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CPX400A
Bench Power Supply

Service Manual

Book Part Number 48511-0910 - Issue 1

Table of Contents

Specification Safety EMC Installation Connections General Circuit Descriptions Calibration Parts List Component Layouts Circuit Diagrams

2 4 5 6 6 7 8 13 15 26 29

1

Specification
General specifications apply for the temperature range 5°C to 40°C. Accuracy specifications apply for the temperature range 18°C to 28°C after 1 hour warm-up with no load and calibration at 23°C. Typical specifications are determined by design and are not guaranteed.

OUTPUT SPECIFICATIONS
Voltage Range: Current Range: Power Range: Output Voltage Setting: Output Current Setting: Operating Mode: 0V to 60V 0A to 20A Up to 420W 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.

CPX 400A POWER ENVELOPE

Output Switch: Output Terminals: Sensing: Output Protection:

Electronic. Preset voltage and current displayed when off. 4mm terminals on 19mm (0·75") pitch. 30A max. Switchable between local and remote. Spring-loaded push terminals for remote connection. Forward protection by Over-Voltage Protection (OVP) trip; maximum voltage that should be applied to the terminals is 70V. Reverse protection by diode clamp for reverse currents up to 3A. The output will be tripped off if a fault causes the internal temperature to rise excessively. 10% to 110% of maximum output voltage set by front panel screwdriver adjustment. Change in output for a 10% line change: Constant voltage: <0.01% of maximum output Constant current: <0.01% of maximum output Change in output for any load change within PowerFlex envelope, remote sense connected: Constant voltage: <0.01% of maximum output Constant current: <0.05% of maximum output 4mVrms max; typically <2mVrms, <10mV pk-pk, at maximum load, CV mode.

Over-temperature Protection: OVP Range: Line Regulation:

Load Regulation:

Ripple & Noise (20MHz bandwidth):

2

Transient Load Response: Temperature Coefficient: Status Indication:

<250us to within 50mV of set level for a 5% to 95% load change. Typically <100ppm/°C Output on lamp. Constant voltage mode lamp. Constant current mode lamp. Unregulated (power limit) lamp Trip message on display.

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 0.1% of reading ± 2 digits, Current 0.3% of reading ± 2 digits

GENERAL
AC Input: Power Consumption: Operating Range: Storage Range: Environmental: Safety: EMC: Size: Weight: 110V 240V AC ± 10%, 50/60Hz. Installation Category II. 1250VA max. +5ºC to +40ºC, 20% to 80% RH. -40ºC to + 70ºC. Indoor use at altitudes up to 2000m, Pollution Degree 2. Complies with EN61010-1. Complies with EN61326. 210 x 130 x 375mm (WxHxD) half rack width x 3U height (optional rack mounting kit available). 6kg

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 that 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 2 environment 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. Do not operate while condensation is present. 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. 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.
Standby.

l

mains supply ON. alternating current (ac) direct current (dc)

4

EMC
This instrument 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
EN61326 (1998) EMC product standard for Electrical Equipment for Measurement, Control and Laboratory Use. Test limits used were: a) b) c) Radiated: Class B Conducted: Class B Harmonics: EN61000-3-2 (2000) Class A; the instrument is Class A by product category.

Immunity
EN61326 (1998) EMC product standard for Electrical Equipment for Measurement, Control and Laboratory Use. Test methods, limits and performance achieved were: a) b) c) d) e) f) EN61000-4-2 (1995) Electrostatic Discharge : 4kV air, 4kV contact, Performance A. EN61000-4-3 (1997) Electromagnetic Field, 3V/m, 80% AM at 1kHz, Performance A. EN61000-4-11 (1994) Voltage Interrupt, 1 cycle, 100%, Performance B. EN61000-4-4 (1995) Fast Transient, 1kV peak (AC line), 0.5kV peak (DC Outputs), Performance B. EN61000-4-5 (1995) Surge, 0.5kV (line to line), 1kV (line to ground), Performance B. EN61000-4-6 (1996) Conducted RF, 3V, 80% AM at 1kHz (AC line only; DC Output connections <3m not tested), Performance A.

According to EN61326 the definitions of performance criteria are: Performance criterion A: `During test normal performance within the specification limits.' Performance criterion B: `During test, temporary degradation, or loss of function or performance which is self-recovering'. Performance criterion C: `During test, temporary degradation, or loss of function or performance which requires operator intervention or system reset occurs.' Where Performance B is stated it is because DC Output regulation may deviate beyond Specification limits under the test conditions. However, the possible deviations are still small and unlikely to be a problem in practice. Note that if operation in a high RF field is unavoidable it is good practice to connect the PSU to the target system using screened leads, which have been passed (together) through an absorbing ferrite sleeve fitted close to the PSU terminals.

Cautions
To ensure continued compliance with the EMC directive observe the following precautions: a) after opening the case for any reason ensure that all signal and ground connections are remade correctly and that 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 Part List.

5

Installation
Mains Operating Voltage
This instrument has a universal input range and will operate from a nominal 115V or 230V mains supply without adjustment. Check that the local supply meets the AC Input requirement given in the Specification.

Mains Lead
Connect the instrument to the AC supply using the mains lead provided. Should a mains plug be required for a different mains outlet socket, a suitably rated and approved mains lead set should be used which is fitted with the required wall plug and an IEC60320 C13 connector for the instrument end. To determine the minimum current rating of the lead-set for the intended AC supply, refer to the power rating information on the equipment or in the Specification. 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.

Ventilation
The power supply is cooled by an intelligent multi-speed fan which vents at the rear. Take care not to restrict the air inlets at top, bottom and side panels or the exit at the rear. In rack-mounted situations allow adequate space around the instrument and/or use a fan tray for forced cooling.

Mounting
This instrument is suitable both for bench use and rack mounting. It is delivered with feet for bench mounting. The front feet include a tilt mechanism for optimal panel angle. A rack kit for mounting one or two of these Half-width 3U high units in a 19" rack is available from the Manufacturers or their overseas agents.

Connections
All connections are made from the front panel. The load should be connected to the positive (red) and negative (black) terminals marked OUTPUT. Remote sense connections to the load, if required, are made from the positive (+) and negative (-) SENSE terminals. Switch the LOCAL/REMOTE switch to REMOTE when remote sensing is required. Switch back to LOCAL when remote sensing is not in use. The terminal marked is connected to the chassis and safety earth ground.

6

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 safely 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 1500VA. High voltages (up to 400V) are always present in the primary-side circuitry, which lies in a clearly defined area at the rear of the main printed circuit boards. 1. 2. Remove the 6 side screws to release the top cover. To remove a Power PCB assemby, undo the two nuts securing the orange and black wires to the Main PCB studs and disconnect wires. Unplug the cable assembly between Power PCB assembly and Control PCB noting the orientation (brown wire to pin 1 corner marker). Undo the two screws on the side of the unit, remove the two plasic rivets, and lift the board assembly out Remove the other Power PCB assembly in the same way. Disconnect the cable assemblies between the Control and the Main board. The front panel assembly can be removed by disconnecting all wires between Main PCB and front panel and undoing the 4 screws that secure the front panel to the chassis. The Control board may then be removed by undoing the 5 screws that secure it to the front panel and gently lifting it out. To remove the Main board disconnect the chassis earth connection and undo the 8 screws that secure the Main PCB support pillars to the chassis (i.e. the screws accessible underneath the chassis) and lift out the PCB assembly with its mounting pillars attached. 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 fasteners have been used otherwise earthing, and hence EMC and safety performance, may be impaired.

