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CV - 6SL

INSTRUCTION MANUAL

6000W

POWER SUPPLY

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TABLE OF CONTENTS

1.0 Specification 5

2.0 Installation 7

2.1 Rack Mounted 7

2.2 Cooling 7

2.3 Filament Module 8

2.4 Electrical Power Input 8

2.5 Grounds 8

2.6 Power Supply to Filament Module 9

2.7 Filament Transformer Connection 9 2.8 Power Supply Control Connectors 9

2.9 Remote I/O Control 10

2.10 Remote Interface 12

2.11 Remote Wiring 15

2.11.1 Gun Control 15

2.11.2 High Voltage Control 16

2.11.3 Customer EPO 17

3.0 Controls and Operation 17

3.1 High Voltage Controls 18

3.2 High Voltage Interlock Chain 18

3.3 High Voltage Ready 19

3.4 High Voltage On 19

3.5 High Voltage Power Supply Meter 19

3.6 Remote Operation "High Voltage" 22

3.7 Gun Controls 21

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TABLE OF CONTENTS CONTINUED

3.8 Gun Operation Using Control Panel 21

3.8.1 Gun Interlocks 21

3.8.2 Gun Ready 22

3.8.3 Gun On 22

3.8.4 Gun Supply Metering 22

3.8.5 Gun Control Indicators 23

3.8.6 Remote Operation "Gun Supply" 23

3.8.7 Gun "Position" Control 24

3.8.8 Bias Control 24

3.8.9 Emission Current Control 24

4.0 Theory Of Operation 25

4.1 Overall 25

4.2 Control "High Voltage" 28

4.3 Control "Gun" 30

4.4 Power Supply Chassis 31

4.5 High Voltage Regulator 33

4.6 High Voltage Power Card 36

4.7 Gun Supply 36

4.8 High Voltage Circuit 37

4.9 Filament Transformer Module 39

5.0 Trouble Shooting 39

5.1 Equipment 39

5.2 Turn On 40

5.3 Regulator Card Adjustments 41

5.4 Card Tests 41

6.0 Drawing List 42

7.0 Parts List 44

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1.0 SPECIFICATION

1.1 INPUT POWER

Model CV-6SL 208V Input Voltage : 280V±10% Frequency : 50/60Hz Phase : Three - 4 Wire Current : 32 Amps Model CV-6SL 400V Input Voltage : 400V±10% For operation from 0ºC to 40ºC. Input as low as 342 VAC may be

accommodated but unit must be operated at less than 35ºC due to reduced fan speed.

Frequency : 50/60Hz Phase : Three - 5 Wire Current : 20 Amps

1.2 Output "High Voltage"

Voltage : 0-10,000V DC (Negative Polarity) Current : 0-600 Milliamperes DC Regulation : 0.5% (+/- 50 Volts) Ripple : 0.5% RMS (140V P-P)

1.3 Output "Filament"

Voltage : 0-10V AC RMS Current : 0-75 Amperes Frequency : 34 kHz or Higher Regulation : +1.0% (0.75 Amps)

1.4 Power Supply Front Panel

Meter : Digital 3.5 Digits LCD : Accuracy + 2% : Select kV "10.00"kV : Select mA "600" mA

Switch : Select Filament “75.0”A : Meter Select kV - mA

Potentiometers : Bias (0-75A) (Screwdriver) 10 Turn

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Indicators : KV Overvoltage Fault : KV Overcurrent Fault : KV Out of Reg : ARC Counter Fault : Rail Fault : Step Start Fault : PWR OK : HV ON : Gun ON : PS Fault

1.5 Main Circuit Breaker

: Emergency Off (mechanical latch)

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1.6 Mechanical

Power Supply : Panel 8.75" High X 19" Wide : Chassis 21" Deep : Weight 42 Pounds

One Gun Filament Module D-2-855-2511 : Base 6 ½" X 11 ¼" : Height 4" : Weight 5 Pounds

1.7 Interconnect

Power Supply to Filament Transformer Module (3 Cables) : B-2-371-247 (W-103B) 12 Feet : B-2-371-248 (W-104A) 12 Feet : B-2-371-283 (W-105B) 12.5 Feet

Filament to Chamber : 3 Feet : D-2-371-224 (W-111)

2.0 INSTALLATION

2.1 Rack Mounted

The power supply can be rack mounted in a standard 19" rack cabinet. It must be supported by two side shelf supports to hold the power supply weight. Caution should be used as the supports should not block the power supply side air input and exit.

The rack vertical height required is 8 3/4 inches. The chassis depth is 21". An additional 3" is required for clearance of terminals, plugs and wiring. The panel should be secured to the rack cabinet by the six mounting holes provided.

2.2 Cooling The power supply is air cooled by an internal fan that pulls air into the power supply chassis from the rear and side panels. The power supply is approximately 85% efficient, thus, 1100 watts of heat must be removed from the cabinet. The customer must ensure a free flow of air is maintained through the cabinet and keep the ambient air temperature at the input to the power supply below 104°F (40°C) or even cooler (<35ºC) if 400VAC unit is operated at less than 360 VAC input.

The main air input to the power supply is on the right side. Auxiliary air inputs are on the rear panel. The fan is located on the left side. All air passages must be unobstructed. If air filters are used on the cabinet air input, they should be checked on a regular schedule for dirt and dust accumulation. The inverters have a temperature sensor that will shut down and latch out further operation if an over temperature condition should occur.

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2.3 Filament Module

The Filament Module is a stand-alone assembly and is located close to the filament and the vacuum chamber. The high current (up to 75 amperes) in the secondary of the transformer can produce excessive losses if the connections are not short and low in inductance. The box cover can be removed for mounting the assembly to a secure location close to the bushings feeding power to the filament. The cover is interlocked and must be reinstalled for operation to commence.

2.4 Electrical Power

The customers' input power plugs to a square flange receptacle TB-1 located on the lower left corner of the rear panel of the power supply. All the power required for the system inputs at this point. A mating plug is provided for the customers input power wires, four female pins and cable clamp are included as part of the assembly.

The CV-6SL can be ordered for the following input voltage sources.

MODEL #CV-6SL 208V #6024-6010 208V-50/60Hz-3 Phase-4 Wire Connect using AWG #10 stranded UL1015 wire MODEL #CV-6SL 400V #6024-6009-0 400V-50/60Hz-3 Phase-5 Wire Connect using AWG #12 stranded UL1015 wire

The 400V systems require an electrical neutral. The neutral supplies power to the single phase gun loads. The neutral current is typically 6 amperes. An external EMI filter such as Schaffner FN356-25-33 or FNL256-25-47 may be needed if conducted noise is a problem in the installation.

2.5 Grounds

Two ground studs are provided on the HVPS rear panel. Also the filament output box has a ground stud. In addition, the interconnect cable has a ground conductor that ensures all assemblies are grounded when interconnected. Connect a #10 AWG minimum protective earth ground wire to the ground studs provided.

Power Supply: Rear Panel

Filament Transformer Module: Interface Panel

Each assembly should be connected to its local ground.

Power Supply: A protective earth ground should be provided as part of the electrical power input. The user should make sure that each cabinet containing the power supply is grounded.

Filament Module: Ground to base of vacuum enclosure

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2.6 Power Supply Chassis To Filament Module

There are three cables interconnecting the power supply with the Filament Module. One cable is coaxial and carries the high voltage. The high voltage cable plugs into the power chassis. The outer shield is grounded to the power supply by a multi turn shell connector. The high voltage cable connection to the filament module is filtered with a special shielded plug. The plug pushes directly into the jack mounted in the filament module. A second cable connects the primary of the filament transformer to its power source. The primary power is alternating voltage high frequency, approximately 34kHz. The conductors are contained within an outer shield that is connected to ground at each end. The third cable carries the position power supply output along with control power for the relays and interlock circuits.

POWER SUPPLY CHASSIS

HIGH VOLTAGE FILAMENT PRIMARY CONTROLS/POSITION J-104 J-106 J-108

W105 W103 W104

J-302 J-303 J-301

FILAMENT MODULE

2.7 Filament Transformer Connection

The filament module output connection is made by a dual conductor high voltage cable contained in a flexible shielded conduit. The dual conductor consists of 15kV insulated wire twisted together and run through the flexible conduit.

CAUTION

It is the customers responsibility to protect the cables extending beyond the end of the flexible conduit. The cables operate at high voltage and must be interlocked to the power supply system.

2.8 Power Supply Control Connectors

There are two methods of connecting to the Power supply for control and monitoring signals. Three connectors on the rear panel of the Power Supply are provided for controlling the power supply. There is no switching implemented for selecting between the two control schemes, so that only one type of control mode can be connected at any given time. 1) Remote I/O control:

The Rear Panel J112 Connector can be used to fully control and monitor both the HV and the GUN power supplies.

2) Local Control Compatibility with the controls and monitoring of the original CV-6S is provided via J101 (HV control) and J103 (Gun Control) connectors. The local controls are separated into a high voltage control section and a gun control section.

All cables described in the next two sections are available as separate items from the CV-6SL

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2.9 Remote I/O control

DB-25 Name

Ribbon Pin (Ref)

1 GUN ON +

Input +24 VDC (from Interlock chain). Connect To Momentary (Normally Open Switch) 1

2 GUN ON -

Output from Momentary contact to +24VDC (Normally Open Switch). Momentary Close to turn Gun On 3

3 GUN OFF + Input +24 VDC (from Interlock chain). To Normally Closed Switch. 5

4 GUN OFF -

Output from Momentary contact to +24 VDC (Normally Closed Switch). Momentary Open to turn Gun Off 7

5 EMISSION SET + 0 to 10 V Control. 100kohm input resistance. 9

6 EMISSION MON + 0 to 6 V Output = 0 to 600 mA. 100 ohm source resistance. 11

7 FILAMENT I MON + 0 to 7.5V Output = 0 to 75 A. Source resistance approx. 1k ohm 13

8 GUN ON CONFIRM + From opto output, +24 VDC when True, 25mA maximum 15

9 GUN SIG CNFRM PWR Connect to +24 VDC Source such as DB pin 12 17

10 GUN OFF CONFIRM + From opto output, +24 VDC when True, 25mA maximum 19

11 H2O INTERLOCK Opto input, Apply +24 VDC to satisfy Interlock 21 12 INTERLOCKS PWR +24 VDC Source from Power Supply 23

13 VAC INTERLOCK From Vacuum Interlock, apply +24 VDC to satisfy Interlock 25

14 VAC INTERLOCK PWR Connected to DB pin 11 inside Power Supply. Use as source +24 VDC Vacuum interlock 2

15 SHIELD COMMON GND 4 16 MONITOR COMMON GND 6 17 HV OFF+ +24 VDC Source from Power Supply 8

18 HV OFF -

Input +24 VDC (from DB pin 12). To Normally Closed Switch. Momentary Open to turn HV Off. Also should be connected to DB pin 19 10

