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CPX200
Dual 35V 10A Power Supply
Service Manual
Book Part Number 48511-0270 - Issue 1
Table of Contents
Specifications Safety EMC General Circuit Descriptions Calibration Parts List Component Layouts Circuit Diagrams
2 4 5 6 7 12 14 22 25
1
Specifications
OUTPUT SPECIFICATIONS
Voltage Range: Current Range: Power Range: Output Voltage Setting: Output Current Setting: Operating Mode: 0V to 35V 0A to 10A Up to 175W By coarse and fine controls. By single logarithmic control. Constant voltage or constant current with automatic cross-over provided that the power demanded stays within the power envelope, see graph. Outside of this envelope the output becomes unregulated.
Output Switch: Output Terminals: Sensing: Output Impedance: Output Protection:
Electronic. Preset voltage and current displayed when off. 4mm terminals on 19mm (0·75") pitch. 15A max. Remote via 4mm terminals or direct via shorting links (provided). Typically <5m in constant voltage mode. Typically >5k in constant current mode (voltage limit at max). Forward protection by Over-Voltage Protection (OVP) trip; maximum voltage that should be applied to the terminals is 50V. Reverse protection by diode clamp for reverse currents up to 3A. 10% to 110% of maximum output voltage set by front panel screwdriver adjustment. <0.01% of maximum output for a 90% load change or 10% line change. 5mVrms max; typically <2mVrms, <20mV pk-pk, both outputs fully loaded (7A @ 25V), CV mode. <2ms to within 100mV of set level for 90% load change. Typically <100ppm/°C Output on lamp. Constant voltage mode lamp. Constant current mode lamp. Unregulated (power limit) lamp Trip message on display.
OVP Range: Load & Line Regulation: Ripple & Noise (20MHz bandwidth): Transient Load Response: Temperature Coefficient: Status Indication:
2
METER SPECIFICATIONS
Meter Types: Meter Resolutions: Meter Accuracies: Dual 4 digit meters with 12.5mm (0.5") LEDs. Reading rate 4 Hz. 10mV, 10mA Voltage 0.2% of reading +/-1 digit, Current 0.5% of reading +/-1 digit
GENERAL
AC Input: Power Consumption: Operating Range: Storage Range: Environmental: Safety: EMC: Size: Weight: 230V AC ± 14%, 50/60Hz. Installation Category II. 600VA max. +5ºc TO +40ºC, 20% TO 80% RH. -40ºC to + 70ºC. Indoor use at altitudes up to 2000m, Pollution Degree 1. Complies with EN61010-1. Complies with EN50081-1 and EN50082-1. 210 x 130 x 350mm (WxHxD) half rack width x 3U height (optional rack mounting kit available). 5kg
3
Safety
This power supply is a Safety Class I instrument according to IEC classification and has been designed to meet the requirements of EN61010-1 (Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use). It is an Installation Category II instrument intended for operation from a normal single phase supply. This instrument has been tested in accordance with EN61010-1 and has been supplied in a safe condition. This instruction manual contains some information and warnings which have to be followed by the user to ensure safe operation and to retain the instrument in a safe condition. This instrument has been designed for indoor use in a Pollution Degree 1 environment (no pollution, or only dry non-conductive pollution) in the temperature range 5°C to 40°C, 20% - 80% RH (non-condensing). It may occasionally be subjected to temperatures between +5° and -10°C without degradation of its safety. Use of this instrument in a manner not specified by these instructions may impair the safety protection provided. Do not operate the instrument outside its rated supply voltages or environmental range. In particular excessive moisture may impair safety. WARNING! THIS INSTRUMENT MUST BE EARTHED Any interruption of the mains earth conductor inside or outside the instrument will make the instrument dangerous. Intentional interruption is prohibited. The protective action must not be negated by the use of an extension cord without a protective conductor. When the instrument is connected to its supply, terminals may be live and opening the covers or removal of parts (except those to which access can be gained by hand) is likely to expose live parts. The apparatus shall be disconnected from all voltage sources before it is opened for any adjustment, replacement, maintenance or repair. Capacitors inside the power supply may still be charged even if the power supply has been disconnected from all voltage sources but will be safely discharged about 10 minutes after switching off power. Any adjustment, maintenance and repair of the opened instrument under voltage shall be avoided as far as possible and, if inevitable, shall be carried out only by a skilled person who is aware of the hazard involved. If the instrument is clearly defective, has been subject to mechanical damage, excessive moisture or chemical corrosion the safety protection may be impaired and the apparatus should be withdrawn from use and returned for checking and repair. Make sure that only fuses with the required rated current and of the specified type are used for replacement. The use of makeshift fuses and the short-circuiting of fuse holders is prohibited. Do not wet the instrument when cleaning it. The following symbols are used on the instrument and in this manual:Earth (ground) terminal. mains supply OFF.
l
mains supply ON. alternating current (ac) direct current (dc)
4
EMC
This power supply has been designed to meet the requirements of the EMC Directive 89/336/EEC. Compliance was demonstrated by meeting the test limits of the following standards:
Emissions
EN50081-1 (1992) Generic emission standard for residential commercial and light industry. Test methods and limits used were: a) EN55022 Conducted, Class B b) EN55022 Radiated, Class B
Immunity
EN50082-1 (1992) Generic immunity standard for residential, commercial and light industry. Test methods and limits used were: a) EN60801-2 (1993) Electrostatic Discharge, 8 kV air discharge. b) IEC801-3 (1984) RF Field, 3 V/m. c) IEC801-4 (1988) Fast Transient, 1 kV peak (AC line) and 0.5kV peak (DC outputs). Note that electrostatic discharge direct to the output terminals will not damage the instrument but may trip the Overvoltage Protection (OVP), turning the output off, see Protection section. Note also that if the power supply is operated in a high RF field, the RF signal will be picked up on unscreened leads between the supply and the load. If the load is likely to be sensitive to such signals, connect it to the supply using screened leads.