3. 4. 5.

6.

7.

7

Circuit Descriptions
Main Board
Mains Input, Filtering and Rectification
The AC input is via a PCB mounted IEC inlet. X-capacitors C1, C5 together with the Y-capacitors C3, C4, C6, C7, the common mode inductors L1 and L2 and differential choke L3 comprise an input filter which ensures that the supply meets both conducted emission and conducted immunity EMC requirements. VD1 clips mains spikes for component protection, while R1 discharges the X-capacitors after removal of the mains supply. PCB mounted fuse FS1 limits damage in the event of forward converter failure. The front panel switch enables / disables the unit and is connected to the Main PCB via two wires soldered at point PJ. Disconnect the Main board by unplugging the connections from the switch. Diodes D1 and D2 form a bridge rectifier and have capacitors C8 and C9 connected across them to bypass noise signals and to snub reverse recovery transients in the diodes D1, D2. C10 decouples the rectified Mains and R2 provides a discharge path for R2 once the mains supply has been removed. R1 limits inrush current and is shorted out by RL1B once the inrush is over (see section on sequencing later in this document).

Auxiliary Supply
IC2 and associated components form a simple flyback power supply to generate the auxiliary rails needed. The auxiliary power supply is self starting and operates in `burst mode', switching at approximately 44kHz when running but being periodically disabled by Q8 to provide a regulated supply of approximately 18 to 19V (set by D20/D21 conduction point). This rail, `+18VPRIM', also supplies IC3 which provides a regulated 12-volt supply. C26 and C27 provide energy storage and decoupling for the `+18VPRIM' and `+12VPRIM' rails respectively. D17 and D18 clamp the voltage across the Primary of T1 to protect IC2. C24 provides local decoupling for the Auxiliary supply

Sequencing
IC1 and associated components control the start-up and shut-down sequencing of the unit. On application of the mains the start-up sequence is: (1) allow bulk capacitance C18/C19 to charge with R1 limiting current. (2) Close relay RL1B. (3) after a suitable delay, to allow for switch bounce, enable PFC section and Power boards. Once the supply is removed the shutdown sequence is: (1) disable PFC section and Power boards (2) after short delay open relay RL1B. This not only ensures that the relay is always switched with zero current, prolonging the life of the relay, but also that inrush current is always limited even if the mains supply drops out and recovers. IC1-A monitors the rectified mains voltage (divided down by R17-19 and R21) to ensure that the supply voltage is sufficient, generating pulses at pin1. If the supply voltage is adequate then the output of IC1-D (pin14) goes permanently high. R26 and C21/C22 now provide a suitable delay for the inrush current when the output of IC1-C goes high, switching RL1 on via D14, R30, R31 and Q1. This shorts out R1 so that it does not dissipate any power when the unit is running. R28 and C23 now introduce a second delay after which the output of IC1-C (pin8) goes high. This provides a second path to hold RL1 on via D15 and switches Q2 to enable both the PFC section and the Power boards.

8

When the ac supply is removed or reduced (for example a prolonged brown out) IC1-B output goes low. This causes IC1-B output to go low which immediately disables the PFC section and the Power boards via D12, Q2 etc. There is now a small delay introduced by R29, D11 and C23, after which IC1-C goes low and RL1 opens (via Q1)

PFC Section
L5, D5 and Q5/Q6 form a classic boost converter to generate a supply of approximately 390 volts. This operates in the following manner. When the FETs Q6/Q6 are on the current in L5 increases, storing energy. When they turn off this energy is transferred to the bulk capacitors thus raising the output voltage. There are various snubbers R11/C14, R15/C16 and R16/C17, which slow down switching edges to reduce EMI and reduce losses in the power components Q5/Q6/D3. Gate drive is provided by Q3 and Q4; C11/C12/C13 provide local decoupling. R6/R7/D7 and R3/R4/R5 shape the gate drive to control switching times. The primary boost stage control is by means of IC4. This contains all the processing circuitry to shape the current taken by the power supply from the mains supply such that it is sinusoidal and in phase with the voltage. For a detailed description refer to the ST Microelectronics `Power Factor Corrector Applications Manual `. The start-up of the PFC section is controlled by IC1 (the sequencing circuit) which releases the soft start signal `SS' for IC4, via Q10, at the end of the start-up sequence described above. IC4 starts generating gate drive pulses to the boost converter; C38 provides a degree of soft start. The output of IC4 pin 8 is the output of an internal multiplier; this generates a current proportional to the desired input current. It has 4 inputs: · · · R42, R43 and R44 supply a current derived from the full wave rectified mains voltage to pin 4. The fixed reference on pin 6. The output from the voltage error amplifier on pin 13. The inputs to the error amp are an internal reference (of about 5.1 volt) and a potential divider chain (VR1, R46-50). This monitors the HT voltage across the output of boost converter. Thus a steady output of about 390 volts (set by VR1) is obtained. A signal proportional to the mains voltage, applied to pin 7. This signal is generated by the two-stage R-C filter formed by the component chain R36-41, C28, C29 between `VRECT+' and pin 7 of IC4.

·

This output forms one of the inputs to an error amplifier; the other input (pin 9) is in effect the actual input current as sensed by the voltage across shunt resistor R60. The output of this error amplifier, pin 5, is the input to the PWM and thus controls the duty cycle of the converter; C34 and R58 are loop compensation. Over-voltage protection feeds into pin 3 via another potential divider chain shutting the PFC stage down if the output goes too high.

Shutdown
The unit can be switched off by an enable switch or by the Control board (using IC6 or IC8) in the event of a fault. This is achieved by pulling down the `shutdown' signal, IC1-A pin3. This appears to the sequencing circuit as a `mains supply is low' signal and thus disables the Power boards and PFC section.

Setup
There are two pots on the Main board. VR2 adjusts the switching frequency and should be set to give 65kHz. VR1 adjusts the HT supply voltage and should be set to give 390 volt with no load at the output. 9

Power Boards
There are two Power boards, one for each channel. They have different PCB layouts but identical circuitry.

Oscillator and Forward Converter
IC1-A, B, C, C2, R43, R3 form a 160kHz oscillator. D-type bistable IC2-A produces a square wave at 80kHz .The square wave at Q output of the D-type is processed by R4, D4, C9 and IC1D to give a drive pulse of about 45% duty ratio. The output from IC1-D is buffered by IC1-E and IC1-F to drive the complimentary emitter followers Q3, Q4 which in turn drive the gate drive transformer T2. The transformer is ac coupled via C13. R14 in series with the primary winding of T2 and is used to control the switching speed of the MOSFETs. R13 in parallel with T2 primary dampens any ringing. A dual-ended forward converter comprising Q1, Q2 and T1 converts the boost voltage from the PFC stage to provide the main low voltage secondary and also the secondary auxiliary voltages. T1 leakage and magnetising energy is returned to the high voltage supply rail via D5, D6 and D7, D8. The turn-off voltage rise is controlled by `loss less' snubber network C3, C4, D1, D2, D3, L1. C37 and R52 subdue residual ringing across the primary winding. The current in the forward converter is monitored by R8 and, if excessive, activates latch Q6, Q10 to provide a pulse-by pulse current limit. A power-back winding is rectified by D9 and filtered by C6, C7. The cooling fan is supplied by Q11, the base of which is driven from an opto isolator. The drive to the fan increases as the output load current increases.