19 HV ON +

Opto Input +24 VDC. Should be connected to DB pin 18. Also should be connected to Momentary (Normally Open Switch) 12

20 HV ON -

Output from Momentary contact to +24 VDC (Normally Closed Switch). Momentary Open to turn HV Off 14

21 KV SET + 0 to 10V Control. 220 kohm input resistance. 16

22 KV MON + 0 to 10V Output = 0 to 10,000 V. 100 ohm source resistance. 18

23 HV ON CONFIRM From opto output, +24VDC when True, 25mA maximum 20

24 HV SIG CNFRM PWR Connect to +24 VDC such as DB pin 12 22

25 HV READY CONFIRM + From opto output, +24 VDC when True, 25mA maximum 24

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Sample Remote I/O Connections

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2.10 Remote Interface: The remote interface designed and supplied with the CV-6S may be connected to the CV-6SL using the J-101 and J-102 cables: HV CONTROL GUN CONTROL

J1 J1

25 COND. W101 15 COND. W102 RIBBON RIBBON

J-101 J-103 POWER SUPPLY CHASSIS

Remote Interface Connections: If you are not going to implement any remote control or monitoring functions, the only system I/O lines that must be connected are:

(1) those supplying interlock signals to the gun control unit (Section 2.11)

(2) the green-black wire pair in the gun control system I/O cable which must be jumpered together to

complete the normally-closed GUN GO OFF*ENABLE loop

(3) the green-black wire pair in the HV control system I/O cable which must be jumpered together to complete the normally-closed HV GO OFF*/ENABLE loop

NOTE

The gun filament current cannot be switched on if the GUN GO OFF*/ENABLE loop is not complete and the high voltage cannot be switched on if the HV OFF*/ENABLE loop is not complete. Either function can be switched on with the other off, but emission current cannot be obtained unless both OFF*/ENABLE loops are closed.

Guidelines For Connecting The External Interlocks

Each of the interlock signals listed in Section 2.11 supplied to each remote gun control unit. If all guns are in one vacuum chamber, the TANK and VACUUM GAUGE interlocks must be connected in parallel.

NOTE

All statements regarding operator and equipment safety are void if the external interlocks are not correctly installed.

CAUTION

The interlocks are internally supplied with 24V DC. Only contact closure need be supplied. The application of voltages to the interlock circuits will cause them serious damage.

Other I/O's: Control and Status Signals

The remote control inputs and status outputs include both digital and analog signals. Digital inputs require a simple contact closure and carry 24V DC at approximately 20mA. All digital outputs are from contact closures rated for 2A @ 220V AC or 2A @ 30V DC.

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Connecting the Gun Control-System I/O Cables(s) (PN B-2-371-184: 10 Ft.) (PN B-2-371-225: 20 Ft.)

Follow the procedure described below in connecting the gun control system I/O cable(s). Refer also to page 11A shows the pinout for the signals that can be interfaced to the gun control unit via its system I/O connector (G1-J13). Section 2.11 provides more detailed information about these signals. STEP ACTION

1. Refer to Section 2.11 and determine which wires will be needed to interface the power

supply to the evaporation system. Tie the unused wires back to the cable insulation and cover the ends with electrical tape. make sure that the exposed ends of the unused conductors do not touch each other or ground.

2. Strip 1/4 inch of insulation away from the end of each of the remaining wires.

3. Attach one of the spade lugs provided with the cables to the end of each wire.

Hollingsworth crimping tool H-7B is recommended for this operation. 4. Carefully note the function of each color-coded wired (See Section 2.11) and connect each

spade lug to the appropriate terminal on the system terminal strip.

5. Plug the other end of the cable into rear panel connector, G1-J2, on the gun control unit.

Repeat this procedure for each additional gun, making sure that signals are routed correctly to either gun control.

Connecting the HV Control System I/O Cable (PN B-2-371-226) 20 ft.

Follow the procedure described below in connecting the HV control system I/O cable(s). Refer also to page 11A which shows the pinout for the signals that can be interfaced to the HV control unit via its system I/O connector, HV-J11. Section 2.11 provides more detailed information about these signals.

STEP ACTION

1. Refer to Section 2.11 and determine which wires will be needed to interface the power

supply to the evaporation system. Tie the unused wires back to the cable insulation and cover the ends with electrical tape. Make sure that the exposed ends of the unused conductors do not touch each other.

2. Strip 1/4 inch of insulation away from the end of each of the wires that will be used.

3. Attach one of the spade lugs provided with the cables to the end of each wire.

Hollingsworth crimping tool H-7B recommended for this operation.

4. Carefully note the function of each color-coded wire (See Section 2.11) and connect each spade lug to the appropriate terminal on the system terminal strip.

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2.11 Remote Wiring

2.11.1 Gun Control

Digital Interlock Inputs (Required) INTERLOCK PIN WIRE FUNCTION TANK 13, 14 O, BK Prevents the gun from being switched on unless

all vacuum system doors and covers are closed and locked so that personnel cannot come into contact with high voltage within the vacuum cubicle.

VACuum 15, 16 W, R Protects the gun filament GAUGE by ensuring that the product chamber ion gauge is on before the gun is switched on

AUXiliary 18, 19 G, R Customer defined. Used with multi pocket sources to ensure that the beam is OFF while the turret is rotating. Must be jumpered ON if not used; can also be jumpered on at JP1 on the display panel PCB.

GUN WATER 20, 21 BL, R Prevents the gun from being switched on unless it is receiving sufficient cooling water. Signal to be supplied by a customer- installed flow switch.

POSITION 22, 23 Y, R Prevents the gun from being switched on unless the beam is correctly positioned in the pocket. Signal can be supplied via these lines by an external beam sweep controller. If no external sweep controller is used, the position PCB in the gun interface chassis supplies this signal internally.

Analog Control Inputs SIGNAL G1-J13 WIRE

PAIR FUNCTION

REMOTE EMISSION CURRENT REQUEST

56, 57 O(+), R(-) If the gun control unit's REMote/RANGE switch is in the REMOTE position, this input linearly controls emission current within the selected range: 0 V = min. current for the selected range; + 10V = max. current for that range

Digital Control Inputs SIGNAL G1-J13 WIRE

PAIR FUNCTION

REMOTE GUN GO OFF*/ENABLE

5, 6 G, BK A momentary open pulse switched off the gun. If all gun control interlocks are made, the gun can be switched on again.

NOTE If these pins are not connected to a remote contact closure, they must be jumpered together or the gun cannot be switched on.

REMOTE GUN GO ON

7, 8 BL, BK If all gun control interlocks are made and the GUN GO OFF*/ENABLE loop is closed, a 2-sec. contact closure across these pins switches on the gun.

FILAMENT CURRENT MONITOR

24, 25 Y, BK A 0 to 7.5 volt signal proportional to 0-75 amperes is available for driving a remote meter. The impedance should be 1 megohm or higher.

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FILAMENT BIAS SET

26, 27 BN, BK This feature is not connected in the CV-6SL. The only Bias control is on the front panel of the CV-6SL

Digital Outputs SIGNAL J2 PIN # WIRE

PAIR FUNCTION

GUN READY 1, 2 R, BK Indicates that all gun control interlocks are made and that the GUN GO OFF*/ENABLE loop is closed so the gun can be switched on.

GUN IS ON 3, 4 W, BK Indicates that the gun is switched on. Analog Outputs SIGNAL J2 PIN # WIRE

PAIR FUNCTION

ACTUAL EMISSION CURRENT

50, 51 BR(+),R(-) Linearly represents the emission current drawn by the gun controlled by this gun control unit: 0 V = 0 A; 10V =1A.

2.11.2 High Voltage Control

Digital Control Inputs SIGNAL HV-J11 WIRE

PAIR FUNCTION

HV GO OFF*/ ENABLE

3, 7 G, BK A momentary open pulse switches off the high voltage. If all HV control interlocks are made, contact closure of this line enables the HV to be switched on.

NOTE If these pins are not connected to a remote contact closure, they must be jumpered together or the HV cannot be switched on.

HV GO ON 4, 9 BL, BK If all HV control interlocks are made and the HV GO OFF*/ENABLE loop is closed, a momentary contact closure switches on the high voltage.

Analog Control Inputs SIGNAL HV-J11 WIRE

PAIR FUNCTION

REMOTE HIGH- 18, 19 W(+),R(-) If the HV control unit's VOLTAGE REQUEST REMote/RANGE switch is in the REMOTE position, this input linearly controls the high voltage within the selected range.

NOTE This input must be O V DC to +10V DC. The HV circuit cannot be controlled by a -10V DC input. The local high voltage set, located on the high voltage control panel, can be activated during remote operation. Jumper the yellow wire connected to pin 20 to the white wire connected to pin 18.

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Digital Outputs SIGNAL HV-J11 WIRE

PAIR FUNCTION

HV READY 1, 5 R, BK Indicates that all HV control interlocks are made and that the HV GO OFF*/ENABLE loop is closed; the HV is ready to be switched on.

HV IS ON 2, 6 W, BK Indicates that the high voltage is on. Analog Outputs SIGNAL HV-J11 WIRE

PAIR FUNCTION

ACTUAL HIGH 15, 16 BR(+),BK(-)

Linearly represents the VOLTAGE load (gun) voltage: 0V = 0 kV, 10V = 10kV

TOTAL POWER SUPPLY CURRENT

22, 23 O(+),BK(-) Linearly represents the total power supply current (i.e., the total emission current drawn by all guns powered by the power supply): 0 V = 0 A; 10V = 1A

2.11.3 Customer EPO (Emergency Panic Off) An Amphenol plug is required for the customer connector, AN3106-14-2P, jumper pins C & D for operation.