Cautions
To ensure continued compliance with the EMC directive the following precautions should be observed: a) after opening the case for any reason ensure that all signal and ground connections are remade correctly before replacing the cover. Always ensure all case screws are correctly refitted and tightened. b) In the event of part replacement becoming necessary, only use components of an identical type, see the Service Manual.
5
General
Service Handling Precautions
Service work or calibration should only be carried out by skilled engineers using high quality test equipment. If the user is in any doubt as to his competence to carry out the work, the instrument should be returned to the manufacturer or their agent overseas for the work to be carried out. The tracks on the printed circuit boards are very fine and may lift if subjected to excessive heat. Use only a miniature temperature-controlled soldering iron and remove all solder with solder wick or suction before attempting to remove a component.
Dismantling the instrument
WARNING Disconnect the power supply from all voltage sources before it is opened for adjustment or repair. Capacitors inside the supply may still be charged even if the supply has been disconnected from all voltage sources but will be safety discharged about 10 minutes after removing power. If any adjustment or repair of the opened supply under voltage is inevitable it shall be carried out only be a skilled person who is aware of the hazard involved. The incoming AC supply to the unit under test should be isolated for safety by means of a 1:1 isolation transformer of at least 700VA. High voltages (up to 400V) are always present in the primary-side circuitry which lies in a clearly defined area at the rear of both the upper (control) and lower (main) printed circuit boards. Removing the link at PJ10 only disconnects HV from the power FETs Q1/Q2 (Q101/Q102). 1. 2. Remove the six screws retaining the top cover. To remove the upper (control) pcb proceed as follows. Unplug the 26-way flat cables to the front panel pcb and the 16-way flat cables to the lower (main) pcb noting their orientation (red stripe to pin 1 corner markers on pcb). Unplug the harnesses from the 50Hz transformer (PJ7, PJ107) and the control connections to the main board (PJ5, PJ105) noting the orientation of the sockets (pin 1 on the socket housing to pin 1 corner markers on pcb). Remove the 4 self-tap screws and lift off the pcb. 3. To remove the lower (main) pcb proceed as follows. Remove the power (M3 nuts) and sense (2-way header) connections to the front panel for both channels noting orientation; inner (insulated) power lead is positive, red sense lead to corner marker on pcb. Unplug the two harness connections from the 50Hz transformer (PJ1 and PJ8) and the connection from the front panel switch (PJ6), noting orientation (pin 1 on the socket housing to pin 1 corner markers on pcb). Remove the safety earth connection to the rear panel; remove the rear panel (3 screws). Remove the 9 screws which secure the main pcb support pillars to the case lower (i.e. the screws accessible underneath the case lower) and lift the pcb clear with its mounting pillars attached. 4. 5. To remove the front panel pcb, first remove the six push-on control knobs then undo the 5 screws securing the pcb to the front panel and lift free. Reassemble in the reverse order taking great care to ensure that all connections are exactly as before dismantling and that no insulation creepage and clearance distances have been compromised. Ensure that only the correct fastenings are used otherwise earthing, and hence EMC and safety performance, may be impaired.
6
Circuit Descriptions
The two outputs are identical with the exception of slight layout variations; only one output (Channel A) is therefore described. Component positions on the other output (Channel B) are numbered from 101 upwards, e.g. C22 on Channel A described is C122 on Channel B.
Power Section
The power section is contained entirely on the main (lower) board; refer to the main pcb schematic. Each output is configured as a double-ended half-bridge operating in continuous flyback mode to reduce switching currents in the power FETs and output diodes; both converters operate from a common high voltage (rectified mains) supply. The secondary power limit is determined by the primary current limit which gives rise to a linear characteristic (between maximum current and maximum voltage) rather than a parabolic characteristic associated with a true `constant power' limit, see Specification section.
Mains Input, Filtering and Rectification
The AC input to the supply is direct via a pcb-mounted IEC inlet connector. Components C9, L3, L4, and C5-C8 comprise an input filter which ensures that the supply meets both conducted emission and conducted immunity EMC requirements. VDR1 `clips' mains spikes for component protection; R3 provides safety discharge for C9, C5 and C8. Pcb-mounted fuse FS1 limits damage on switchmode failure; the front panel mains switch is connected via PJ6; RT1 reduces the mains inrush current when the unit is turned on from cold. BRI is a bridge rectifier and C1, C2 the reservoir capacitors for the high voltage rail which is linked at PJ10 to VBULKA and VBULKB of Channel A and Channel B respectively. L1 and L2 reduce current spikes caused by the switching of the FETs. BR1 and C1, C2 can also be configured as a voltage doubler for 115VAC operation by fitting the header into PJ1B instead of PJ1A; however, for operation up to full power (350W) L3 and L4 must be changed to 8Amp components. PJ1 is also the point from which mains power is fed to the auxiliary mains transformer.
Operation of the Double-ended Half-bridge
A simplified version of the power switching stage is shown below.
When FETs Q1 and Q2 are turned on, current flows in the primary winding of power transformer T1, storing energy in the primary inductance; D3 and D4 are reverse-biased so no current flows in 7
the secondary. When Q1 and Q2 are turned off the voltage across the primary will reverse and generally bring diodes D1 and D2 into conduction; D1, D2 provide clamp protection against overvoltage caused by leakage inductance in the transformer, so protecting the FETs. At the same time the secondary e.m.f. generated will cause current to flow through D3, D4 into C14 and the load; as soon as this starts to happen current will cease to flow through D1 and D2 and the energy stored in the primary is transferred to the secondary. Zener diodes D7 and D8 protect the FETs in the event of a voltage surge and protect the drive circuit in the event of a FET failure.