Main output.
The voltage on the secondary winding is rectified and L-C filtered and fed to a linear regulator. To minimise power dissipation in the linear regulating element, the voltage across it is maintained at about 1V by means of a magamp. The linear regulation is performed by MOSFET Q9, which receives gate drive from the Control PCB. The voltage across Q9 is monitored by Q8, which generates reset current to the magamp MA1 whenever the voltage across Q9 forward biases the base-emitter junction of Q8. D19, D18 are the main rectifier and flywheel diodes. The rectified pulse is filtered by L3 and C23, C24. D11, R12 and C11 generate a negative rail to sink the base bias current of Q8, which would otherwise cause the output to remain slightly positive when 0V was set on the front panel. In the event of a fault where control of the magamp is lost and the voltage across the filter capacitors rises above 49V, the opto isolator IC5 is activated via zener diode D22 and R28 and causes primary side latch Q6, Q10 to inhibit drive pulses to the converter transistors Q1, Q2. The forward current pulses in the secondary winding are monitored with current transformer T3. D33 rectifies and averages this signal to control the drive to the cooling fan via opto isolator IC7. D26 rectifies the signal and feeds it to the front panel to be used by the power-flex control circuit. PTC TH1 monitors the temperature of the secondary heatsink and, in the event of excessive heatsink temperature, Q7 is switched on which in turn causes the op-amp IC4-B to disable the linear output MOSFET. This is a latched condition and requires the interruption of the mains supply to resume operation

Secondary Auxiliary Power Supply.
The power rails for the control electronics are generated from an auxiliary winding on the main converter transformer. 10

The +15V rail is derived from R1, D16, C18, R24, R49 and transistor switch Q12. During power down, the +15V rail is switched off by Q13, which detects the reduction of voltage to the switch Q12. This causes the output from the power supply to quickly reduce to zero. The +5V rail is rectified by D17, D30 and filtered by L4 and C17. The inductor L4 is held in continuous conduction and thus the voltage at the input to the three terminal regulator IC6 is maintained at low value. The 5V rail is peak rectified by D13, C15 and regulated by IC8.

Control Board
The control board contains two identical control circuits one for each output. The following description is for channel A but may also be used for channel B except all component references for channel B are 100 higher than the equivalent component on channel A ; for example, where this description discusses IC1, the channel B reference is IC101.

Voltage Control
D6 provides the reference (VREF), nominally 2.45V. IC7C buffers the voltage control potentiometers VR1 and VR2; VR5 sets the maximum output voltage. The voltage at IC7-C pin 8 will be between 0V and approximately 8.09V depending on output voltage. IC7-A is a differential amplifier; VR9 trims differential gain to ensure good voltage regulation, see Calibration section. The output of IC7-C drives the input of IC7-A when the ON-OFF switch, SW1A, is in the ON position. When SW1A is in the OFF position the input of IC7-A is grounded via Q4 switched by R92, setting the output volts to zero. The output of IC7-A provides the gate drive (GATE) to the regulating MOSFET on the Main PCB via D3. SW1-B selects between local and remote sense.

Current Control
IC7-D is the error amplifier, which compares the voltage on the wiper of VR3, the current limit control, with the voltage generated across the current sense resistor R21 and amplified by IC7-B. When the output current reaches the set limit, IC7-D takes control via D4, changing the supply from constant voltage to constant current mode. At the same time Q1 is turned on by IC7-D. This turns on the `constant current' LED via IC9. VR4 sets the maximum output current; VR8 adjusts the output current to be the same as the preset current at low levels, see Calibration section.

Power-flex Control
IC8-B provides power-flex control. This operates on the principal that, for any forward converter with constant primary supply voltage, the output power is proportional to the average current in the forward diode. This current is sensed using a current transformer on the Power board (T3). In practice the proportionality has to be modified slightly because at higher output voltages the maximum output current is lower, resulting in lower losses on the Power board, and the output power can be a little higher (e.g. 420W at 42V cf. 400W at 20V). To reflect this the current limit also has to be slightly proportional to the peak current in the forward diode. T3, D26 and R38 on the power board provide a signal representing the forward diode current. IC8-B compares this signal (averaged by R95, R19, R68 and C44) with a reference generated by VR13 and modified slightly (by VR15, R49, D12 and C43) to give a slight proportionality to the peak of the current. At the maximum power level its output starts to go low, thus reducing the output voltage demand via D13 and R10 limiting the maximum output power.

11

IC8-C detects when this circuit is operating, providing a signal to IC9-B via R76 and Q5 to light LED4 `UNREG'. The UNREG mode should not be thought of as a constant power mode; it is instead a rough power limit. In this mode there will be increased output noise and poorer regulation.

OVP Trip and Setpoint.
Each channel has a user settable OVP trip. This is set by VR5, adjustable through a hole in the front panel with a tool such as a small screwdriver). The OVP level is buffered by IC11-A. If an OVP condition occurs then the output of IC11-B goes high; D14 and R89 provide positive feed back to latch the output high and Q4 is turned on via D15 to force the output voltage demand to zero. Switch K1 provides a signal to the microcontroller to display the OVP set point. When the user switches the output off, via SW1A, Q6 turns on resetting the latch.

Measurement and Display
IC9 provides the logic to drive the mode indicator LEDs: LED1 `Constant voltage', LED2 `constant current' and LED4 `unreg'; LED3 `output on' is switched directly by SW1A. The two 4-digit LED displays DIS1 and DIS2 are driven by the microcontroller IC3. This displays each digit in turn, writing the correct bit pattern for each digit to IC6 and then selecting the digit via IC1. The microcontroller uses the signal `SW1A' to decide if it should display actual or preset levels. IC2 is a Delta-Sigma type A to D converter; its 2.45-volt reference is applied between pins 9 and 10 and buffered by IC4. It measures the output voltage differentially (between pins 15 and 16) and also the programmed voltage (between pins 14 and 18); this allows VR16 to be used to correct for any input offset voltage error in IC7A. The other measurements, OVP setting, output current and current limit are single-ended measurements measured with respect to Aux 0V. All communication between IC2 and IC3 is transmitted along a serial (SPI) interface.

12

Calibration
Refer to the General section for dismantling instructions and safety precautions. All adjustments are on the front panel Control board. Allow 5-minute warm-up before commencing calibration.

Equipment Required
A 5½ digit multimeter with better than 0.05% accuracy on dc Volts and better than 0.1% accuracy on dc current to 20 Amps; alternatively use a precision shunt for current measurement. Rheostat or other high power load arrangement to provide up to full load. 1k 1% 0.25W resistor.