3.0 CONTROLS AND OPERATION

3.1 Front Panel Indicators and Controls The Front Panel provides ten LED indicators, a Digital Panel Meter with three switch select settings, a Bias Potentiometer, an Emergency Off Switch and the main circuit breaker. 3.1.1 LED Indicators:

PWR ON: AC Power is supplied and LV DC power supplies are on. HV ON: Will Glow Yellow when the HV Power supply is ready but OFF Will Glow Green when HV is ON GUN ON: Will Glow Yellow when the GUN Supply is ready but OFF Will Glow Green when Filament Supply (Gun) is ON PS Fault: Any of the Fault conditions detailed below is true. HV will be OFF KV Overvoltage Fault: Output HV exceeded 10.6kV KV Overcurrent Fault: Output emission current exceeded 630mA KV Out of Reg: Unit is not Voltage regulating within specification. Arc Counter Fault: A series of arcs in excess of the arc counter setting have occurred Rail Fault: Excessive current was drawn by the inverter power switches Step Start Fault: The Inverter DC rail could not be charged during HV turn On

3.1.2 Digital Panel Meter: 3 ½ Digit LCD Panel Meter with 3 position selection switch EM I: Emission Current, 0 to 600 mA FIL I: Filament (Gun) Current, 0 to 75.0 A kV: HV output, 0 to 10.00 kV

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3.1.3 Bias Potentiometer: 10 Turn Pot accessed through Recessed opening. The potentiometer is set at a current below the normal operating current. The bias functions as a preheat or idle for the filament. This is the only control that will affect the bias setting on the CV-6SL.

3.1.4 Emergency Off Switch: When pushed, opens the interlock and immediately turns off the HV and Gun. When Emergency Off is activated, neither HV nor Gun can be turned on. Rotate CW to clear the Emergency Off condition.

3.1.5 Main Power On: Turn AC power on and off. Is also a 20A circuit breaker that will open in the event of excessive AC line current.

3.2 High Voltage Controls

The high voltage power supply is protected by a main circuit breaker and controlled by a contactor at its input. When the circuit breaker is OFF, all power to the system is OFF. When the circuit breaker is closed and the contactor is open, only the high voltage power supply is OFF.

The high voltage power supply is a closed loop voltage regulated supply. There is an internal potentiometer adjust on the regulator circuit card that limits the maximum current available from the supply. When the limit, usually factory set at 660mA, is reached, the regulator automatically transfers from the voltage regulation to current regulation and continues operation in the current regulation mode. This will cause the KV Out of Reg LED to light.

3.3 High Voltage Interlock Chain

There is a series chain of interlocks that must be closed for high voltage operation. If any one of the interlocks in the chain is open, the high voltage ON contactor cannot be closed and, if an interlock opens during operation, the contactor opens, turning OFF high voltage. The door interlock LED will be illuminated with a fault or an opening in the interlock chain. The contacts in the interlock chain are:

• Temperature switch PS-S1 on the inverter heat sink • Emergency OFF switch PS-S3 power supply front panel • Access switch S-301 in the filament module • EPO J110 Pins C and D • The Rear Panel Remote I/O connector Interlocks are:

• VAC Interlock • H2O Interlock • HV OFF normally closed pushbutton

• The Control Panel Interlocks are: • High voltage OFF push-button HV S1 (If Control Panel is used) • Key switch HV-S5 on the high voltage control panel (If Control Panel is used) • Remote high voltage OFF HV-J2, wires green and black on the remote interface. • The "DOORS" indicator on the control panel (if used) will extinguish when all the interlocks

are closed and the interlock chain is satisfied.

NOTE: The interlocks will be satisfied if either of the control schemes (Rear Panel Remote I/O, J112 or the Control Panel) properly satisfy their interlock requirements. When using the Control Panel it is not necessary to work the interlocks on the Rear Panel Remote I/O connector.

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3.3 High Voltage "Ready"

The high voltage power supply is in a "ready" to turn on condition when the interlock chain is closed and the internal faults are reset. The internal faults circuits located on the High Voltage regulator circuit board 9120028-010 are summed and if the Control Panel is used, displayed on the high voltage control as HV-I7. “Fault”

The Front Panel LED “HV ON” will glow yellow when the high voltage power supply is “ready”.

3.4 High Voltage ON

When the high voltage ON push-button is depressed, the regulator circuit card commands the high voltage ON as a two step function. First, the auxiliary contactor K1 pulls in and the DC rail capacitor is charged slowly through a series impedance. When the charge is complete, the main three phase contactor K2 is commanded to close. After the two step function is completed, the inverter is enabled and high voltage ramps ON. The high voltage will ramp up to the voltage commanded. The turn ON has a ramp of approximately 20 milliseconds. The Front Panel LED “HV ON” will turn Green when the high voltage power supply turns HV ON.

3.5 Control Panel Display and Indicators (if used)

3.5.1 High Voltage Power Supply Meters The LCD meter provides two readouts for the power supply: output DC voltage and total output DC current. Switch HV S4 selects voltage as "10.00" kV and current as "600" mA. At initial turn on, the output voltage can be monitored. However, the output current will be zero until the gun has been turned ON and the filament circuit becomes active.

3.5.2 Out Of Regulation Indicator The "out of regulation" indicator is illuminated anytime high voltage has been turned ON and the output voltage is out of the + 0.5% voltage regulation window. The operator will note the indicator flashes ON at turn-on and is extinguished as the output voltage arrives at the commanded level.

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3.6 Remote Operation "High Voltage" when using the Control Panel Remote Inputs

The remote interface has the following functions available:

High Voltage OFF Contact Opening HV-J2 G-BK High Voltage ON Contact Closure HV-J2 BL-BK

High Voltage Reference Command 0-10V = 0-10kV Output High Voltage Monitor 0-10V = 0-10kV Output Current Monitor 0-6V = 0-600 Milliamperes

H.V. Ready Response Contact Closure HV-J2 R-BK H.V. ON Response Contact Closure HV-J2 W-BK

The remote off, kV monitor, mA monitor, H.V. ready and H.V. ON are always active.

The reference command and H.V. ON are switched functions and transfer between local control and remote control. A screwdriver is required to make the through-the-panel selection (HV-S3). A control panel indicator is illuminated to indicate remote operation (HV-I1).

3.7 Gun Controls

There are two circuit breakers on the rear panel that protect the gun and controls circuits. These breakers must be ON for system operation.

The optional position supply becomes active when the main circuit breaker PSCB1 is turned ON. It will also be seen the 24V control logic circuits are energized with the initial circuit breaker turn ON. The Gun ON and OFF circuits control the following:

Filament Power High Voltage Vacuum Relays - located in the filament module. The relay connects high voltage to the output circuit.

3.8 GUN Operation when using Control Panel

3.8.1 Gun Interlocks

There is an interlock chain or series of contacts that must be satisfied with contact closures before achieving a ready for GUN turn on condition. The contact closures are provided through the remote interface from the users hardware (see Section 2.11). They are connected to G1-J2 on the Gun Control rear panel.

G1-J2 Tank Orange - Black G1-J2 Vacuum White - Red G1-J2 Auxiliary Green - Red G1-J2 Water H2O Blue - Red G1-J2 Position Yellow - Red

Note: If the internal position control is used, no external contacts are required. Terminal position G1-J2, green - black, Gun OFF must be jumpered for operation in the local or remote mode. If the user does not plan to operate with a remote off switch, he must place a jumper between the two terminals.

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3.8.2 Gun "Ready"

When all the interlocks are satisfied, "Closed", the circuit is ready for the gun to be turned ON. The indicator in the gun off switch, G1-I2, will be illuminated. The circuits that must be satisfied for gun operation are: Remote Off G1-J2 Green-Black Gun Control Off G1-S1 Control Panel Tank Interlock G1-J2 Orange-Black Vacuum Interlock G1-J2 Green-Red Auxiliary Interlock G1-J2 Blue-Red Water Interlock G1-J2 Yellow-Red Position Supply Adjustment G1-J2 Brown-Red

3.8.3 Gun "ON"

The "Gun ON" command turns on the filament power supply. The filament supply is controlled by a closed loop regulated circuit. At turn ON, the filament ramps up and regulates to the current level commanded by the bias potentiometer, a screwdriver adjustment on the control panel. If high voltage is ON, the high voltage regulator sends a signal to the filament regulator to transfer the reference command from the bias adjustment potentiometer to the emission current potentiometer, also located on the control panel, with a calibrated 10 turn dial. If high voltage is off, the filament current command adjustment stays with the bias adjustment pot until such time the high voltage is turned ON. The output vacuum relay, located in the "filament transformer module", switches the high voltage output onto one leg of the high current filament transformer, secondary. In a single gun system, the relay does not transfer until both the high voltage and gun circuits are turned ON.

3.8.4 Gun Power Supply Metering

The 3 1/2 digit LCD meter has a selector switch. G1-S4 that provides the operator with three circuit-monitoring positions. Emission current: The current is monitored in the high voltage leg of the gun circuit. The maximum emission current is read as "600"mA. Filament Current: The primary current of the filament transformer is monitored, rectified and provided as an external readout (7.5V = 75 amperes) and the meter will read "75.0" amperes. A remote filament current monitor is provided as 7.5V = 75 Amps. Position Current: The output current of the position power supply is monitored and will read "3.00" amperes. There is no external readout for position current.

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3.8.5 Gun Control Indicators The LED indicators are powered in a series chain. If the first interlock in the chain is broken, all indicators that follow are not satisfied. The sequence is:

1. Tank G1-I7 2. Vacuum G1-I6 3. Auxiliary G1-I5 4. Water G1-I4 5. Position G1-I3

When each of the above five interlocks are closed, their respective LED's are illuminated. The ready indicator in the GUN Off push-button will be illuminated when the position indicator illuminates.

6. Ready G1-I2

The operator must clear the first unsatisfied interlock to know the status of the second and so on.

The "Gun On" indicator is located in the Gun ON push-button. The ready indicator and the ready function disappears when the gun is turned "ON".

3.8.6 Remote Operation "Gun Supply"

The remote interface has the following functions available: Gun ON Contact Closure G1-J2 Blue-Black Gun OFF Contact Opening G1-J2 Green-Black Emission Current Command 0-10V = 0-600mA G1-J2 Orange-Red Position Supply Interlock Contact Closure G1-J2 Yellow-Red Water Interlock Contact Closure G1-J2 Blue-Red Auxiliary Interlock Contact Closure G1-J2 Green-Red Vacuum Interlock Contact Closure G1-J2 White-Red Tank Interlock Contact Closure G1-J2 Orange-Black Gun ON Response Contact Closure G1-J2 White-Black Gun Ready Response Contact Closure G1-J2 Red-Black Emission Current Monitor 0-6V = 0-600mA G1-J2 Brown-Red Filament Current Monitor 0-7.5V = 75 Amps G1-J2 Yellow-Black Filament Bias Command 0-10V = 75 Amps G1-J2 Brown-Black Active Bias Set in Remote G1-J2 Green-White If the remote control circuit is not used, the Gun Off input G1-J13, Green-Black wires must be jumpered for operation at the local panel. There are three functions transferred between local and remote operation by the local-remote switch.