FET Drive Circuit
IC1 is an IR2110 drive IC which has the necessary on-chip isolation (500V) to be able to drive both FETs. The FETs need 15V gate drive. The 15V supply for Q2 is generated from the auxiliary mains transformer via BR2 and IC16; this rail also powers all the ground-referenced control circuitry on the primary side, including the UC3846. Q1 needs an isolated supply which is generated from an extra winding on the power transformer in phase with the secondary; D5 and C23 rectify and smooth the transformer output, dropper resistor R15 and 15V zener D9 regulate the rail. Until the FETs start switching no 15V supply for Q1 is generated. To overcome this R21 is used to charge C23 at start-up; when VBULKA reaches about 150V there is enough voltage on C23 to turn on the high rail of IC1 and maintain the FET in an oscillating mode independent of output loading. If for any reason this rail should drop below 8V, IC1 will switch off, thus maintaining a good enhancement voltage across the gate at all times. R8, C10 and R9, C11 are snubber networks for Q1 and Q2 respectively.
Output Filtering
Large switching spikes caused by the switching of FETS Q1, Q2 and rectifying diodes D3, D4 are filtered by the output stage to bring both differential noise and common mode noise into specification. Snubber network R10, C13 reduces noise generated by the output diodes. L5 and C16 comprise the main differential filter; R16 damps any ringing in the filter. R13, R17 and R20 are a small pre-load, ensuring voltage loop control with no external load and providing some load for the L5, C16 filter. The common mode filter L7, C15/C27 further reduces differential noise. Common-mode noise is minimised by the low capacitance design of power transformer and is attenuated by C17, C18; R19 provides a discharge path for these capacitors when the output terminals are floated from ground. Solid ground connections at E1 and E2 are essential for good common-mode noise performance. The front panel mounted components LLA, CAA and CAB provide both differential and commonmode attenuation at high frequencies (>2MHz); HF differential noise is attenuated by the leakage inductance of LLA with CAB and HF common-mode noise is attenuated by LLA and CAA.
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Control Section
The control circuitry is contained entirely on the control (upper) board with the exception of the current transformer (T2) which is fitted on the main board and the user controls themselves which are on the front panel board.
Voltage Control Loop
The feedback voltage for the voltage control loop is fed from the main board via PJ4 pin 5 (+SENSE A) and PJ4 pin 8 (-SENSE A); R12/C21 and R11/C19 (all on the main board) ensure stability when long leads are used with remote sense. Usual operation is with the sense connections made directly at the output terminals but up to 1V drop in the connecting leads can be corrected for by sensing remotely. PTC1 and PTC2 (on the main board) provide an alternative permanent sense connection if no other sense connection is made. If, during remote sense operation, the output terminals become disconnected from the load, PTC1 and PTC2 also provide current limiting protection when the load attempts to draw current from the sense terminals. IC2 buffers and inverts the front panel voltage controls VR1, VR2 to give approximately 2·62V at maximum output (35V). IC1 is a differential amplifier with a voltage gain of 13·3 set by R18, R20 and R19, R21, VR4. VR4 trims the differential gain which ensures voltage regulation is maintained during remote sense operation when there is a voltage difference between SENSE and OUTPUT, see Calibration section. The output of the op. amp. IC1 drives the input diode of the opto coupler OPT1. This is a low noise device and helps to prevent switching noise and pickup from getting into the control loop. The output of the opto-coupler drives current through R13; the voltage developed across R13 is fed to IC5 pin 5 the input of the error amplifier of the PWM controller, IC5. This amplifier is configured as a voltage follower with a gain of one. IC5 then converts this input signal into a pulse width modulated squarewave which is used to drive the two power FETs Q1 and Q2, via IC1 (all on the main board).
Current Control Loop
The current control loop uses the voltage across the current sense resistor R14 (main board) which is fed to the control board via PJ4 pin 7 (ISENSE+A) and PJ4 pin 2 (ISENSE-A). IC6 provides a gain of 10 and its output is fed to the high gain amplifier IC17, the other input of which (ISETA) is derived from the front panel current limit control, VR4, via PJ8 pin 2. When the current sensed through R14 is below the set level, the output of IC17 is high, driving the maximum current into opto OPT3 via R6 which in turn develops the maximum voltage across R11 at pin 1 of IC5. When the output current approaches the set level the output of IC17 falls and the voltage across R11 drops. This voltage is fed to IC4 pin 1, the current limit adjust input of the PWM controller, and acts to reduce the peak current in the primary as the voltage across R11 falls, irrespective of the voltage control loop.
Overvoltage Protection (OVP)
The overvoltage trip point is set by preset VR3 on the front panel board (it is a screwdriver adjustment through the front panel). This voltage (OVPSETA) is fed via PJ8 pins 4 and 8 to the inverting input of comparator IC4-C; the output voltage (OVPDETECT+A) is sensed at the common-mode choke L7 (main board) and fed to the other input of IC4-C via PJ4 pin 6. When the output voltage exceeds the set OVP the output of IC4-C goes high, turning on Q4 and Q3 which latches the comparator in the high state. When the comparator output goes high, current is driven into the opto OPT2 via D9; the output of the opto goes to 5V, pulling pin 16 of IC5 high which shuts it down. The power supply needs to be switched off to allow the OVP circuit to reset.