Voltage Calibration
Switch O/P ON and set Volts controls so that Volts display reads 0.02V exactly. Switch O/P OFF and adjust VR16/116 (preset Volts offset compensation) for 0.02V exactly on the display. Switch O/P ON and connect multimeter to output. Check output LED is ON. Check current display reads 0.00 to 0.01A. Increase voltage and current controls to MAX. Adjust VR5/105 (maximum output volts) for a reading of 61.7XVolts on multimeter. Adjust VR17/117 (measured volts) to match UUT voltage display to external meter +/- 0.02V. Switch O/P OFF. Adjust VR10/110 (preset volts) for previous reading on voltage display exactly.

Current Calibration
With O/P OFF, set Voltage to 10.0XVolts (Current still at MAX). Connect a 1k resistor to output. Set O/P ON. Adjust VR11/111 (current sense amp offset compensation) for 0.01A on UUT current display. Remove 1k resistor. Set current limit to MIN (Volts still at 10.0X). Connect load across output. Switch O/P ON. Adjust VR8/108 (current control amp offset compensation) for a reading of 0.003A +/- 0.001A on external current meter. Check CI LED is ON and current display reads 0.00A. With O/P ON increase current control to MAX (Volts still at 10.0X). Adjust variable load for a reading of 18.XXAmps on current meter. Adjust VR7/107 (measured output current) to match UUT current display to external current meter +/- 0.02A.

Powerflex Calibration plus Volts and Current Max Adjustments
Increase voltage controls to MAX (Current still at MAX). Adjust variable load for a reading of 7.3XAmps. Adjust VR13/113 (Powerflex limit at max volts) until UNREG LED just lights (and CV LED is off). Adjust VR5/105 (maximum output volts) for a reading of 60.21Volts to 60.36Volts on DUT display. Adjust variable load for a reading of 20.1XAmps (ensure DUT remains in UNREG mode, not CI mode). Adjust VR15/115 (Powerflex limit at max current) until output voltage is 21.1XVolts (UNREG mode). Adjust variable load until CI LED comes on. Adjust VR4/104 (maximum output current) for a current meter reading of 20.2XAmps.

Set OVP
Switch O/P OFF. Disconnect load. Adjust VR14/114 fully clockwise. With front panel OVP button held down, adjust front panel SET OVP pot until display shows 18.XXVolts. Release OVP button and adjust voltage controls until preset output volts match OVP voltage setting +/- 0.02V. Switch O/P ON. Adjust VR14/114 slowly anticlockwise until display just shows `trip'.

13

Turn O/P OFF, reduce fine O/P volts a little and turn O/P ON again. Increase fine volts slowly until O/P just trips again; check that O/P volts are the same as OVP volts +/-0.05V. Repeat a. if not, otherwise reset front panel OVP pot to MAX.

Voltage Regulation
Connect +sense to the +output terminal, connect sense to the output terminal. Connect the DMM (set to Volts) across the sense terminals, no load, output ON. Adjust voltage controls for a reading of 18.xxxx on the DMM; note exact reading. Connect approximately 19A load to the output terminals and adjust VR9 (differential voltage gain) until the external DMM matches the previous reading.

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. Measure differential and common-mode noise one at a time on a 20MHz TRMS voltmeter or use a 20MHz bandwidth-limited scope for peak-topeak measurements.

14

Parts List
PCB ASSEMBLY CPX400A MAIN Part No. 44115-2000
Part Number 20205-0700 20234-0034 20234-0100 20613-0018 20613-0026 20661-0225 20670-0364 20670-0365 20670-0520 22040-0940 22109-0310 22154-0680 22154-0690 22154-0740 22247-0030 22312-0250 22315-0255 22520-0190 22573-0048 22573-0070 22573-0211 22573-0222 22573-0247 22575-0076 23105-0150 23105-0220 23105-1100 23105-1120 23105-1220 23105-2100 23105-2150 23105-2180 23105-2220 23105-2470 23105-2680 Description STUD M4 X 10 KFH-M4-10ET SCREW M4 X 6 PNHDPZ ZPST SCREW M3 X 6 PNHD C/W EX SH/P WASHER SIL-PAD TO-3P/247 PLAIN SIL-PAD 900S 100MM X 25MM SPACER Hex M3 x 12 NPBR CLIP MAX01H FOR TO220+MAX H/S CLIP MAX03H FOR TO247+MAX H/S HEATSINK MAX505 178MM PLAIN BEAD (DOUBLE) - FERRITE TRANSFORMER - AUX - CPX400A CHOKE 1.2mH/12A COMMON MODE INDUCTOR BOOST - CPX400a PFC CHOKE 17.5uH/12A CPX400A RELAY 1P C/O 16A 12V FUSE CLIP 0.25in. PCB MTG FUSE 15AT HRC CER 1.25 X 0.25 AC RECEP 10AMP R/A SOLDER MTG HEADER 3WAY STR SIL STD/GOLD HEADER 4WAY STR SIL STD HEADER 3 WAY STR F/LOCK .156 HEADER 2 WAY STR F/LOCK .156 HEADER 2 WAY STR .1P F/LOCK HEADER 8 WAY (2x4) STR SKELTN RES SM0805 15R0F W1 RES SM0805 22R0F W1 RES SM0805 100RF W1 RES SM0805 120RF W1 RES SM0805 220RF W1 RES SM0805 1K00F W1 RES SM0805 1K50F W1 RES SM0805 1K80F W1 RES SM0805 2K20F W1 RES SM0805 4K70F W1 RES SM0805 6K80F W1 Position OUTPUT TERMINALS (4) FOR HS1 and HS2 FOR PCB SPACERS FOR HSD3 FOR HSD1, D2, Q5, Q6 PCB SPACERS FOR D1, D2, D3 FOR Q5, Q6 HS1 FB1 T1 L1,L2,L4 L5 L3 RL1 FOR FS1 FS1 P6 PJ4 TP1 LK1 PJ5-7 P4 PJ1, 2, 101, 102 R3, 6 R4, 7 R63 R35 R56 R22, 23, 34, 64, 73, 74 R57, 59 R29 R62 R30, 32, 33, 65, 66, 67 R71, 72 15