Gun Turn On G1-J2 Blue-Black Emission Current Command G1-J2 Orange-Red Bias Current Command G1-J2 Brown-Black

All other readouts, monitor signals and interlocks are active in both modes.

When the remote local switch is in remote, a front panel LED is illuminated - G1-I8.

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3.8.7 Gun "Position" Control G1-R1 "Optional"

The gun position supply is active when the main circuit breaker is closed on the power supply. The 10-turn potentiometer on the control panel supplies the reference for a 0-3 ampere power supply. The position current is monitored by the panel LCD meter when selector switch G1-S4 is in the "POS I" position. The position of the beam must be within a preset window before operation starts. The limits of the beam are set on the gun supply circuit card in the power supply chassis. There is a low limit setting, R63,and a high limit current setting, R-64. These are factory set and do not require additional adjustment in the field. If a filament supply is purchased without a position supply and a position supply is required at a later date, a new filament supply with position supply will have to be ordered. #6024 - 6105-0 Filament Supply With Position Supply #6024 - 6106-0 Filament Supply Without Position Supply

3.8.8 Bias Control G1-R3

The Bias Control does not work with the CV-6SL. The Bias Pot on the Front Panel of the CV-6SL is the only active Bias control

3.8.9 "Emission Current" Control G1-R2

The emission current control located on the control panel provides a reference for emission current operation. A 10-turn calibrated dial provides the operator with an indication of the set level prior to turn ON; maximum 1000 = 600mA. When the gun is turned On, the "On" function activates the filament supply. The circuit at turn On uses the bias set, (a screwdriver adjustment, as a reference setting). When high voltage is turned ON, the circuit automatically transfers the reference input from the bias pot to the Emission Current pot. This function allows the filament to preheat at an idle level below the operating level. The emission current potentiometer can be preset prior to turn ON. The power supply will automatically go to the bias level, then automatically ramps to the emission current level with high voltage turn ON. The current can be monitored by selecting "Emission Current" on the meter select switch.

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4.0 THEORY OF OPERATION 4.1 Overall

The power supply provides three power sources to the CV-6S System.

High Voltage Power - 10kV DC - 600mA Filament Power - 10V AC - 75 Amperes Position Power 15V DC - 3 Amperes

(Optional) Each power supply operates independently with the addition of emission current control by the filament supply. The system operates as a voltage regulated high voltage power supply; a current regulated filament supply; a current regulated position supply.

The sequence of turn ON can vary. The position supply turns ON with the main circuit breaker. The filament supply turns ON with GUN ON. The filament supply turns ON and ramps to a level determined by the "Bias Adjust Pot". The high voltage can be turned on anytime. If high voltage turn ON follows Gun ON, the high voltage ramps to the level preset determined by the screwdriver H.V. Adjust Potentiometer. When the high voltage arrives at the preset voltage, the filament supply reference automatically transfers from the bias reference pot setting to the Emission Current Pot setting. At this operating condition, the temperature of the filament determines the load current out of the high voltage power supply. The filament supply uses high voltage current as feedback, thus, emission current (HV mA) is regulated by the filament supply.

High Voltage Power

The high voltage power supply utilizes high frequency switching technology to develop the high voltage 6000 watts of power. The AC input power is rectified directly off the input line using the common three phase bridge rectifier circuit. The resulting DC power establishes a+ (positive) rail voltage and - (negative) rail voltage. The DC rail power is converted to high frequency AC at 22k Hz by IGBT solid-state switches. The high frequency power is stepped up in voltage by a transformer and rectified to provide a DC voltage of 10,000 volts. The power supply is rated to deliver 600 mA of current at any voltage from near zero to 10,000 volts. The high voltage power supply functions as a voltage regulated circuit.

Filament Power

The filament circuit, similar to the high voltage circuit, utilizes high frequency technology. The filament circuit requires single phase power of approximately 208 to 230 volts.

A single phase bridge rectifier circuit provides the raw DC power for the high frequency switches. The DC voltage is filtered and a + (positive) rail voltage and a - (negative) rail voltage is established. The filament supply uses FET switches and operates at a higher frequency, 40k Hz. The filament transformer steps down the voltage with a ratio of 8 : 1 to provide the 10 volts at the filament. There are no rectifiers on the output of the transformer as the filament input is high frequency AC. The filament circuit is current regulated. There are two modes of filament operation: One with high voltage OFF and one with HV ON.

A. H.V. OFF

Filament Reference: BIAS POT Filament Feedback: Filament Primary Current

B. H.V. ON

Filament Reference: Emission Current POT Filament Feedback: High Voltage Current

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The switching between the operational modes is performed automatically on the Gun Supply Circuit Card. The high voltage power supply initiates the switching when the high voltage is turned on and operating in its regulation window.

Position Power (Optional)

The position supply uses the rail voltage provided on the input to the Gun Supply Card. The position supply is low power, 15 volts at 45 watts. The supply uses a solid-state inverter circuit switching at 100k Hz frequency. The supply is current regulated with feedback from a low end shunt. The position supply has a positive DC output. The negative low end is grounded.

The filament supply PCB must be ordered with a position supply.

#6024 - 6105-0 "Optional" Filament Supply PCB CV-XS (with position supply)

#6024 - 6106-0 "Standard" Filament Supply PCB CV-XS (without position supply)

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4.2 Control "High Voltage" (Optional)

1. HV-S4 Meter Select Switch: The switch selects between power supply output voltage and power supply total current. The voltage readout maximum is 10.0kV and the current maximum is 600mA.

2. HV-S3 Remote-Local Switch: The switch transfers the following functions to the remote

interface:

High Voltage ON H.V. Reference (0-10V) = 0-600mA

High voltage OFF is always active on the remote interface and must be jumpered if not used.

3. HV-R1 High Voltage Adjust: The screwdriver adjustment provides a reference for the high

voltage. The POT is usually set at one level and does not require additional adjustment. The power supply will turn ON and ramp up to the preset voltage. The pot is a 3-turn adjustment.

4. HV-S5 Key Switch: The key switch is in the high voltage interlock chain and functions as a

lockout for high voltage operation. The switch must be ON for high voltage operation. The key can be removed in the OFF position.

5. HV-S2 High Voltage ON: When the interlock chain is complete with the high voltage ready

indicator illuminated, high voltage can be turned ON.

HV-I6 High Voltage ON: The indicator will be illuminated when high voltage turns ON.

6. HV-S1 High Voltage OFF: The switch is one of several switches that turn high voltage off.

HV-I5 Ready For High Voltage: The indicator is the last indicator in a series that must be satisfied for High Voltage Ready. The light is extinguished with High Voltage ON.

7. HV-I4 Out of Regulation: The high voltage power supply functions as a voltage regulator.

The light is illuminated when the power supply is out of the voltage regulation window.

HV-I2 Power: The indicator is illuminated with the main power applied to the power supply and the main circuit breaker is closed.

HV-I3 Doors: The doors indicator is illuminated when several external and internal interlocks are closed:

Filament Transformer Module cover in place Power supply cover in place Temperature switch closed in a satisfactory range

HV-I1 Remote: The Remote-Local switch selecting remote operation.

8. HV-M1 Meter: The 3.5 digit LCD meter has two readouts selected by switch HV S4.

Power Supply Current: "600" mA Power Supply Voltage: "10.0" kV

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4.3 Control "Gun" (Optional)

1. G1-S4 Selector Switch: Provides a readout of the three gun related circuits. The emission current 0-600mA is high voltage current and requires that both the gun and high voltage power supplies be ON. The filament current 0-75.0 amperes provides a readout with Gun ON. The optional position current 0-3.00 amperes is active with the main circuit breaker and filament breaker closed.

2. G1-R1 Position Control: The calibrated 10-turn potentiometer provides a reference to the position power supply located on the gun circuit board. The position supply controls the location of the beam. The position indicator illuminates when the beam is positioned within a window determined by the low/high position potentiometers located on the gun circuit board. The position indicator must be illuminated for operation to start.

NOTE: The position controls are standard on all GUN control panels. The position supply located on the "Filament Supply PCB" must be ordered as an option.

3. G1-R3 Bias: The bias control adjusts the filament current prior to high voltage turn on. When high voltage is turned ON, the filament reference transfers to emission current regulation and the emission current 10-turn control. The correct bias level is adjusted for long filament life and smooth transfer between filament current feedback and emission current feedback.

4. G1-R2 Emission Current Adjustment: The emission Current potentiometer is used as a

reference for high voltage current during system operation. The impedance of the load is determined by the temperature of the filament with high voltage ON.

5. G1-S2 Gun On: The gun can be turned ON at anytime, but the sequence of Gun ON then

high voltage ON is the most appropriate. There is a series of interlocks that must be satisfied before the gun can be turned on. All interlocks must close for a ready to turn Gun ON condition. The following is a list of the interlocks:

When a remote position supply is used, its contacts, indicating the beam position is correct, should close - G1-J2 Yellow-Red.

• Remote Gun OFF Switch G1-J2 Green-Black Wires

Must be jumpered for operation

• Gun Off Switch G1-S1 Gun Control Panel

• Tank Interlock G1-J2 Orange-Black

• Vacuum Interlock G1-J2 White-Red

• Auxiliary Interlock G1-J2 Green-Red

• Water Interlock G1-J2 Blue-Red

• When the position Power Supply is within a window and with all the interlocks closed, we have a Gun Ready for turn ON. G1-I2 in the off switch is illuminated. G1-I1 Gun On: The Gun On indicator will be illuminated when the gun has been turned on.

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6. G1-S1 Gun Off: The gun off switch opens to break the latch on the gun ON holding circuit. The switch's function is the same as an interlock opening.

G1-I2 Gun Ready: The gun is ready for turn on after closing a chain of interlocks. See Paragraph 5 for Gun On and the list of interlocks.

7. G1-I7 Tank: The tank interlock is a customer input and must have a contact that closes

across the external interlock G1-J2, Orange-Black. If the tank interlock is open, all other interlocks will not provide an indication, as the tank is the first of the series.

G1-I6 Vacuum: The vacuum interlock must present a closure across G1-J2, White-Red. If the interlock is open, all the interlocks that follow will not indicate.

G1-I5 Auxiliary: The auxiliary interlock is a customer supplied contact closure across G1-J2, Green-Red. If the contact is open, all the interlocks that follow will not indicate.

G1-I4 Water: The water interlock must present a contact closure across G1-J2, Blue-Red. If the contact is open, all the interlocks that follow will not indicate.

G1-I3 Position: The position interlock closes when the position of the beam is within the limits preset on the gun regulator card. If all the above interlocks are illuminated, the ready light in the Gun OFF switch will be illuminated. The gun is ready for turn ON.