9
Primary Current Control and Primary Current Limit
The primary current is sensed by transformer T2 on the main board; the primary is in series with T1 and the secondary is fed to D2/R2 on the control board via PJ5 pins 1 and 2. D2 rectifies the signal which appears as a voltage across R2 in parallel with VR5/R22; R1 and D1 allow the current transformer to be reset on each cycle. The ramp voltage developed across R22, corresponding to the ramp current in the primary of T1/T2, is fed to IC5 pin 4, the +current sense input of the PWM controller, via VR5/R22. This arrangement provides pulse-by-pulse primary current control, giving better overall voltage loop control by improving line regulation and load response. In normal operation the pulse is terminated at a point determined by the voltage on IC5 pin 5, the error amplifier input; the greater the demand from the voltage control loop via the error amplifier, the higher the primary current will ramp before the pulse is terminated. There is, additionally, an overriding limit mechanism in IC5 which terminates the pulse when the ramp at pin 4 reaches a certain level, regardless of a demand for more power by the signal on pin 5. Since VR5 `scales' the voltage applied to IC5 pin 4, VR5 effectively sets the primary current limit which in turn sets the secondary power limit, see Calibration section.
Front Edge Blanking
Front edge blanking is provided by Q1, C2, R4, D24 and C3. Front edge blanking prevents the switching spikes caused by main board FETs Q1 and Q2 being fed into pin 4 of IC5 via the primary current limit circuit (T2, D2, R2, VR5, R22 and R3).
Measurement and Display
The measurement system and display are controlled by a microcontroller IC11. The measurement of output and preset values of voltage, current and OVP is performed by the 12 bit analog to digital converter IC12. The measurement rate is controlled by the 4·0MHz ceramic resonator XL1 connected between pins 22 and 23 and the buffered version of this 4MHz signal at pin 25 is used as the clock to the microcontroller IC1. The ADC, IC12, is a dual slope converter and provides just over 8 readings per second when clocked at 4MHz. The ADC is run in continuous mode and the status signal on pin 2 is read by the microcontroller every 6ms. When a reading is ready the microcontroller reads the 12 bit binary value and then converts it to 7 segment BCD and stores it ready to be sent to the display. After each reading the microcontroller switches the input multiplexers IC13 and IC14 to the next required input. In this way it is possible to read and display any of the following: Preset Volts Preset Current OVP Output Volts Output Current The multiplexers are controlled by the latch, IC6, on the front panel board which also drives the additional indicator LEDs; this latch is driven by the microcontroller, IC11. The decision on what to measure and display at any time is taken by the microcontroller and in order to do this correctly a number of status signals and switches are monitored on a regular basis. These are:
VLIMDA ILIMDA OVPTRIPA OVPKEYA OUTPUTA from IC4-B from IC4-A the OVP trip signal the OVP key signal the output on/off switch signal
All these signals may be read by the microcontroller as required. 10
The +2·45V reference line VREF+A is derived from reference diode D23 attenuated to about 188mV by divider R83, R82 at the reference input of analogue to digital converter IC12, yielding a sensitivity of about 92uV per digit. The set current signal ISETA is taken from the VR4 wiper on the front panel board via PJ8 pin 2 and on to the ADC as IPROGA, via adjustable attenuating chain R92, VR3, R93, for display of the preset current level. The voltage control signal VSETA is derived from the wipers of the coarse and fine voltage controls VR1 and VR2 on the front panel board via PJ8 pin 3 and on to the ADC as VPROGA via adjustable attenuating chain R88, VR7, R89, for display of preset voltage level. The OVP front panel preset potentiometer VR3 is fed from the reference voltage defined by zener D4. The OVP set from VR3 wiper, OVPSETA, is fed via PJ8 pin 4 and on to the ADC input via divider R90, R91 for display of preset over voltage trip level. Actual output volts are fed from the main board, via PJ4 pin 9 (+VESENSEA) and PJ4 pin 10 ( VESENSEA), to attenuating chain R78, VR8 and R80 and on to the ADC. The voltage across the current sense resistor, attenuated by R18 and VR1 (main board) is fed via PJ4 pin 1 (O/P CURRENT SENSE +A) and PJ4 pin 2 (O/P CURRENT SENSE A) to the ADC.
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Calibration
Refer to the General section for dismantling instructions and safety precautions. Component numbers are given for Channel A/Channel B, e.g. VR1/VR101, where VR1 refers to Channel A and VR101 to Channel B. Channel A is marked as Output 1 on the front panel, Channel B as Output 2. All adjustments are on the control board unless otherwise stated.
Equipment Required
5½ digit multimeter with better than 0·05% DC Volts accuracy and better than 0·1% DC Amps accuracy (to 10A); alternatively use a precision shunt for current measurement. Rheostat or other high power load arrangement to provide up to 5A load at 35V and 10A and 12V. A small switch, 15k resistor and diode.
Voltage Calibration
Connect DMM, set to Volts, across output. Set voltage controls to minimum and current control to maximum. Switch output ON and check for a reading of 00·00V ± 0·01V on display and DMM. Set voltage controls to maximum. Adjust VR16/VR116 (maximum output volts) for a reading of 35·30V ± 0·02V on the DMM. Adjust VR2/VR102 (preset volts) until display matches DMM. Connect rheostat to output and adjust for nominally 4A at maximum output voltage. Reduce current limit (current control anticlockwise) until output just enters CI mode. Adjust VR8/VR108 (measured volts) until display matches DMM reading.
Current Calibration
Connect DMM, set to 20A range, in series with rheostat set to about 1. With output OFF set voltage controls to maximum and current control to 0·10A. Switch output ON and adjust VR1/VR101 for 0·10A ± ·01A on DMM. Set voltage controls to 12V, current control to maximum; supply should be in CI mode. Adjust VR6/VR106 (maximum output current) for 10·20A ± ·02A on DMM. Switch output OFF. Adjust VR3/VR103 (preset current) until display matches maximum output set by VR6/VR106 above. Increase rheostat resistance until unit enters CV mode. Adjust VR1/VR101 (measured current) on main board until display matches DMM reading.