PCB ASSEMBLY CPX400A MAIN Part No. 44115-2000 /continued...
Part Number 23105-2910 23105-3100 23105-3220 23105-3330 23105-3390 23105-4100 23105-4180 23105-4200 23105-4220 23105-4390 23105-4470 23105-5100 23185-0000 23202-4220 23209-4220 23210-4150 23271-0019 23274-0210 23275-0010 23377-2220 23386-0010 23405-0101 23406-2474 23424-0459 23424-0459 23424-0468 23424-0469 23461-0020 23461-0030 23461-0040 23461-0080 23461-0200 23461-0300 23557-0612 23557-0665 23557-0667 Description RES SM0805 9K10F W1 RES SM0805 10K0F W1 RES SM0805 22K0F W1 RES SM0805 33K0F W1 RES SM0805 39K0F W1 RES SM0805 100KF W1 RES SM0805 180KF W1 RES SM0805 200KF W1 RES SM0805 220KF W1 RES SM0805 390KF W1 RES SM0805 470KF W1 RES SM0805 1M00F W1 RES ZERO OHM RES 220KF W60 MF 50PPM RES 220KF W75 MF 100PPM RES 150KJ 2W MF 250PPM RES 0R01J 2W MR RES 39R0J 7W MF (STAND-OFF) RES 47R0J 3W MO RES PS/H 2K2 CF 10MM VARISTOR V275LA20A CAP SM0805 100P CER COG CAP SM0805 470NK 16V CER X7R CAP 4N7 250V AC CER STR/LNG Y CAP 4N7 250V AC CER STR/LNG Y CAP 470PK 1KV CER P5 CAP 220PK 1KV CER P5 CAP SM0805 100NZ 50V CER Y5V CAP SM0805 220NK 16V CER X7R CAP SM0805 1N0K 50V CER X7R CAP SM0805 47NJ 50V CER X7R CAP SM0805 2N2J 50V CER X7R CAP SM0805 100NK 25V CER X7R CAP 1U0 100V/50V ELEC RE2 P2 CAP 2U2 50V ELEC RE2 P2 CAP 220U 25V ELEC RE2 P3.5 Position R50 R24, 68, 70 R21, 31, 55 R41, 61 R58 R5, 45 R39, 40, 46, 47, 48 R28 R17, 18, 19, 49 R37, 38, 43, 44, 54 R36, 42, 51, 52, 53 R25, 26 R10 R69 R2 R14 R60 R1 R11, 15, 16 VR1, 2 VD1 C47, 48 C21, 22, 38 C3, 4, 6, 7, 8, 9 C4 C16, 17 C14 C49 C29 C34, 35, 36, 37 C32 C33 C11, 12, 13, 20, 23, 25, 31, 41 C40 C45 C26, 27, 30

16

PCB ASSEMBLY CPX400A MAIN Part No. 44115-2000 /continued...
Part Number 23557-0825 23557-0827 23557-0831 23557-0950 23620-0247 23684-0020 23684-0021 23684-0023 25021-0010 25031-0200 25115-1010 25118-0110 25130-0915 25132-0230 25132-0240 25340-1020 25377-1000 25377-1000 25381-1020 25601-0740 27001-0060 27106-0506 27160-0017 27168-0040 27168-0060 35555-4310 Description CAP 100U 50V LOW ESR P3.5 CAP 470U 100V LOW ESR P7.5 CAP 10U 400V ELEC P5 CAP 470U 400V ELEC S/I P10 CAP 220NK 63V P/E P5 CAP 1UM 250VAC X2 P/P P27.5 CAP 2U2K 400V P/P P27.5 CAP 2U2M 275VAC X2 P/P P27.5 DIO SM LL4148 SWITCHING MM DIO BYC10-600 TO-220AC DIO SM US1J 1A 600V 75ns DIO 2x11A 800V IXYS DSP8-08A DIO ZEN 75V W4 DIO SM ZEN 5V1 W35 SOT23 DIO SM ZEN 9V1 W35 SOT23 TRAN SM PNP FZT751 60V 3A TRAN SM NPN BC849C SOT23 TRAN SM NPN BC849C SOT23 TRAN SM NPN FZT651 60V 3A TRAN MOSFET N CHAN IRFPS 37N5UA OPTO-COUPLER SFH615A-3 IC LM324N 14 PIN READ TECH SPEC IC V/REG 7812 TO220 IC L4981A 20 PIN IC TNY254P 8 PIN PCB - MAIN - CPX400A Position C44 C42, 43 C24 C18, 19 C28 C1, 46 C10 C5 D6, 7, 10-16, 22, 24, 26, 27 D3 D18, 19 D1, 2 D17 D23, 25 D20, 21 Q4 Q1, 2, 8, 9, 10 Q10 Q3 Q5, 6 IC5, 6 IC1 IC3 IC4 IC2 PCB

PCB ASSEMBLY CPX400A POWER L/R Part No. 44115-2070
Part Number 20073-9801 20105-0510 20234-0034 20613-0018 20613-0026 20653-0210 20670-0360 20670-0364 Description SCREW No.4x1/4in. Plastite INSERT THREADED KF2-M3-ET SCREW M4 X 6 PNHDPZ ZPST WASHER SIL-PAD TO-3P/247 PLAIN SIL-PAD 900S 100MM X 25MM CABLE TIE 370 X 4.8MM HEATSINK MAXS515 100MM PLAIN CLIP MAX01H FOR TO220+MAX H/S Position HS2 FIXING LEFT & RIGHT CHASSIS FIXINGS HS1 FIXING LEFT & RIGHT FOR HS1,2 FOR HS2 FOR T1, L3, MA1 LEFT & RIGHT HS2L,HS2R FOR HS1/2 LEFT & RIGHT (8) 17

PCB ASSEMBLY CPX400A POWER L/R Part No. 44115-2070 /continued...
Part Number 20670-0365 20670-0480 22040-0060 22040-0940 22109-0130 22109-0280 22109-0340 22154-0160 22154-0460 22154-0550 22154-0630 22154-0650 22573-0041 22573-0048 22573-0209 22574-0308 23185-0000 23202-0100 23202-1100 23202-1220 23202-1330 23202-1470 23202-1680 23202-2100 23202-2220 23202-2270 23202-2390 23202-3100 Description CLIP MAX03H FOR TO247+MAX H/S HEATSINK MAXS526 100MM PLAIN FERRITE SLEEVE 2.25IDx7.55L BEAD (DOUBLE) - FERRITE TRANSFORMER GATE DRIVE - EX TRANSFORMER CURRENT SENS CPX400 TRANSFORMER HF POWER - CPX400A CHOKE 1mH AXIAL 1.3 OHMS CHOKE 1mH (EF16) - EX MAGAMP - CPX400 CHOKE OUTPUT (ETD) CPX400 CHOKE 760uH CM CPX400 HEADER 2WAY STR SIL STD/GOLD HEADER 3WAY STR SIL STD/GOLD HEADER 9 WAY STRAIGHT .156P SKT 8 WAY (2x4) RES ZERO OHM RES 10R0F W60 MF 50PPM RES 100RF W60 MF 50PPM RES 220RF W25 MF 50PPM RES 330RF W25 MF 50PPM RES 470RF W60 MF 50PPM RES 680RF W60 MF 50PPM RES 1K00F W60 MF 50PPM RES 2K20F W60 MF 50PPM RES 2K70F W25 MF 50PPM RES 3K90F W25 MF 50PPM RES 10K0F W60 MF 50PPM Position FOR HS1/2 LEFT & RIGHT (6) HS1L, HS1R L5L, L5R FB1L, 1R, 3L, 3R T2L, 2R T3L, 3R T1L, 1R L4L, 4R L1L, 1R MA1L, 1R L3L, 3R L6L, 6R TP1L, 1R, 2L, 2R TP3L, 3R PJ4L, 4R PJ1L, 1R, 2L, 2R LK1L, LK1R, R25L, R25R R56L, 56R R38L, 38R R19L, 19R R7L, 7R, 44L, 44R, 45L, 45R R13L, 13R, 21L, 21R R54L, 54R R4L, 4R, 33L, 33R R37L, 37R R3L, 3R R30L, 30R R32L, 32R, 35L, 35R, 39L, 39R, 40L, 40R, 41L, 41R, 42L, 42R, 47L, 47R, 48L, 48R, 55L, 55R R43L, 43R R16L, 16R R46L, 46R, 51R R23L, 23R, 31L, 31R R24L, 29R, 49L, 49R R50L, 50R