G1-I8 Remote: The remote indicator provides the operator an indication that the remote-local switch is in the remote position.

8. G1-S3 Remote-Local Switch: The remote-local switch transfers the Gun ON function, the

emission current set reference, and bias current set from the panel control to the remote interface. all other panel functions remain active.

4.4 Power Supply Chassis

The power supply chassis contains all the power supplies in the system. The input AC power connects to an AMP CPC connector located on the rear panel. A main circuit breaker PS-CB1 located on the front panel functions as the main disconnect for the system. If the main breaker is off, all power for the system is off.

Note: Maintenance personnel should take caution as the protection circuit located behind the input terminal strip is activated anytime power is connected to the terminal strip. Main power should be disconnected anytime the power supply chassis is accessed.

The three-phase AC power at the load side of the main breaker connects to three items:

The Power Circuit C-6-1895-49B The Gun Circuit Breaker CB-2 The Control Circuit Breaker CB-3

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CB-2: The circuit breaker protects the gun power supply.

CB-3: The circuit breaker protects the primary of the control step-down transformer T-2. This circuit provides power for all +24V DC and -24V DC in the system. All control power originates through this breaker.

B-1: There is one fan, B-1, that forces air through the power supply. It is very important that the air passages remain clear. A temperature switch located on the main heat sink will shutdown operation, should the fan or the cooling become ineffective.

PS-S3: An emergency off switch, located on the front panel, turns off high voltage, should an emergency STOP be required. The emergency Off turns off high voltage and returns the gun to the BIAS level of operation. The switch has a mechanical latch function and must be reset for operation to continue. Turn or rotate the knob to reset the switch.

PS-I1: The Mains On indicator on the front panel normally turns ON with the main circuit breaker. There are three fuses that must be intact for the indicator to come ON:

Fuse 1 and Fuse 2 on the 24V power supply Fuse 1 on the regulator circuit board

L-1 Inductor: L-1 is a filter inductor connected at the input to the rail capacitors. The inductor is part of an L-C filter. The capacitor, part of the L-C filter, is located on the Power Circuit Card, C-6-1895-49.

PS-S1 Switch: S-1 is a temperature switch located on the main inverter heat sink. It is selected to operate at 170ºF.

L-2 Indicator: L-2 is a 100 microhenry inductor used on the 400V power supply. The inductor connects between the input, three phase neutral and an artificial neutral located on the power board.

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4.5 High Voltage Regulator 9120028-010

The regulator for the high voltage power supply is the heart of the power supply. It controls, regulates the output voltage and current, communicates with the outside system, protects the power supply from internal and external faults. There are three interface connectors:

J5 Connection to components in the chassis J7 Ribbon cable to the HV inverter power card J4 Ribbon cable to the Gun Supply card J3 Ribbon cable to the Local Panel Gun control J6 Ribbon cable to the Local Panel HV control J2 Ribbon to rear panel Remote I/O Connector

1. K.V. Regulator: The reference voltage 0-10 volts connects to the regulator by way of J2-18

or J6-21. The signal enters the KV reference inverter U-16, Pin 13. The positive 10V signal is inverted to negative 10 volts at Pin 14. Pot R-86 provides for a small range of calibration of the reference. FET Q-3 clamps the reference to ground, prior to turn ON and during a fault shutdown sequence. Capacitor C-32 in combination with resistor R-76 and R-86 provide an RC for the reference rise at high voltage turn ON (0.0022 MFD X 75k ohms = 165 us).

The voltage feedback (sample of the output voltage) is connected to J-6, Pins 1 and 2. The feedback voltage divider (20 MEG Ohms) delivers 500 microamperes at 10,000 volts to the K.V. feedback buffer U-16, Pin 2. The divider is capacitive compensated and requires low end compensation by Pot R-58. The buffer provides a positive voltage 10 volt signal at Pin 1 for 10,000 volts on the output. The positive signals combine with an equal negative signal from the reference inverter to give 0 volts at the input to the KV error amp U-16 Pin 6. The KV error amp does what it has to do to keep the signal on Pin 6 at zero. The error amp output is positive during operation. The signal is the input to the pulse width modulator. The level of the voltage is proportional to the pulse width at the output of the PWM (Pulse Width Modulator chip U-15).

2. MA Regulator: The MA regulator is similar to the KV regulator in most of its functions.

The MA reference is set by an on board potentiometer R-124. The power supply will deliver load current up to the setting on the pot. If more current is commanded by the load, the power supply functions in the current regulation mode. The pot is set for the power supply to deliver 660mA.

The current feedback input is connected to J-6 Pins 3 and 5. The external resistor is selected to deliver 5 volts at 600mA to the current feedback circuit. The current feedback and current reference combine at the mA error amplifier U-21 Pin 6. It is the error amplifiers function when in control under current regulation to keep Pin 6 at zero. The Voltage and Current error amplifiers are tied by diodes CR13 and CR36 so that whichever regulator less power to the output is in control. When U-21 Pin 7 is more negative than U-16 Pin 7, the current regulator is in control. LED CR-53 is illuminated when the current error amp is in control.

An optical coupler, U-17, has an LED that turns ON when the voltage error amp is in control. The optical coupler sends a signal to the filament circuit to transfer from the Bias operation to emission operation (J5 - Pins 14 and 15). A second signal is sent to the "out of regulation LED" on the high voltage control panel and extinguishes the LED (J4 - Pin 14).

3. Output Monitor Buffers:

kV Monitor: The signal out of the kV feedback buffer, U-16 Pin 1, is designed to be 10V for 10,000 volts output. There is no calibration of the signal. There is calibration on the kV

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monitor as R-103 on the input to the buffer U-16 Pin 10 provides adjustment. Pin 25 on J-6 connects to the kV readout circuit in the control panel. mA Monitor: The 5 volt signal from the external current monitoring shunt is raised to 10 volts at the output of the mA feedback buffer U-21 Pin 14. This signal is calibrated by Pot R-112 and buffered by U-21 at Pin 1. The signal at the output is 6 volts for 600mA. The signal on J-6 Pin 23 connects to the current monitoring signal in the H.V. control panel.

4. Fault: There are three (3) fault inputs to the board.

Input Current (Inverter Current) Output Voltage (kV FB) Output Current (mA FB)

Input Current - The input current sense circuit utilizes a hall effect module on the power board to produce an isolated signal proportional to the current in the IGBT switches. Any abnormal or higher current in the load reflects a higher current in the primary circuit that must be conducted by the IGBT's. The current must flow through the hall effect device and shows up as an increased voltage on J7, terminals 2 and 3. The increased voltage appears on the regulator circuit board as a rail fault (RF) and is one of the rollback inputs. If the fault is large in both amplitude and duration, a latched fault occurs.

Rollback: The term "rollback" is used to describe the power supply operation when the load arcs. The fault is detected by one of the above fault inputs. The power supply inverter switches are commanded to shut off for approximately 200 microseconds. At the same time, the reference signals for the input voltage and current are clamped to zero. At the end of the 200 microsecond clamp time, the power supply is reactivated and the output turns on and ramps up to the original reference current and voltage command settings. This action is called a "rollback". If the output arcs again, the cycle is repeated. Rollback Counter: An integrator circuit increases the output voltage a few mV at U19-8 each time a rollback is detected. When a sufficient number of arcs in a quick series occurs, the output of U19-8 will increase to a level greater than the Arc Counter Threshold on U25-9 and an Arc Counter Fault will be set. If the arc sequence stops before the threshold is exceeded, the output of the integrator on U19-8 will decay back towards zero volts because of the discharge through 10 Megohm R132. The Arc Counter Threshold Pot, R186, has a range of approx 5 seconds at full CCW to greater than 2 minutes at full CW setting.

Output Voltage: The voltage feedback divider located in the high voltage section consists of a 20 megohm resistor paralleled by a capacitor. The combination produces a compensated voltage divider with a frequency response of approximately one (1) microsecond. The signal is buffered by U1 before it enters the overvoltage sense circuit at U12.

A second overvoltage circuit detects the change of output voltage DV/DT. An output arc would cause a rapid voltage change that is detected by the circuit. U19 at pin 3 is capacitively coupled via C-40 to the DC kV monitor circuit.

Output Current: The slow overcurrent fault signal input originates in the current shunt located in the low end of the high voltage circuit. The mA feedback is buffered by U21 Pin 13. The output Pin 14 inputs the slow overcurrent circuit at U25-6. The sensitivity of the trip level is set by Pot R-167.

The faults are divided into two categories:

Latched Faults Rollbacks

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Latched Faults: The latched faults are seen in the circuit around U24. The latched faults are:

Overvoltage Fault Slow Overload Fault Arc Counter Fault Rail Fault

Each latched fault has a sensitivity adjustment and an LED readout on the board that identifies that each respective fault caused the power supply shut down. Some conditions may result in more than one fault triggering the shut down. A latched shut down disables the inverters and opens the main contactor. The HV OFF push-button must be pressed to reset the latch.

FAULT SENSITIVITY ADJUSTMENT LED READOUT

Overvoltage R-156 (factory sealed) CR-51 Overcurrent R-167 (factory sealed) CR-52 Arc Counter R-186 CR-54 Rail Fault R-189 (factory sealed) CR-55 PS Fault none CR-4

Rollbacks: The rollbacks have two sense circuits. The rail sensor on the power board inputs comparator U3 at Pin 6. Resistor R-61 provides a sensitivity adjustment.

The second rollback input is the DV/DT sense circuit with the input at U3 Pin 3. The comparators output TP13 is normally high and goes low for a DV/DT fault.

5. High Voltage On: The high voltage ON sequence requires the external interlocks to close and

the interlock chain satisfied in order to obtaining a "ready" for high voltage. The 24V power source is through the fuse on the regulator board. The two fuses on top of the 24V power supply are external to the board. When +24V DC is present at the start of the interlock chain, the indicator on the front of the power supply MAINS ON will be illuminated. When all interlocks are closed,, satisfied, the HV Ready indicator in the HV OFF push-button will be illuminated. The start of the interlock chain is Pin 17 on J4. The end of the interlock chain is Pin 11 on J4; in addition, +15V will be present on Pin 15 on J4 (one side of the HV ON push-button). Pushing HV On places a +15V pulse on U11, Pin 2. Pin 17 of U2 pulls down, turning on Q5, starting the HV ON step sequence. When Q5 turns on, 24V is placed on the emitter of Q6. Resistor R127 functions as a latch to hold HV ON. If any of the interlocks are opened or the HV OFF switch is pushed, the +24V power holding HV ON is broken and HV immediately turns OFF.