Set Power Limit
Switch output OFF, set voltage control to 12·1V, current control to maximum. Switch output ON, set rheostat so that current is 10·0A (ensure CV mode is maintained). Adjust VR5/VR105 (power limit) until the UNREG l.e.d. just lights; back off VR5/VR105 until CV is lit and UNREG is off. Set voltage controls to maximum and check unit enters UNREG mode. Increase rheostat resistance until unit enters CV mode again; check meter reads between 5A and 6·2A. Remove load.
OVP Calibration
Set voltage controls to minimum, current control to maximum. Set VR7/VR107 fully anticlockwise. Switch output ON. Press OVP button and set front panel OVP control (screwdriver adjustment) for a display of 20·00V; release OVP button. Set output voltage to 20·00V and adjust VR7/VR107 (OVP calibrate) slowly anticlockwise until OVP is tripped (display reads TRIP). Turn output OFF and reset front panel OVP control fully clockwise.
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Differential Gain Adjustment
Remove the link between the OUTPUT and SENSE terminals and fit a diode, anode to SENSE and cathode to OUTPUT; connect a small switch across the diode. Leave the link in place between +OUTPUT and +SENSE and connect a 15k resistor between +OUTPUT and SENSE. Connect the DMM, set to Volts, between the sense terminals. Close the switch, switch the output ON and set the output to approximately 17V; note the exact reading. Open the switch and adjust VR4/VR104 for exactly the same reading; close the switch again and check the reading is unchanged. Remove the diode, resistor and switch and refit the sense link.
Noise Measurements
Differential and common-mode noise checks can be made using the arrangement below. Keep all unscreened connections as short as possible.
Make measurements with the output fully loaded (e.g. 25V @ 7A). Measure differential and common-mode noise one at a time on a 20MHz TRMS voltmeter or use a 20MHz bandwidthlimited scope for peak-to-peak measurements.
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Parts List
PCB ASSY FRONT PANEL - (44115-0820) Part Number 22226-0140 22573-0056 23202-0270 23202-1910 23202-2150 23202-3100 23202-3470 23202-4470 23347-0140 23347-0150 23382-3100 23557-0658 23620-0246 25061-0200 25061-9503 27164-0506 27231-2730 27234-5730 35555-2260 Part Number 20030-0263 20038-9501 20210-0101 20234-0011 20611-0003 20613-0006 20661-0800 20670-0130 20670-9002 22315-0440 22315-0452 22573-0205 22574-0122 Description KEYSWITCH DARK GREY HEADER 16 WAY STR SIL RES 27R0F W25 MF 50PPM RES 910RF W25 MF 50PPM RES 1K50F W25 MF 50PPM RES 10K0F W25 MF 50PPM RES 47K0F W25 MF 50PPM RES 470KF W25 MF 50PPM POT 10K LIN POT 10K LOG RES PS/H10K CERMET MIN CAP 100U 25V ELEC P2.5 CAP 100NK 63V P/E P5 LED - T1 ROUND (3MM) - RED DISPLAY - 4 DIGIT LED IC ULN-2803A IC 74HC273 IC 74AC573 PCB - FRONT PANEL Description WASHER M3 ZPST WASHER M3 SPRING NUT M3 ZPST SCREW M3 X 10 PNHDPZ NPST BUSH POLYESTER TO220 J22-5006 WASHER (SIL-PAD) TO220 SPACER TRANSISTOR MTG TO18 HEATSINK PCB MTG 25MM HIGH T0220 CLIP ON HEATSINK FUSE 375mAT SUBMIN PCB MTG FUSE 1.0AT SUBMIN PCB MTG HEADER 5 WAY STRAIGHT .156P SKT DIL 28 PIN Position FOR IC8/9,108/109 FOR IC8/9,108/109 FOR IC8/9,108/109 FOR IC8/9,108/109 FOR IC8,108 FOR IC8/108 FOR IC3,103 HS1,101 FOR IC10,110 FS3,4,103,104 FS1,2,101,102 PJ5,7,105,107 FOR IC11,111 Position K1,2,101,102 FOR DISPLAYS R1-8,101-108 R21,121 R17,18,38,39,117,118,138,139 R19,31,40,119,131,140 R9,12,109,112 R20,120 VR1,2,101,102 VR4,104 VR3,103 C1,101 C2,15-19,102,115-119 LED1-4,101-104 DISP1,2,101,102 IC8,108 IC6,7,106,107 IC5,10,105,110