23202-3220 23202-3470 23202-4100 23206-5680 23207-1220 23207-4390

RES 22K0F W25 MF 50PPM RES 47K0F W25 MF 50PPM RES 100KF W25 MF 50PPM RES 6M80F W60 MF 50PPM RES 220RJ 1W MF 250PPM RES 390KJ 1W MF 250PPM

18

PCB ASSEMBLY CPX400A POWER L/R Part No. 44115-2070 /continued...
Part Number 23210-0470 23210-1100 23210-2100 23210-2120 23210-2220 23210-3560 23222-0022 23222-0047 23222-0220 23222-0470 23222-1220 23222-1330 23274-0020 23275-0010 23388-0010 23424-0459 23424-0466 23424-0468 23424-0469 23424-0472 23557-0661 23557-0673 23557-0776 23557-0820 23557-0825 23620-0246 Description RES 47R0J 2W MF 250PPM RES 100RJ 2W MF 250PPM RES 1K00J 2W MF 250PPM RES 1K20J 2W MF 250PPM RES 2K20J 2W MF 250PPM RES 56K0J 2W MF 250PPM RES 2R20J W33 MF FUSIBLE NRF25 RES 4R70J W33 MF FUSIBLE NFR25 RES 22R0J W33 MF FUSIBLE NRF25 RES 47R0J W33 MF FUSIBLE NFR25 RES 220RJ W33 MF FUSIBLE NFR25 RES 330RJ MF FUSIBLE NFR25 RES 0R10J 2W5 WW T RES 47R0J 3W MO THERMISTOR PTC TAG 90 DEG CAP 4N7 250V AC CER STR/LNG Y CAP 1N0K 1KV CER P5 CAP 470PK 1KV CER P5 CAP 220PK 1KV CER P5 CAP 2N2K 1KV CER P5/P7.5 CAP 470U 25V ELEC RE2 P5 CAP 22U 35V ELEC RE2 P2 CAP 680U 100V ELEC P7.5 CAP 10U 50V ELEC LOW ESR P2 CAP 100U 50V LOW ESR P3.5 CAP 100NK 63V P/E P5 Position R9L, 9R R22L, 22R R15L, 15R R20L, 20R R53L, 53R R26L, 26R R17L, 17R, 18L, 18R R1L, 1R R10L, 10R, 34L, 34R R28L, 28R R12L, 12R, 27L, 27R R29L, 29R R8L, 8R R11L, 11R, 52L, 52R TH1L, 1R, 2R C44L, 44R C14L, 14R C10L, 10R, 16L, 16R C37L, 37R C3L, 3R, 4L, 4R C17L, 17R C15L, 15R C23L, 23R, 24L, 24R, 32L, 32R C6L, 6R, 18L, 18R, 30L, 30R C28L, 28R C5L, 5R, 7L, 7R, 8L, 8R, 12L, 12R, 21L, 21R, 22L, 22R, 26L, 26R, 27L, 27R, 35L, 35R, 40L, 40R C11L, 11R, 38L, 38R C25L, 25R C19L, 19R, 20L, 20R C1L, 1R C2L, 2R C13L, 13R C9L, 9R

23620-0264 23620-0268 23620-9007 23621-0314 23685-0002 23685-0013 23685-0015

CAP 100NK 400V P/E 368 SER P15 CAP 220NK 400V P/E 468 SER P15 CAP 10NK 100V P/E P5 CAP 1U0K 400V P/E P27.5 CAP 1N0J 100V P/P FKP2 CAP 330NK 160V P/P P15 CAP 470PJ 100V P/P FKP2 P5

19

PCB ASSEMBLY CPX400A POWER L/R Part No. 44115-2070 /continued...
Part Number 25021-0910 Description DIO BAV21 Position D4L, 4R, 9L, 9R,10L,10R,12L,12R,13L,13R, 14L,14R,15L,15R,16L,16R, 24L, 24R, 27L, 27R, 28L, 28R, 29L, 29R, 31L, 31R D17L, 17R, 30L, 30R D26L, 26R, 33L, 33R D1L,1R, 2L, 2R, 3L, 3R, 5L, 5R, 6L, 6R, 7L, 7R, 8L, 8R, 11L, 11R D18L, 18R, 19L, 19R D23L, 23R D32L, 32R D22L, 22R Q8L, 8R Q5L, 5R Q6L, 6R, 7L, 7R,10L,10R,12L,12R,13L,13R Q4L, 4R Q3L, 3R,11L,11R Q9L, 9R Q1L,1R, 2L, 2R IC5L, 5R, 7L, 7R IC4L, 4R IC6L, 6R IC3L, 3R IC8L, 8R IC2L, 2R IC1L,1R PCB

25031-0060 25031-0100 25031-0110 25031-0240 25130-0207 25130-0916 25130-0918 25349-3500 25349-4210 25349-5560 25384-9001 25388-0211 25601-0700 25601-0740 27001-0060 27106-0513 27160-0009 27160-0013 27160-0014 27226-0130 27226-0690 35555-4060C

DIO BYW100-200 DIO BAX12A DIO BYV26C DIO BYV42E-200 TO-220AB DIO ZEN 15V W4 DIO ZEN 3V3 W4 DIO ZEN 68V W4 TRAN PNP MJE350 TRAN PNP BF421 TRAN PNP BC556 TRAN PNP ZTX751 TRAN NPN ZTX651 TRAN MOSFET N CHAN IRFP064 TRAN MOSFET N CHAN IRFPS 37N5UA OPTO-COUPLER SFH615A-3 IC LM358N 8 PIN IC V/REG 7805 TO220 IC V/REG 7815 TO220 IC V/REG 7905 TO220 IC 4013B 14 PIN IC 4069UB 14 PIN PCB - PWR LEFT/RIGHT - CPX400

PCB ASSY CPX400A Control/Front Panel/Terminals Part No. 44115-2060
Part Number 20030-0263 20038-9501 20234-0011 20670-0510 22041-0010 22218-0214 22225-0220 22226-0101 20 Description WASHER M3 ZPST BULK STOCK WASHER M3 Spring BULK STOCK SCREW M3 X 10 PNHDPZ ZPST BULK STOCK HEATSINK - BOLT ON - 15DEGC/W BEAD FERRITE SM0805 SWITCH SLIDE - KNITTER MFP221N SWITCH PUSH/PUSH SPPH11470B KEYSWITCH - ALPS SKHHBW Position FOR R21, R121 FOR R21, R121 FOR R21, R121 HS1, 101 FB1, 2, 101, 102 SW2, 102 SW1, 101 K1, 101