6. Pulse Width Modulator: The pulse width circuits operate at a fixed frequency determined by

R148, R154 and C58. The components are selected for operation at 22KHz. The output on Pins A and B are present anytime the input Pins 5 and 8 are not clamped low by the off BUSS. The width of the output pulses at 45 microsecond intervals is determined by the voltage at the input Pin 1. At low output voltage, the pulses are very narrow; at high output and full power, the pulses fill out to the maximum width of 22 microseconds.

7: Interlock Circuits: Optoisolators U-8, U-9 and U-10 are provided to support Ready, Interlock and Ready/Reset logic when the Control Panels are not used. Similarly U-6 is used for HV ON, U-5 and U-11 are used for GUN ON and GUN OFF respectively when the optional Control Panels are not used.

8. Power Supplies: The board requires the following voltages:

+ 24V DC Unregulated Input To Board - 24V DC Unregulated

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+ 15V DC Regulated U-12 - 15V DC Regulated U-14 + 10V DC Regulated U-13 + 5V DC Regulated U-1

8. mA Feedback Output: An output signal is provided on P1 that is used as a ground referenced

power supply current feedback signal to P2 pins 2, 3 on the Gun Card: C-6-1899-98.

0-600 MA power supply current equals 0-6V DC output on P1 pins 2, 3.

4.6 High Voltage Power Card C-6-1895-49

The input thre-phase line voltage connects directly to P-1, P-2 and P-3 located on the power card. Contactor K-1, when energized, charges the rail capacitors as part of a two step turn on function. Resistors R-42 and R-43 limit the current during the initial charge. Transistors Q-7 and Q-8 turn on after completion of the charge and send a signal across a voltage barrier that the charge is complete and the circuit is ready for the main contactor K-2 to close. Note, the output of U-1 turns on Q-10 that in turn energizes relays K-2. All voltage for the turn on circuit comes from the 24 volts through the interlock chain.

High voltage turn ON is confirmed with the 24V return on Pin 15 of P-6.

There are two IGBT's inverter switches mounted between the heat sink and circuit card. The inverter functions as high speed switches and connects the primary of the high voltage transformer between the center point of the rail capacitors and the rails. Thus, the transformer sees 1/2 the rail voltage. The inverter switch between the (+)rail and the (-)rail at a frequency of 22KHz.

Each IGBT has a gate drive circuit located on the Gate Driver Board C-6-1884-69. A coupling transformer located on the board provides voltage isolation between the gates. The gate board output jacks plug directly into their respective IGBT Gate Terminals located in clearance slots below the inverter board.

4.7 Gun Supply C-6-1899-98

The gun supply circuit board contains two regulated power supplies plus functions as the interface with the gun control. The circuit board has two interface jacks and an optical receiver that provide connections to the outside circuits. P-1 connects to the Gun Control located in a separate chassis. J-1 is an 18 Pin, Phoenix connector located in the chassis base. All power enters and exits through J-1.

1. Filament Regulator: The single phase 220 volt power for the filament and positions circuits

enters on Pin 5 and 7. The circuit is protected by fuses F-1 and F-2. The A.C. power is rectified by CR-5 and filtered by inductors L-2 and L-3 in combination with rail capacitors C-1 and C-2. It should be noted, both the filament power supply inverter and position supply inverter utilize the same D.C. rail capacitors. The filament inverts Q-1 and Q-2 switch, the primary of the filament transformer, between the rails at a frequency of approximately 40KHz. It should be noted, the filament transformer connects to the center point of the rail capacitors, thus, half of the rail voltage is impressed alternately on the transformer by the FET inverters. Transistors Q-3 and Q-4, in conjunction with transformer T-2, provide the gate drive for the FETS. Inductor L-1 has a dual function of adding impedance in the primary and a sensing circuit for fault currents. C-3 are tuning capacitors for the output circuit.

The filament current feedback circuit utilizes transformer T-4 to measure the filament transformer primary current. The signal is rectified by CR-13 and calibrated by R-29. The

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feedback signal 7.5V = 75 amperes enters the filament circuit error amp at U-1 Pin 9 by way of R-25. The reference voltage originates with the bias potentiometer on the gun control panel and enters the board on P-1 Pin 1. This circuit controls the filament with high voltage off. When high voltage is ON and operating within the voltage regulation window, a signal enters the board on Pin 14 of J-1. The negative signal removes the clamp on the MA error amp U-2 Pin 1 and activates the MA ref. inverter chip U-2 Pins 5, 6 & 7. The filament command signal transfers from the preheat bias set pot to the emission command pot. Both are located on the gun control panel. In this mode the reference originates in the emission current potentiometer on the gun control and enters the board on P-1 Pin 13 (10V = 600mA). The feedback for this mode of operation originates at the 9120028 regulator card P1 connected to P2 on the C-6-1899-98 gun card. The feedback signal enters the error amplifier chip U-2 at Pin 2 by way of R-43.

Pot R-81 is factory set to limit the maximum filament current to 50 amperes. Pot R-50 is used for calibration of the bias set pot on the control panel. With the pot calibrated R-81 is then set to limit the filament current to 50 amperes. R-48 is used to calibrate the emission current control. R-105 is set slightly positive to give the emission command control when operating close to zero current.

The pulse width modulator chip U-3 converts the voltage present on Pin 2 to pulses of a constant frequency but with varying width. The frequency of pulses at the output on Pins A and B is determined by R-17, R-16 and C-8.

The filament power supply turns on by a positive 24V signal present on P-1 Pin 10. Optical coupler U-4 pulls Pin 10 of U-3 low.

2. Position Supply (optional): The position supply turns on with Main Power ON. The supply

utilizes rail capacitors C-1 and C-2 as its source of power. U-8 is an Off-line PWM (Pulse Width Modulator) switch. Its internal oscillator operates at 100KHz. The positive rail voltage, 277 maximum, appears at the high end of transformer T-3. The negative rail is connected to the source of U-8. The position supply output is connected to P-2 terminals 10 and 11 with 10 grounded. Resistor R-51 is a current feedback shunt. The signal is amplified by U-13. The output of U13 Pin 7 will be 3 volts for 3 amperes DC output current. Resistor R-55 provides calibration of the circuit. The position error amplifier, U-13 Pin 1 output, is optical coupled to the power chip U-8 by coupler U-12. The position supply must provide an output signal when its output is operating within preset limits. The limits are set by R-64 low limit and R-63 high limit. When the position supply current is above the low limit but below the high limit, transistor Q-6 pulls down and energizes a relay located on the gun control.

High Voltage Monitor C-6-1887-47 (optional): The circuit provides for current monitoring of a floating output signal. Resistor R-1 functions as a current shunt and develops 6 volts at 600mA DC. The signal can be calibrated by pot R-8. Zener diode CR-2 provides power for the voltage to frequency module U-1. The transmitter has no output with high voltage off and current to power up and function properly. LED U-2 transmits the digital signal to the filament supply board. Capacitors C-1 and C-2 protect the circuit from fault currents during output arcing.

4.8 High Voltage Circuit

The high voltage transformer has one secondary winding. The two blue wires input a voltage doubler rectifier circuit.

The board next to the side wall contains the rectifiers. Each diode element is paralleled by a capacitor. There are three electrical connections to the board: The low end connection, the high voltage output and the midpoint connection to the transformer.

39

The high voltage output PCB assembly contains –

Tuning Capacitors C-22 to C-31 Doubler Capacitors C-5 and C-6 Filter Capacitor C-7 Feedback Divider C-9 and R-2 With Series Res R-6 Output Series Resistors R-1A, 1B, 1C, 1D, 1E, 1F Low End Current Shunt R-3A, 3B

The metering signals connect to jack J-4. The high voltage output is two terminals at J-7 and J-8.

CAUTION

The maximum voltage on the board is 10kV DC. The operator and maintenance personnel should NOT access the board with power connected to the system.

Capacitor C-7 is a DC filter capacitors that reduces the output ripple to the 0.5% specified. Capacitors C-22 to C-31 function as an AC tuning capacitor for the secondary of the high voltage transformer.

The voltage feedback divider is made up of R-2 and C-9. The combination provides a compensated feedback signal representing the voltage at 10kV. The low-end shunt is R-3. The 5 ohms provides 3 volts with a load of 600 milliamperes. The current through this shunt represents total power supply output current and is displayed on the H.V. control panel. R-1 is the power supply output current limiting resistor.

40

4.9 Filament Transformer Module

The filament power supply provides an A.C. voltage for filament operation. The frequency of operation is 34 kHz. The filament transformer provides 10 volts at 75 amperes maximum to the filament for operation. The filament transformer has a single turn secondary providing the power. The 40 mills thickness of copper connects to the two brass studs located in the G-10 output plate.

CAUTION

During operation 10kV, 10,000 volts DC, is connected to these studs. The filament transformer housing provides protection for personnel. The filament output wires are located in a flexible metal conduit. The conduit connects to the customer’s assembly where the filament wires are protected from access during operation.

The circuit breaker on the power supply chassis should be OFF anytime access is required in the area of the box.

Vacuum Relay: The box contains a vacuum relay that connects the high voltage cable to the transformer secondary.

Microswitch: The box cover is interlocked and will drop out high voltage or prevent high voltage operation anytime the cover is not in place.

5.0 TROUBLE SHOOTING

5.1 Equipment

The power supply system is packaged in three separate assemblies:

A. Power Supply Chassis B. Control Assembly C. Output Transformer Module

In addition, there are interconnect cables and customer connections required.

The power supply system has several protection features that must be reset and or replaced before operation can begin.

Power: Make sure the input voltage matches the input voltage stamped on the rear panel of the equipment. Make sure all three phases of the power source is present. . Note: A neutral connection is required on 400 V inputs; make sure it is connected.

Circuit Breakers: There are several circuit breakers protecting the equipment. Make sure they are in their ON position.

Main Circuit Breaker: Front Panel Filament Supply Circuit Breaker: Rear Panel Control Circuit Breaker: Rear Panel

Fuses: There are fuses in the system protecting low power circuits. Make sure the fuses are in place and in functioning condition.

Power Inverter PC Board F1, F2 GDC-2A 24V Control Supply PC Board F1, F2 GDC-3A HV Regulator PC Board F1 GDC-500mA Filament Regulator PC Board F1, F2 GDC-5A

41

Interconnect Cables: There are five interconnect cables in the power supply chassis that make connection between the circuit boards and the circuit boards and the jacks on the rear panel. Make sure they are in place and making connection.

There are two shield ribbon cables connecting between the power supply chassis and the control. Make sure the connections are in place and bolted in position.

There are three cables that connect to each transformer module. Make sure the cables are screwed tight and make a secure connection.