PCB ASSY CNTL - (44115-0810)
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PCB ASSY CNTL (44115-0810) continued/..... Part No. 22575-0062 22575-0064 23185-0000 23189-0560 23190-1100 23202-0220 23202-1470 23202-1750 23202-2100 23202-2150 23202-2200 23202-2240 23202-2300 23202-2360 23202-2390 23202-2430 23202-2470 23202-2560 23202-2680 23202-2750 23202-2820 23202-3100 Position HEADER 10 WAY (2X5) STR HEADER 26 WAY (2X13) STR RES ZERO OHM RES 56RJ 1W6 500PPM TYPE PR37 RES 100RJ 2W5 500PPM TYPE PR52 RES 22R0F W25 MF 50PPM RES 470RF W25 MF 50PPM RES 750RF W25 MF 50PPM RES 1K00F W25 MF 50PPM RES 1K50F W25 MF 50PPM RES 2K00F W25 MF 50PPM RES 2K40F W25 MF 50PPM RES 3K00F W25 MF 50PPM RES 3K60F W25 MF 50PPM RES 3K90F W25 MF 50PPM RES 4K30F W25 MF 50PPM RES 4K70F W25 MF 50PPM RES 5K60F W25 MF 50PPM RES 6K80F W25 MF 50PPM RES 7K50F W25 MF 50PPM RES 8K20F W25 MF 50PPM RES 10K0F W25 MF 50PPM Description PJ4,104 PJ8,108 LK2,7,8,102,107,108 R2,102 R15,115 R84,184 R55,155 R12,22,112,122 R3,17,39,57,61,68,95,96,103,117,139, 157,161,168,195,196 R6,94,106,194 R13,72,113,172 R10,110 R97,197 R91,191 R44,144 R46,146 R5,23,28,29,33,36,37,48,73,105,123,128, 129,133,136,137,148,173 R11,111 R21,121 R20,120 R80,180 R7,38,40,41,43,49,59,60,64,71,79,82,85, 107,138,140,141,143,149,159,160,164, 171,179,182,185 R9,109 R30,130 R16,54,116,154 R66,166 R8,108 R74,174 R75,76,175,176 R89,93,189,193 R26,126 R42,47,77,81,90,142,147,177,181,190 R27,127
23202-3120 23202-3180 23202-3200 23202-3220 23202-3270 23202-3300 23202-3330 23202-3360 23202-3430 23202-3470 23202-3560
RES 12K0F W25 MF 50PPM RES 18K0F W25 MF 50PPM RES 20K0F W25 MF 50PPM RES 22K0F W25 MF 50PPM RES 27K0F W25 MF 50PPM RES 30K0F W25 MF 50PPM RES 33K0F W25 MF 50PPM RES 36K0F W25 MF 50PPM RES 43K0F W25 MF 50PPM RES 47K0F W25 MF 50PPM RES 56K0F W25 MF 50PPM
15
PCB ASSY CNTL - (44115-0810) continued/... Part No. 23202-4100 23202-4120 23202-4160 23202-4200 23202-4750 23202-4820 23202-5100 23206-1470 23210-3100 23301-0457 23377-1470 23377-2100 23377-2220 23377-2470 23377-3100 23377-3220 23379-2220 23379-3100 23427-0331 23427-0374 23427-0384 23557-0611 23557-0612 23557-0658 23557-0660 23557-0664 23620-0245 23620-0246 Position RES 100KF W25 MF RES 120KF W25 MF 50PPM RES 160KF W25 MF 50PPM RES 200KF W25 MF 50PPM RES 750KF W25 MF 50PPM RES 820KF W25 MF 50PPM RES 1M00F W25 MF 50PPM RES 470RF W6 MF 50PPM RES 10K0J 2W MF 250PPM RES NETWK SIL 47K X 4S RES PS/H 470R CF 10MM RES PS/H1K0 CF 10MM RES PS/H2K2 CF 10MM RES PS/H4K7 CF 10MM RES PS/H10K CF 10MM RES PS/H22K CF 10MM RES PS/H2K2 Cermet 10MM RES PS/H10K Cermet 10MM CAP1N0K 63V CER HI K P5 CAP 100PJ 100V CER N150 P2.5 CAP 220PK 100V CER MED K P2.5 CAP 47U 10V ELEC P2 CAP 1U0 50V ELEC P2 CAP 100U 25V ELEC P2.5 CAP 2200U 16V ELEC P5 CAP 1000U 35V ELEC P5 CAP 4N7K 63V P/E P5 CAP 100NK 63V P/E P5 Description R18,19,86,87,118,119,186,187 R83,183 R53,153 R34,88,134,188 R14,114 R92,192 R78,178 R4,104 R1,101 RP4,104 VR5,105 VR4,104 VR6,106 VR7,107 VR16,116 VR1,101 VR8,108 VR2,3,102,103 C16,116 C3,18,103,118 C2,102 C48,50,148,150 C10,21,42,110,121,142 C25,26,36,125,126,136 C13,113 C27,29,127,129 C8,108 C1,6,11,12,14,15,17,19,20,23,28, 30-33,35, 38-40,47,49,54,101,106,111, 112,114,115, 117,119,120,123,128, 130-133, 135,138-140,147,149,154 C22,122 C46,146 C7,107 C43,51,52,143,151,152 C5,9,34,105,109,134 C44,144
23620-0247 23620-0249 23620-0252 23620-0256 23620-9007 23621-0310 16
CAP 220NK 63V P/E P5 CAP 330NK 63V P/E P5 CAP 2N2K 63V P/E P5 CAP 1U0K 63V P/E P5 CAP 10NK 100V P/E P5 CAP10NJ 400V P/E P7.5
PCB ASSY CNTL - (44115-0810) continued/...