PCB ASSY CPX400A Control/Front Panel/Terminals Part No. 44115-2060 /continued...
Part Number 22467-0120 22573-0071 22573-0209 22573-0222 22573-0247 22574-0167 22575-0064 23105-0470 23105-0560 23105-1100 23105-1330 23105-1470 23105-1680 23105-1820 23105-2100 Description TERMINAL BLOCK 2W - LIGHT GREY HEADER 5WAY STR SIL STD HEADER 9 WAY STRAIGHT .156P HEADER 2 WAY STR F/LOCK .156 HEADER 2 WAY STR .1P F/LOCK SKT 32W SIL TURNED PIN HEADER 26 WAY (2X13) STR SKEL RES SM0805 47R0F W1 RES SM0805 56R0F W1 RES SM0805 100RF W1 RES SM0805 330RF W1 RES SM0805 470RF W1 RES SM0805 680RF W1 RES SM0805 820RF W1 RES SM0805 1K00F W1 Position SK1, 101 PJ3, 103 PJ1, 101 PJ7, 107 PJ2, 102 FOR DISPLAYS PJ4, PJ104 R8, 108 R203-210, 303-310 R40, 140 R95, 195 R45, 145 R22, 122 R84, 184 R11, 12, 19, 23, 27, 42, 59, 61, 65, 67, 67, 70, 74, 79, 80, 81, 82, 83, 94, 96, 111, 112, 119, 123, 127, 142, 159, 161, 165, 167, 170, 174, 174, 179, 180, 181, 182, 183, 194, 196 R47, 147 R10, 110 R2, 7, 102, 107 R46, 55, 56, 146, 155, 156 R38, 39, 72, 138, 139, 172 R34, 134 R85, 185 R14, 15, 16, 18, 20, 30, 32, 41, 43, 44, 48, 51, 52, 62, 63, 66, 68, 69, 71, 73, 75, 76, 77, 78, 86, 87, 89, 98,100,114,115,116, 118,120,130,132,141,143,144,148,151, 152,162,163, 166, 168,169,171,173, 175, 176,177,178, 186, 187, 189, 198, 200 R33, 88, 133, 188 R4, 53, 104, 153 R64, 164 R5, 25, 105, 125 R160 R60 R91, 191 21

23105-2150 23105-2220 23105-2330 23105-2360 23105-2470 23105-2510 23105-2750 23105-3100

RES SM0805 1K50F W1 RES SM0805 2K20F W1 RES SM0805 3K30F W1 RES SM0805 3K60F W1 RES SM0805 4K70F W1 RES SM0805 5K10F W1 RES SM0805 7K50F W1 RES SM0805 10K0F W1

23105-3105 23105-3150 23105-3220 23105-3270 23105-3300 23105-3300 23105-3330

RES SM0805 10K5F W1 RES SM0805 15K0F W1 RES SM0805 22K0F W1 RES SM0805 27K0F W1 RES SM0805 30K0F W1 RES SM0805 30K0F W1 RES SM0805 33K0F W1

PCB ASSY CPX400A Control/Front Panel/Terminals Part No. 44115-2060 /continued...
Part Number 23105-3470 23105-3560 23105-3560 23105-3560 23105-3560 23105-3560 23105-3560 23105-3680 23105-4100 23105-4150 23105-4180 23105-4270 23105-4470 23105-4560 23105-5100 23105-5200 23105-5470 23105-6100 23202-1220 23296-0020 23347-0140 23347-0150 23382-3100 23385-1200 23385-1470 23385-2220 23385-2470 23385-3100 23385-3470 23385-4100 23388-0030 23405-0100 23405-0101 23405-0221 23405-0470 23427-9211 Description RES SM0805 47K0F W1 RES SM0805 56K0F W1 RES SM0805 56K0F W1 RES SM0805 56K0F W1 RES SM0805 56K0F W1 RES SM0805 56K0F W1 RES SM0805 56K0F W1 RES SM0805 68K0F W1 RES SM0805 100KF W1 RES SM0805 150KF W1 RES SM0805 180KF W1 RES SM0805 270KF W1 RES SM0805 470KF W1 RES SM0805 560KF W1 RES SM0805 1M00F W1 RES SM0805 2M00F W1 RES SM0805 4M7F W1 RES SM0805 10M0F W1 RES 220RF W25 MF 50PPM RES 0R01D 4 TERM 30PPM PBV POT 10K LIN VO12L-PV25F-B10K POT 10K LOG VO12L-PV25F-15A10K RES PS/H 10K CERMET MIN RES PS/H 200R CF 6MM RES PS/H 470R CF 6MM RES PS/H 2K2 CF 6MM RES PS/H 4K7 CF 6MM RES PS/H 10K CF 6MM RES PS/H 47K CF 6MM RES PS/H 100K CF 6MM THERMISTOR PTC 100 OHM 265V CAP SM0805 10P CER COG CAP SM0805 100P CER COG CAP SM0805 220P CER COG CAP SM0805 47P CER COG CAP 470PK 100V CER MED K P2.5 Position R6, 50, 92, 96, 99, 106, 150, 196, 196, 199 R131 R136 R137 R211 R212 R31, 36, 37, 131, 137, 211, 212, 311, 312 R3, 103 R17, 117, 202, 302 R49, 149 R93, 193 R90, 190 R28, 29, 128, 129 R1, 24, 101, 124 R13, 113 R54, 154 R201, 301 R9, 26, 109, 126 R57, 58, 157, 158 R21, 121 VR1, 2, 101, 102 VR3, 103 VR12, 112 VR7, 107 VR4, 104 VR5, 9, 10, 105, 109, 110 VR17, 117 VR13, 113 VR14-16, 114, 116 VR8, 11, 108, 111 TH1, 2, 101, 102 C5, 45, 56, 66 C59, 159 C13,15,19, 24, 68,113,115,119,124,168 C132 C32

22

PCB ASSY CPX400A Control/Front Panel/Terminals Part No. 44115-2060 /continued...
Part Number 23427-9211 23461-0015 23461-0015 23461-0015 23461-0020 Description CAP 470PK 100V CER MED K P2.5 CAP SM0805 10NK 50V CER X7R CAP SM0805 10NK 50V CER X7R CAP SM0805 10NK 50V CER X7R CAP SM0805 100NZ 50V CER Y5V Position C114 C117 C139 C14,17, 32, 39,114,117,139,169 C2, 6, 7, 8, 9,10,11,12,16, 23, 27, 28, 33, 34, 35, 37, 43, 46, 53, 54, 60, 61, 62, 63, 70, 71,102,106,107,108,109,110,111,112, 116,123,127,128,133,134,135,137,143, 146,153,154,160,161,162,163,170,171 C44, 144 C1, 101 C52, 152 C20, 22, 120, 122 C21, 51, 121, 151 C4, 104 C3, 25, 26, 49, 50, 55, 57, 103, 125, 126, 149, 150, 155, 157 C18, 58, 64, 65, 118, 158, 164, 165 C36, 136 C30, 67, 130, 167 C31, 41, 42, 47, 53,131,141,142,147,153 D1-4, 7-9,12-16,101-104,109-109,112-116 LED1-4, 101, 104 DIS1, 2, 101, 102 D10, 110 Q1, 3, 5, 101, 103, 105 Q4, 6, 104, 106 IC11, 111 IC7, 8, 107, 108 IC4, 104 IC2, 102 D6, 106 IC1, 101 IC9, 109 IC6, 106 IC3, 103 XTL1, 2 PCB PJ5, 105 23