5.2 Turn On

(A) With house power present at TB-1 on the rear panel of the power supply, turn on all circuit

breakers.

The PWR OK light on the power supply chassis should be illuminated. If not illuminated, check the following:

CHECK: Rear Panel Circuit Breakers Fuses on the 24V Control Supply Assembly Fuse on the regulator circuit board

The power supply cooling fan should be ON. The 24 volt control power should be present throughout the system.

(B) High Voltage Control Panel (If Used):

The power light should be illuminated The 24V control power should be present

Check item (A) and interconnect between the power supply and control assembly ribbon cables.

The DOORS light will be illuminated with interlock chain closed. CHECK: Turn On key switch Temperature switch below 170oF External Interlock J110 Pins C-D Jumpered Emergency OFF push-button active "Rotate" Transformer Module cover closed The green light in the HV OFF switch should be illuminated

HV READY FOR TURN ON

(C) H.V. ON (Using the optional Control Panel): The high voltage ON function requires the ready light in the HV OFF switch to be illuminated. Check the items in (B) for a High Voltage Ready.

The HV ON function is a multi-sequence turn ON. Pressing the ON push-button energizes a relay on the power card that slowly charges the rail capacitors. If the capacitors do not charge in approximately 50 ms to energize the main contactor, check the following:

Fuses F-1 and F-2 on the power board C-6-1895-49 the fault will be seen as a step-start fault and LED CR-56 on the front panel circuit board the HV regulator will be illuminated.

(D) Gun Ready (Using the optional Control Panel):

42

The gun can be turned ON at anytime (before or after high voltage turn ON). Emission current regulation will not take place until the high voltage is turned ON and in regulation.

Make sure all the interlock lights are illuminated. Contact closures are required on the external interface.

Tank Vacuum Auxiliary Water Position

Make sure the contacts of a remote, normally closed, GUN OFF switch is located across the green and black wires.

5.3 9120028 Regulator Card User Adjustment:

The Only User Adjustment is R-186 for the Arc Counter Fault sensitivity. Adjustment requires removal of the top cover. It is located on the regulator card mounted to the front panel and is the third potentiometer counting from the left side of the unit. Full CCW will allow continuous arcing for several seconds, while full CW will allow in excess of 2 minutes of continuous arcing.

5.4 Card Tests

It is recommended that a card be returned to the manufacturer for repair, calibration and adjustment. It may be difficult to determine which card is the problem card. This section provides an overview of the cards and their inter-relation. The majority of the circuit boards relate to the high voltage power supply.

HV Regulator 9120028-010 Power Card 208V C-6-1896-49A Power Card 400V C-6-1895-49B HV Rectifier C-6-1897-48 HV Output C-6-1891-56 Optional Cards: HV Control Panel C-6-1886-406 HV Control Interface C-6-1886-407 HV Control Connector C-6-1886-413

The Gun Supply is contained on one board.

Gun Supply C-6-1899-98D Optional Cards: Gun Control Panel C-6-1886-404 Gun Control Interface C-6-1886-405 Gun Control Connector C-6-1886-412

The 24 volt supply is required by all circuits and systems.

24V Supply Card C-6-1895-51

43

6.0 DRAWING LIST CV6-SL 208V

System Schematic (208V) D-6-7-1448 Rev 13

System Interconnect C-6-5-590 Rev 6

Output Transformer Module B-6-3-4021 Rev 4

Output Transformer Relay Box D-2-855-2511 Rev 8 Assembly

H.V. Metering PC (optional) B-6-1887-47 Rev 12

H.V. Output PC B-6-1891-56 Rev 6

H.V. Multiplier PC C-6-1897-48 Rev 4

208V Power Card C-6-1895-49A Rev 26

380V Power Card C-6-1895-49B Rev 27

480V Power Card C-6-1895-49N Rev 0

24V Supply PC C-6-1895-51X Rev 4

H.V. Regulator PC D-6-1899-85A Rev 27

Gun Supply PC (208/380V) C-6-1899-98B Rev 12

Gun Supply PC (480V) C-6-1899-98C Rev 4

H.V. Control D-6-7-1442 Rev 5

Gun Control D-6-7-1443 Rev 7

Dual Gate Driver C-6-1884-69 Rev 5

1

F

E

C

D

B

A

1

2 3 4 5 6

2 3 4 5 6

7 8

F

E

7 8

C

D

B

A

D

1

F

E

C

D

B

A

1

2 3 4 5 6

2 3 4 5 6

7 8

F

E

7 8

C

D

B

A

D

44

6.0 DRAWING LIST CV6-SL 400V

System Schematic D600048-001 Rev G

System Interconnect D600049-001 Rev D

Output Transformer Module B-6-3-4021 Rev 4 Output Transformer Relay Box Assembly D-2-855-2511 Rev 8