Part No. 23685-0002 23685-0007 25021-0901 25115-0907 25130-0903 25211-9302 25336-5590 25380-0229 25601-0470 27001-0020 27001-0030 27103-0020 27106-0520 27153-0030 27160-0014 27160-0017 27160-0440 27161-0120 27168-0020 27226-0510 27250-2000 28502-0010 35555-2250 Part Number 20030-0263 20037-0301 20038-9501 20062-9303 20062-9305 20205-0610 20210-0101 20234-0025 20234-0027
Position CAP 1N0J 100V P/P CAP 100NK 160V P/P P10 DIO 1N4148 B/R DIO 1N4002 B/R DIO ZEN 5V1 W4 RECTIFIER BRIDGE W02G TRAN PNP BC559C TRAN NPN BC549 TRAN MOSFET N CHAN 2N7000 OPTO-COUPLER CNY17-3 OPTO-COUPLER HCPL-4503 IC LM339 IC OP-07 IC 7109 IC V/REG 7905 IC V/REG 7812 IC V/REG LM2940CT5 IC V/REF ZN404/ZRA245 2.45V IC UC3846N IC 4051B IC MCU8 PIC16C55XT-P RESONATOR CER 4MHZ CSA4.00MG PCB - CONTROL Description WASHER M3 ZPST WASHER M3 SHK/PROOF I/T ZPST WASHER M3 Spring SCREW NO 6x0.5in. PNHDPZ ST/AB SCREW No.6x3/4in. Pozi. Pan STUD M3 X 10 KFH-M3-10ET NUT M3 ZPST SCREW M3 X 12 PNHDPZ ZPST SCREW M3 X 6 PNHDPZ ZPST
Description C4,104 C45,145 D1,2,3,5,6,8,9,11-17,24,101,102,103,105, 106,108,109, 111-117,124 D7,10,107,110 D4,104 BR1,101 Q3,103 Q2,4,5,102,104,105 Q1,101 OPT2,102 OPT3,4,103,104 IC4,104 IC1,2,6,17,101,102,106,117 IC12,112 IC10,110 IC8,108 IC9,109 D23,123 IC5,105 IC13,14,113,114 IC11,111 XL1,101
PCB ASSY - MAIN (44115-0800) Position FOR D3,4,103,104, PCB, IEC E,E1,E2 FOR D3,4,103,104, PCB, IEC FOR SK1,101 MAIN/CONTROL PCB PILLARS W3,4,103,104, IEC INLET FOR D3,4,103,104, IEC INLET FOR D3,4,103,104 FOR PCB SPACERS
17
PCB ASSY - MAIN (44115-0800) continued/... Part No. 20611-0003 20613-0012 20613-9401 20661-0225 20661-0408 20670-0135 20670-0200 20670-0260 22109-0050 22109-0070 22154-0120 22154-0110 22154-0090 22154-0200 22154-0220 22300-0211 22315-0248 22315-0402 22520-0160 22573-0202 22573-0204 22573-0205 22573-0206 22573-0207 22575-0062 23183-3470 23183-4100 23184-0047 23184-2120 23190-1100 23202-0270 23202-1220 23202-1330 23202-2100 23206-0470 23206-5680 18 Position BUSH POLYESTER TO220 J22-5006 WASHER NON-INSULATING WASHER TO220 ADHESIVE SPACER Hex M3 x 12ZPST SPACER Rnd/Hex/ST 2.5 L CLIP GP02 FOR PCB MTG H/SINKS HEATSINK PCB MTG 50MM HIGH HEATSINK DRILLED M/F -0261 TRANSFORMER HF POWER - CPX TRANSFORMER CURRENT SENSE CPX CHOKE 10uH AXIAL 35 MILLIOHMS CHOKE 130uH/4A CHOKE 10UH/12A - CPX CHOKE 1mH/10A COMMON MODE CPX CHOKE 3.3mH/4A COMMON MODE FUSEHOLDER PCB MOUNTING FUSE 10A ANTISURGE (T) HBC CER FUSE 100mAT TL PCB MTG AC MAINS RECEP 10AMP R/ANG MTG HEADER 2 WAY STRAIGHT .156P HEADER 4 WAY STRAIGHT .156P HEADER 5 WAY STRAIGHT .156P HEADER 6 WAY STRAIGHT .156P HEADER 7 WAY STRAIGHT .156P HEADER 10 WAY (2X5) STR RES 47KJ 1W CF RES 100KJ 1W CF RES 4R7J 2W CF RES 1K2J 2W CF RES 100RJ 2W5 500PPM TYPE PR52 RES 27R0F W25 MF 50PPM RES 220RF W25 MF 50PPM RES 330RF W25 MF 50PPM RES 1K00F W25 MF 50PPM RES 47R0F W60 MF 50PPM RES 6M80F W6 MF 50PPM Description FOR D3,4,103,104 FOR Q1,2,101,102 FOR D3,4,103,104 FOR PCB MAIN/CONTROL PCBS FOR Q1,2,101,102 SK2,3,102,103 SK1,101 T1,101 T2,102 L1,2 L3 L5,105 L7,107 L4 FOR FS1 FS1 FS2,102 PJ3 PJ2,102 PJ9 PJ5,105 PJ10 PJ1A,6 PJ4,104 R21,121 R1,2 R16,116 R13,17,20,113,117,120 R8,9,10,108,109,110 R4,6,104,106 R11,12,111,112 R18,118 R5,7,105,107 R15,115 R19,119
PCB ASSY - MAIN (44115-0800) continued/...
Part No. 23209-5100 23296-0020 23379-1100 23386-0010 23386-0030 23388-0030 23424-0459 23556-0230 23556-0222 23556-0225 23557-0612 23557-0655 23557-0659 23557-0676 23620-0246 23620-0261 23620-9007 23684-0010 23687-0010 25031-0060 25031-0070 25031-0080 25117-0020 25130-0207 25131-0224 25211-0302 25211-9302 25601-0440 27160-0015 27168-0100 35555-2270
Position RES 1M00F W75 MF 100PPM RES 0R01D 4 TERM 30PPM PBV RES PS/H 100R Cermet 10MM VARISTOR V275LA20A THERMISTOR - INRUSH LIMITER 4A THERMISTOR PTC 2322.661.15693 CAP 4N7 250V AC CER Y RATED CAP 1000UM 200V ELEC CAP 100U 385/400V ELEC CAP 2200U 50V ELEC LOW ESR CAP 1U0 50V ELEC P2 CAP 470U 35V ELEC P5 CAP 47U 25V ELEC P2 CAP 470U 63V ELEC P5 CAP 100NK 63V P/E P5 CAP 100NK 400V P/E CAP 10NK 100V P/E P5 CAP 470NK 250VAC X2 P/P P27.5 CAP 1N0F 400V P/P AXIAL DIO BYV27 DIO BYV29-400 DIO BYV32E DIO 1N5401 DIO ZEN 15V W4 DIO ZEN 18V 1W3 BRIDGE RECTIFIER D5SB60 RECTIFIER BRIDGE W02G TRAN MOSFET N CHAN 500V 10A IC V/REG 78L15 TO92 (NS) IC IR2110 MOSFET DRIVER PCB - MAIN
Description R3 R14,114 VR1,101 VDR1 RT1 PTC1,2,101,102 C6,7 C1,2 C12,112 C14,114 C22,23,25,122,123,125 C61,161 C63,163 C15,16,115,116 C19,21,24,26,27,62,119,121,124,126, 127,162 C17,18,117,118 C13,113 C5,8,9 C10,11,110,111 D5,105 D1,2,101,102 D3, 4,103,104 D6,106 D9,109 D7, 8,107,108 BR1 BR2,102 Q1, 2,101,102 IC16,116 IC1,101
19
REAR PANEL ASSY - (46912-0520) Part No.
