test Setup 54 5.25 The same ground current and pickup problems can exist if an RMS voltmeter is substituted in place of the oscilloscope in Figure 5-3. However, the oscillo scope display, unlike the true AMS meter reading, tells the observer immediately whether the fundamental period of the signal displayed is 8.3 milliseconds (1/1202) oF 16.7 milliseconds (1/60H2). Since the fundamental ripple frequency presant on the output of an HP supply is 120Hz (due to fuil-wave rectification), {an oscilloscope dieplay showing a 120Hz fundamental ‘component is indicative of a “clean” measurement set- up, while the presence of @ 60Hz fundamental usually ‘means that an improved setup will resuit in a more accurate (and lower! value of measured ripple, 5.26 Figure -38 shows a correct method of measur- Ing the output ripple of a constant voltage power supply Using a single-ended scope. The ground loop path is broken by floeting the power supply output. Note that, 10 ensure that no potential difference exists benween the supply and the oscilloscope, itis recommended that ‘whenever possible they both be plugged into the same ae power buss. Ifthe same buss cannot be used, both ‘a grounds must be at earth ground potential. 527 Either a twisted pair or (preferably) a shielded ‘wo-wire cable should be used to connect the output ‘terminals of the power supply to the vertical Input term inals of the scope. When using a twisted psir, care must bbe teken that one of the two wires is connected to the ‘grounded input terminal of the oscilloscope. When using shielded two-wite itis essontial for the shield to be com ected to ground at one end only to prevent ground current flowing through this shield from inducing signal in the shielded leads, 5-28 To verify thet the oscilloscope is not displaying tipple that is induced in the leads or picked up from the grounds, the (+) scope lead should be shorved to the (©) seope lead at the power supply terminals, The ripple value obtained when the leads ere shorted should be subtracted from the ectual ripple measurement. 5-29 In most cases, the single-ended scope method of Figure 5-38 will be adequate to eliminate non-real com- ponents of ripple so that a satisfactory measurement may be obtained. However, in more stubborn cases, (or if high frequency noise up to 20MHz must be measured, Ft may be necessary to use a differential scope with floating input es shown in Figure 5-3. If desired, two single-conductor shielded cables mey be substituted ini | | place of the shielded two-wire cable with equal success. Because ofits common mode rejection, a differential oscilloscope displays only the difference in signal be- ‘wean its two vertical input terminals, thus ignoring the cffects of any common mode signal produced by the difference in the ac potential between the power supply case and scope case, Before using a differential input scope in this manner, however, itis imperative that th common mode rejection capability of the scope be verified by shorting together its two input leads at the ‘power supply and observing the trace on the CRT. If this trace isa straight line, then the scope is properly ignoring any common mode signal present. If this trace {snot a straight line, then the scope is nat rejecting the ground signal and must be realigned in accordance with the manufacturers instructions until proper common ‘modo rejection is attained. 5:30 Ripple and/or noise output measurement pro- ‘cedures are given in the following steps, Ifa high fr ‘quency noise measurement Is desired, an oscilloscope ‘with sufficient bandwidth (20MH2) must be used. To ‘measure the ripple/noise output, proceed as follows: a, Connect oscilloscope or RMS voltmeter as shown in Figures 6-38 or 6-3C. '. Connect input pawer and observe oscilloscope. ce The observed ripple shuld be less than ImVrms and 2mV p-p. 5-31 Load Transient Recovery Definition: The time “X" for output voltage 1 covery to within “Y" mlilvolts of the nominal output voltage following a "2" amp step change in load current ~ where: “7 = BOysee, “Y"" = 15mV, and "2" is the specified losd current change, equal to half of the current rating of the supply. The nominal out- put voltage is defined as the DC level half way be- tween the static output voltage before and after the imposed foad change. 5:32 Transiant recovery time may be measured at any input fine voltage comoined with any output voltage and load eurrent within rating. 8.33. Reaconable care must be taken In switching the load resistance on and of. A hand-operated switch in series with the load is not adequate, since the resulting one-shot displays are difficult to observe on most oscilo- scopes, and the arc energy occurring during switching 65 action completely masks the display with a noise burst. ‘Transistor load switching devices are expensive if reason ably rapid load current changes are to be acheived. 5.34 A mercury-wetted relay, at connected in the load switching cireut of Figure §-4 should be used for load: ing and unloading the supply. When this load switch is ‘connected to a 60H2 AC input, the mercury-wetted relay will open and close 60 times por second. Adjustmont of ‘the 25K control permits adjustment of the duty cycle Of the load current switching and reduetion in jitter of ‘he oscilloscope display. This relay may also be used with @ 80H2 ac input. 5-35 The maximum load rating listed in Figure 6-4 must be observed in order to preserve the mercury-wetted relay contacts. Switching of larger load currents can be accomplished with mereury pool relays; with this tech- ‘nique fast rise times ean still be obtained, but the large inertia of mercury pool relays limits the maximum repetition rate of load switching and makes the clear display of the transient recovery characteristic on an oscilloscope more dificult. wel $e gs ae | hoy ier sy ous ine |x srg eoeasr ona Figuro 5-4. Transiont Recovery Time, Test Setup