23461-0030 23461-0040 23557-0612 23557-0731 23559-2221 23559-3470 23559-5100 23559-6010 23620-0264 23620-0268 23620-0288 25021-0010 25061-0304 25061-0520 25117-0020 25340-1000 25601-1000 27106-1110 27106-1160 27106-1350 27153-1160 27161-2030 27164-1060 27239-1320 27239-5740 27250-2140 28500-0800 35555-4570 43171-2440

CAP SM0805 220NK 16V CER X7R CAP SM0805 1N0K 50V CER X7R CAP 1U0 100V/50V ELEC RE2 P2 CAP 100U 100V ELEC LOW ESR P5 CAP SM 220U 10V AL ELEC CAP SM 47UF 16V AL ELEC CAP SM 10UF 35V AL ELEC CAP SM 1U0F 50V AL ELEC CAP 100NK 400V P/E 368 SER P15 CAP 220NK 400V P/E 468 SER P15 CAP 100NK 100V P/E P5 DIO SM LL4148 SWITCHING MM LED SM0805 RED DISPLAY 4 DIG .56 LED 9MM LEG DIO 1N5401 TRAN SM PNP BC859C SOT23 TRAN SM MOSFET N CHAN BSS138 IC SM LM358M DUAL OP AMP SO8 IC SM LM324M OP AMP SO14 IC SM OPA277 PREC AMP SO8 IC SM ADS1241 8x24 ADC SSOP28 IC SM V/REF ZRC250 2.5V 2% TRAN SM ULN2803AFW NPN SOL18 IC SM 74HC132 SO14 IC SM 74HC574 SO20 IC SM PIC16F72-I/SS SSOP28 XTAL - 4.9152MHZ - MICROPROCSR PCB - CNTL/F.PNL/TERM - CPX400A CONN ASSY CNTL/FPNL 26W CPX400

Casing and Other Items
Part Number 20010-0255 20010-0256 20010-0257 20030-0263 20030-0266 20037-0244 20037-0301 Description RIVET SNAP-LOCK 4.1IDx7.5TH RIVET SNAP-LOCK 4.1IDx7.5TH T RIVET SNAP-LOCK 3.6IDx2.2-3.1T WASHER M3 ZPST WASHER M4 ZPST WASHER 2BA SHK/PROOF E/T ZPST WASHER M3 SHK/PROOF I/T ZPST Location FAN GUARD/FAN TO REAR PANEL POWER PCBS/CHASSIS R.PANEL/CHASSIS CONTROL PCB/F.PANEL EARTH TERMINAL PCB/F.PANEL TERMINALS CONTROL PCB, CHASSIS/PILLARS, F.PANEL/CHASSIS, TERMINAL PCB/F.PANEL, POWER PCBS/CHASSIS FRONT FEET EARTH EARTH, STUDS CASE UPPER, R.PANEL/CHASSIS BEZEL FIXING EARTH, STUDS CASE UPPER/CHASSIS, REARPANEL BACK FEET CONTROL PCB/F.PANEL CONTROL PCB, PCB SPACERS, POWER PCBS/CHASSIS, TERMINAL PCB FRONT FEET FRONT PANEL EARTH TO FAN DISPLAY PCB/F.PANEL CONTROL PCB POWER PCBS/CHASSIS FRONT FEET BACK FEET QTY 1 EARTH REAR PANEL (3 PASSES, 2 TURNS), QTY 2 NINE WAYCONNECTORS CONTROL/MAIN, POWER L/R 22219-0130 22571-1050 22571-1060 24 SWITCH ROCKER GOLD SPST UL SP TERMINAL TP/5LT RED/LGREY TERMINAL TP/5LT BLACK/LGREY FRONT PANEL SWITCH +VE OUTPUT TERMINAL -VE OUTPUT TERMINAL

20037-0304 20037-0401 20038-9502 20063-0010 20065-0070 20210-0102 20213-0040 20234-0016 20234-0024 20234-0027

WASHER M4 SHK/PROOF I/T ZPST SOLDER TAG SHAKEPROOF - M4 WASHER M4 SPRING SCREW No.6 x 3/8 NIB HDPZ ST/AB SCREW No.2 x 1/4 PLAST PNHDPZ NUT M4 ZPST CAPTIVE NUT SPIRE NO.6 SCREW M4 x 16 PNHDPZ ZPST SCREW M3 x 16 PNHDPZ ZPST SCREW M3 x 6 PNHDPZ ZPST

20234-0028 20234-0100 20236-0010 20500-0010 20661-0280 20661-0292 20661-0293 20662-0570 20662-9101 22040-0030

SCREW M4 x 10 PNHDPZ ZPST SCREW M3x6 PNHDPZ C/W EXT SH/P SCREW M4 x 12 TAMPERPROOF FAN GUARD 80MM SPACER HEX STUD M3 x 8 NPBR SPACER Clr No.4x7.9MM SELF/RET SPACER RND M4 Cl x 4 NUL FOOT SELF ADHESIVE GREY INSTRUMENT FOOT FERRITE SLEEVE APPROX 8/16/14L

Casing and Other Items /continued...
Part Number 22571-1070 22575-0077 22575-0202 Description TERMINAL TP/5LT LGREY/LGREY SKT 2 WAY IDT .1P SKT 2W .156 20AWG (YELLOW) IDT Position EARTH TERMINAL FAN, FRONT PANEL PJ5 ON MAIN (PINS 1 & 2 LINKED), PJ2 ON CNTL TO PJ7 ON MAIN, PJ102 ON CNTL TO PJ6 ON MAIN. LK1 ON MAIN CONTROL/POWER PCBS FOR FRONT PANEL LEDS

22575-0203 22575-0209 25061-0350 28522-0030 31346-0260 31711-0180 33143-0290 33143-0300 33331-7370 33331-8120-3 33331-8730 33537-0990 33537-1000 37113-2030 37113-2060 37151-0440 43187-1720

SKT 3W .156 20AWG (YELLOW) IDT SKT 9W .156 20AWG (YELLOW) IDT LIGHT PIPE LED STR 12.7MM FAN 80MM 24VDC 3000RPM INSULATOR FOR MAX505 x 180MM BEZEL - HALF RACK 3U NEW FR UL FOOT TILT - HOUSING FOOT TILT - SUPPORT FRONT PANEL - CPX REV REAR PANEL PRTD - CPX400A OVERLAY FRONT PANEL CPX400A CASE LOWER - CPX400 CASE UPPER - CPX400 KEYCAP 8 x 3MM LIGHT GREY F/R KEYCAP 8 x 6MM LIGHT GREY F/R KNOB 16MM D-SHAFT L/GREY F/R WIRE SET CUT - CPX400A

25

Component Layouts

26

Control/Front Panel/Terminal Pcb

Main Pcb

Power Board Left
27

Power Board - Right
28

Circuit Diagrams

29

Circuit Diagram - Main - CPX400A

Circuit Diagram - Power - CPX400/400A

Control/Front Panel/Terminal CPX400A - Channel A

Control/Front Panel/Terminal Pcb CPX400A - Channel B