20030-0266 20037-0401 20038-9502 20210-0102 20213-0010 20234-0029 20236-0010 22115-0260 22575-0204 22575-0205 22575-0207 33331-3540
Description
WASHER M4 ZPST SOLDER TAG SHAKEPROOF - 4BA WASHER M4 Spring NUT M4 ZPST CAPTIVE NUT SNU-1219-17-00 SCREW M4 X 12 PNHDPZ ZPST SCREW M4 X 12 TAMPERPROOF TRANSFORMER - CPX200 SKT4W .156 20AWG IDT SKT5W .156 20AWG IDT SKT7W .156 20AWG IDT REAR PANEL PRINTED
Position
TRANSFORMER, EARTH EARTH TRANSFORMER, EARTH TRANSFORMER, EARTH TRANSFORMER EARTH PJ9 PJ7,107 PJ1A
FRONT PANEL ASSY - (46912-0510) Part No.
20030-0263 20037-0247 20037-0305 20038-9501 20038-9503 20234-0027 20657-0110 20657-0111 22040-0030 22219-0050 22450-0020 22451-0200 22571-0670 22571-0680 22571-0690 22571-0691 22575-0202 22575-0207 23424-0454 23620-0232 33331-3520 33331-3530 35331-0080
Description
WASHER M3 ZPST WASHER 4BA SHK/PROOF I/T ZPST WASHER 5/16in.SHK/PRF I/T ZPST WASHER M3 Spring WASHER M3.5 SPRING SCREW M3 X 6 PNHDPZ ZPST KNOB 15MM DA150 006 GREY/99 CAP BLK LINE C157/132 GREY 99 FERRITE SLEEVE APPROX 7/14/15L SWITCH ROCKER DPST SOLDER LUGS EYELET M3.5 (4BA) SHRD BLUE SOLDER TAG 4BA TERMINAL INSULATED RED TERMINAL INSULATED BLACK TERMINAL INSULATED GREEN WASHER ALUMINIUM FOR TP2E TERM SKT2W .156 20AWG IDT SKT7W .156 20AWG IDT CAP 10NZ 1KV CER P10 CAP 47NK 63V P/E P5 FRONT PANEL OVERLAY FRONT PANEL SHORTING BAR - PLATED
Position
PCB FIXING GREEN TERMINAL GREEN TERMINAL PCB FIXING TERMINALS PCB FIXING
LLA,LLB MAINS SWITCH SENSE LEADS TERMINAL TP2 TP2 TP2 EARTH TERMINAL PJ2,102 PJ6 CAA,CAB CBA,CBB
CASE PARTS - (51153-0901) 20
Part Number 20030-0266 20037-0301 20038-9501 20062-0700 20062-9303 20063-0010 20210-0101 20213-0010 20234-0027 20234-0028 20662-0201 20662-0530 22491-0010 22491-0020 22575-0204 22575-0205 31711-0080 33171-0130 33537-0640 33537-0690 37522-0160 37541-1040 43171-1340 43171-1490 48511-0260
Description WASHER M4 ZPST WASHER M3 SHK/PROOF I/T ZPST WASHER M3 Spring SCREW NO 6 X 3/8 RFLNGPZ ST/AB SCREW NO 6x0.5in. PNHDPZ ST/AB SCREW NO6 X 3/8 NIB HDPZ ST/AB NUT M3 ZPST CAPTIVE NUT SNU-1219-17-00 SCREW M3 X 6 PNHDPZ ZPST SCREW M4 X 10 PNHDPZ ZPST BRACKET PLAS FOOT 3786-7001 FOOT POLY/E BLACK P2629 MAINS LEAD 2M IEC SKT/STRIPPED END OR MAINS LEAD 2M IEC SKT/EURO PLUG SKT4W .156 20AWG IDT SKT5W .156 20AWG IDT BEZEL HALF RACK - 3U CASE SPRING FOOT CASE UPPER CASE LOWER LABEL SER NO - THURLBY-THANDAR LABEL - CE CONN ASSY 10W MAIN/CNTL CPX CONN ASSY 26W KB/CNTL CPX INSTRUCTION MANUAL
Position RUBBER FEET FRONT PANEL, EARTH PCB PILLARS, STUDS R.PANEL/CHASSIS CONTROL TO MAIN PILLARS CASE UPPER FRONT PANEL, STUDS CASE UPPER/LOWER PCB SPACERS FEET
PJ9,10 PJ5,105
PJ4,104 PJ8,108
21
Component Layouts
FRONT PANEL PCB
22
CONTROL PCB
23
MAIN PCB
24
Circuit Diagrams
25
CONTROL PCB (PART) - CHANNEL A
(CHANNEL B IDENTICAL)
CONTROL PCB (PART) - CHANNEL A
(CHANNEL B IDENTICAL)
MAIN(POWER) PCB
Thurlby Thandar Instruments Ltd Glebe Road, Huntingdon, Cambridgeshire PE29 7DR, England Telephone: (44) 01480 412451 Fax: (44) 01480 450409 e mail: [email protected] web site: www.tti-test.com