H.V. Output PC C-6-1891-56 Rev 6

H.V. Multiplier PC C-6-1897-48 Rev 4

24V Supply PC C-6-1895-51X Rev 4

H.V. Regulator PC 9120028-011 Rev G

Gun Supply PC C-6-1899-98D Rev 2

H.V. Control (Optional) D-6-7-1442 Rev 5

Gun Control (Optional) D-6-7-1443 Rev 7

380V Power Card C-6-1895-49B Rev 27

Dual Gate Driver C-6-1884-69 Rev 5

1

F

E

C

D

B

A

1

2 3 4 5 6

2 3 4 5 6

7 8

F

E

7 8

C

D

B

A

D

1

F

E

C

D

B

A

1

2 3 4 5 6

2 3 4 5 6

7 8

F

E

7 8

C

D

B

A

D

P/OJ5 100R80

60V, .5AMPSA05

Q4R88100k

60V, .5AMPSA05

Q7

R9920.0

LF347BN

U19:B

10.0kR93

R871.00k

100V.01

C43

50V.1C45

+15

10.0kR82

4.75kR92

R953.32k

1.00kR100

+15

R1344.75k

R13910.0k

100kR74

U17H11B1

75V, 0.3ACR29

100R163

R1614.75kR79

1.00k

R911.00k

50V.022C42

100R166

100V.01C61

A

A

-15

-15

R60105k100V

.01C31

A

A

.01C38

100V

A

200kR153

24.9kR118

100kR63

1.00kR64

U16:D

LF347BN

200V, 5%1000pF

C73

105kR157

100V,5%2200pFC32

56.2kR76

U21:CLF347BN

1.00kR149

.047C39

50V

A

+15

9.09kR90 75V, 0.3A

CR21 100V.01

C41 R8147.5k

U19:A

LF347BN

R771.00k

R83100k

A

A R11710.0k

R10810.0k

-15

50V.1

C58

1.00kR126R154

10.0

LF347BN

U21:A

A

R16449.9k

+15

200V, 5%1000pFC40

R1211.00k R55

100

A

+15

10.0kR89

+15

A

R751.00k

50V.1

C46

50V.1

C44

-15

+15

R594.75k

+15

1.00kR85

CR1875V, 0.3A

CR1775V, 0.3A

R13112.1k

66.5kR137

R944.75k

50V.1

C56

100V,5%2200pFC36

47.5kR116

200V, 5%1000pF

C53

U19:D

LF347BN

294R144

50V.047C65

+5

+15

+15

R140121k

75V, 0.3ACR46

75V, 0.3ACR47

CR1675V, 0.3ACR15

75V, 0.3A

CR4475V, 0.3A

200V, 5%39pFC62

1.00kR104

R1091.00k

R1272.74k

200V,5%220pFC52

10M, 1/4WR132

ULN2804AU18:B

4.75kR96

50V,20%4.7C85

50V,20%

4.7C49

75V, 0.3A

CR23

75V, 0.3ACR37

CR671N4448

75V, 0.3A

CR2675V, 0.3A

U19:C

LF347BN

CR661N4448

75V, 0.3A

CR4175V, 0.3A75V, 0.3A

CR34

A 1.00kR125

1.00kR130

R6920.0k

R1941.00k

AR26422k200V,5%

470pFC10

-15

A

200kR180

200kR148

50V.1

C29

-15

R4320.0k

R5310.0

A

A

A

TP6AGND

A

A

49.9kR152

50V.022C51

+15

50V.022C57

100kR147 10.0k

R151

A

U21:D

LF347BN

R14249.9k

R1411.00k

200V, 5%1000pF

C37

100kR159

200kR72

249kR66

C304700pF200V,5%

1.00kR49

49.9kR56P/OJ5

U16:A

LF347BN

+15

10.0R45

20.0kR30

20.0kR28

R221.00k

50V.1

C28+15

75V, 0.3ACR7

75V, 0.3ACR9

A

2.74kR193

20.0kR192

-15

2.2K,.5WR191

4.75kR40

200V,5%4700pF

C24

200V,5%100pFC23

10.0kR36

200V,5%4700pF

C22

LF347BN

U16:B

75V, 0.3ACR13

2.2K,.5WR42

R541.00k

+15

249R33

LF347BN

U21:B

200V,5%330pFC70

R7349.9k

A

10.0R115

50V.1

C55

-15

+15

75V, 0.3ACR28

CR3275V, 0.3A

47.5kR114

100kR41

200V,5%100pFC47

100V.01C48

1.00kR101

A

CR53GRN/YEL

U27H11B1

47.5kR29

50V.047C21

A

200V,5%100pF

C18

A

2.2K,.5WR68 R39

1.00k

A

75V, 0.3ACR14

U15UC3526AN

R5710.0k

1.00kR61R65

10.0k

LF347BN

U16:C

A

A

1.00kR11375V, 0.3A

CR36

CR3875V, 0.3A

CR1075V, 0.3A

+5

15.0kR67

+15

100R52 R106

47.5k

R1202.2K,.5W

R471.00k

75V, 0.3A

CR35

50V.1

C19

R2547.5k

R3510.0k

10.0kR37

200V,5%2700pFC26

.47C27

50V

R5110.0

+24

-15

100kR27

+15

R2449.9k

4.75kR176

CR56GRN/YEL

50V.47

C12

4.75kR98

475R102

ULN2804AU18:A

49.9R84

R7010.0k2.2K,.5W

R105

CR2475V, 0.3A

CR2775V, 0.3A

CR2575V, 0.3A

330,.5WR110

-15

CR4575V, 0.3A

50V.1

C14+15

10.0R46

R621.00k200V,5%

4700pFC33

20.0kR111

R4810.0

10.0kR172CR48

75V, 0.3A

A

R1354.75k

50V.1C71 R162

100k

CR3175V, 0.3A

CR4275V, 0.3A

75V, 0.3ACR50

CR4075V, 0.3A

-15

4.75kR171

50V

C76.47

50V.1C74

R17010.0k

50V.1C59

475R129

R16847.5k

475R188

100V.01C79

1.00kR190

+15

.1

C82

339COMP

U25:E

CR651N4448

75V, 0.3A

+15

2.2K,.5WR123

C344700pF

200V,5%

339COMP

U25:D100V

C80.01

+5

200V,5%4700pFC83

C81.1

R18749.9

R185715

10C2020%

1.00kR38

1.00kR23

10C8

20%

+15

+15

50V.1

C9

A

A

A

A

R324.75k 50V,20%

4.7C17

TP16AGND

+15

.1C90

339COMP

U25:A

CD4044BU24

1.00kR184

+15

R1452.2K,.5W

C63.01

100V

R16910.0k

10C7520%

U25:C

COMP339

100V.01

C66

CR641N4448

75V, 0.3A

R1582.74k

50V,20%

C692.2

+52.74kR182

2.74kR183

1.00kR150

R16520.5k

100V.01C84

2.2K,.5WR155

U25:B

339COMP

50V.1

C72+15

R1602.2K,.5W

+15

C67.01

100V

+15

1.00k

R178

R1771.00k

CR52GRN/YEL

CR51GRN/YEL

CR4GRN/YEL

75V, 0.3ACR59

CR6075V, 0.3A

CR55GRN/YEL

CR54GRN/YEL

1.00k

R175

1.00k

R174

2.2K,.5WR173

CR5875V, 0.3A

CR5775V, 0.3A

75V, 0.3ACR30

1000V, 1A1N4007CR62

50V.1

C68

47.5kR119

P/OJ5

-15

+24

10C720%

P/OJ5

10C1120%

INOUT-15V

LM320TU14

OUT IN+15V

LM340T-15U12

CR631N40071000V, 1A

+5+15

50V.1C3

50V.1C4

CR12GRN/YEL

OUTIN+5V

U17805CT

CR11GRN/YEL

2.2K,.5WR4

2.2K,.5WR12.2K,.5W

R44

H11B1U2

2.2K,.5WR19

2.2K,.5WR13

Q2MPSA0560V, .5A

H11B1U8

3W, 5%240R50

H11B1U3

2.2K,.5WR7

2.2K,.5WR5

2.2K, .5WR20

60V, .5AMPSA05Q1

U6H11B1

2.2K, .5WR15

2.2K, .5WR10

4.75kR3

C5

50V.1

4.75kR2

4.75kR6

2.2K, .5WR9

U5H11B1

U9H11B1

C54.150V

CR8GRN/YEL

23.7kR21

4.75kR16

2.2K, .5WR14

H11B1U7

U11H11B1

200V,5%470pF

C60

240R31

3W, 5%

19 17 15 13 11 9 7 5 3 125 23 21 J2:A 468101214161820 2222426 J2:B

A

4.75kR12

2.2K, .5WR17

U10H11B1

A

CONNECT GROUNDS AT SINGLE POINT

1

3

5

7

9

11

13

15

J4:A

1

3

5

7

9

11

13

15

J3:A

1N4448CR1

75V, 0.3A

50V.1C15

H11B1U4

S1:A2P-3T2P-3T

S1:B

50V.1C6

Q10MPSA0560V, .5A

75V, 0.3A

CR31N4448

R82.2K, .5W

+5

50V.1C13

50V.1C16

+5

50V.1

C25

50V.1C1

J1

2

4

6

8

10

12

14

16

J3:B

2

4

6

8

10

12

14

16

J4:B

50V.1C2

45

7.0 PARTS LIST CV-6SL 400V

PART # DESCRIPTION

6024-6009-0 POWER SUPPLY, CV-6SL 400V 1-GUN BRC-10-600N-380-3PH-50-SATIS

POWER SUPPLIES INCLUDE:

* FILAMENT SUPPLY PCB, CV-XS (W/OUT POSITION SUPPLY) (C-6-1899-98-D)

* ONE-GUN HV OUTPUT PCB (Made up of 2 bds, the 48 bd & 56 bd)

* FILAMENT MODULE, CV-XS (1-GUN VERSION) (D-2-2)

* HV OUTPUT LEAD SET, CV-XS (3 FT) (B-2-371-224) * OPERATOR'S MANUAL

6024-6021-0 CV-6 SGC KIT

6024-6101-1 HV/GUN CONTROL PANEL SATIS LOGO 8528552075 6024-6114-0 1 CV-6S CONTROL CALBE SET (10 FT) 90-2-371-255 6024-6124-0 1 USER I/O HV CONTROL CABLE (10 FT) 90-2-371-185 6024-6125-0 1 USER I/O GUN CONTROL CABLE (1O FT) 90-2-371-184

6024-6101-0 CONTROL PANEL, CV-XS HV/G1 GTL SATIS (1/2 RACK) D-2-855-2075

6024-6101-1 1 HV/GUN CONTROL PANEL SATIS LOGO

8528552075

6024-6103-0 CONTROL PANEL, CV-XS G2 CTL SATIS (1/4 RACK) D-2-855-2071

6024-6105-? FILAMENT SUPPLY PCB (W/POSITION)

C-6-1899-98-A

6024-6106-? FILAMENT SUPPLY PCB (W/OUT POSITION) C-6-1899-98-D

6024-6107-0 HV OUTPUT PCB, CV-XS

D-2-855-2076 (Made up of 2 bds, 48 & 51)

46

6024-6112-1 HV OUTPUT CABLE, CV-XS (20 FT) B-2-371-257

6024-6113-1 FILAMENT MODULE CABLE, CV-XS SATIS (12 FT)

C-2-371-248 (W-104A Interconnect Cable)

6024-6113-2 FILAMENT MODULE CABLE, CV-XS SATIS (12 FT) C-2-371-247 (W-103B Interconnect Cable)

6024-6114-0 CONTROL PANEL CABLE SET, CV-XS (10 FT)

C-2-371-165 (Includes 2 cables)

6024-6115-0 GUN-2 CONTROL PANEL CABLE, CV-XS (10 FT) C-2-371-256

6024-6116-? HV OUTPUT LEAD SET, CV-XS (3 FT)

C-2-371-224

6024-6117-1 POSITION CONTROL INTERCONNECT CABLE (SATIS 20 FT) B-2-371-179A

6024-6122-0 INVERTER ASSEMBLY, CV-6S (380V)

8528552077

6024-61??-0 HV REGULATOR PCB, CV-XS 9120028-010

6024-6124-0 1 USER I/O HV CONTROL CABLE (10 FT)

90-2-371-185

6024-6124-1 HV CONTROL REMOTE INTERFACE CABLE (20 FT) D-2-371-226 W-107A

6024-6125-0 1 USER I/O GUN CONTROL CABLE (10 FT) 90-2-371-184

6024-6125-1 GUN CONTROL REMOTE INTERFACE CABLE (20 FT)

D-2-371-225 W-106A

6024-6109-1 FILAMENT MODULE (with HV Cable Connection) D-2-855-2511

6024-6126-1 FILAMENT MODULE, (with HV Cable Connector)

D-2-855-2512

6024-6127-0 PINK HV CABLE ASSEMBLY (13 FT) D-2-371-253 W-110

6024-6145-0 “Y” CABLE

C3710538-001 W-11

NOTE 4: SERVICE SPARES KIT, CV-XSL INCLUDES:

* CONTROL PANEL PCB, HV CONTROL CV-XS * CONTROL PANEL PCB, GUN CONTROL CV-XS * FILAMENT SUPPLY PCB, CV-XS (W/OUT POSITION SUPPLY)

47

* HV OUTPUT PCB, CV-XS * FILAMENT MODULE, CV-XS (1-GUN VERSION) * INVERTER ASSEMBLY, CV-6S * HV REGULATOR PCB, CV-XSL

48

7.0 PARTS LIST CV-6SL 208 PART # DESCRIPTION

6024-6002-0 POWER SUPPLY, CV-6S BOCCT 208V 1-GUN (* Note 1) BRC-10-600N-208-3PH-60-B0C

6024-6003-0 POWER SUPPLY, CV-6S BOCCT 240V 1-GUN (* Note 1) BRC-10-600N-240-3PH-60-BOC

6024-6004-0 POWER SUPPLY, CV-6S BOCCT 380V 1-GUN (* Note 1) BRC-10-600N-380-3PH-50-BOC

6024-6005-0 POWER SUPPLY, CV-6S BOCCT 415V 1-GUN (* Note 1) BRC-10-600-415-3PH-50-BOC

6024-6006-0 POWER SUPPLY, CV-6S BOCCT 480V 1-GUN (* Note 1) BRC-10-600N-480-3PH-60-BOC

NOTE 1: POWER SUPPLIES INCLUDE:

* (OPERATING VOLTAGE AND LOGOS AS SPECIFIED) * FILAMENT SUPPLY PCB, CV-XS (W/OUT POSITION SUPPLY) (C-6-1899-98-B) * ONE-GUN HV OUTPUT PCB (Made up of 2 bds, the 48 bd & 56 bd) * HV METERING PCB (C-6-1887-47 bd) * CONTROL PANEL, CV-XS HV/G1 (1/2 RACK) (D-2-855-2074) * FILAMENT MODULE, CV-XS (1-GUN VERSION) (D-2-855-2511) * HV OUTPUT CABLE, CV-XS (20 FT) (B-2-371-257) * FILAMENT MODULE CABLES, CV-XS (20 FT) (W-103A & W-104B INTERCONNECT CABLES) * CONTROL PANEL CABLE SET, CV-XS (10 FT) (Made up of 2 cables W-101 & 102) * HV OUTPUT LEAD SET, CV-XS (3 FT) (B-2-371-224) * OPERATOR'S MANUAL * GUN CONTROL REMOTE INTERFACE CABLE (85-2-371-225) * HV CONTROL REMOTE INTERFACE CABLE (85-2-371-226)

SPARE PARTS:

6024-6102-0 CONTROL PANEL, CV-XS HV/G1 CTL BOCCT (1/2 RACK) D-2-855-2074

6024-6104-0 CONTROL PANEL, CV-XS G2 CTL BOCCT (1/4 RACK)

D-2-855-2067

6024-6105-? FILAMENT SUPPLY PCB (W/POSITION) C-6-1899-98-A

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6024-6106-? FILAMENT SUPPLY PCB (W/OUT POSITION)

C-6-1899-98-B 6024-6107-0 HV OUTPUT PCB, CV-XS

D-2-855-2076 (Made up of 2 bds, 48 & 51)

6024-6108-0 HV METERING PCB, CV-XS (2-GUN OPTION) C-6-1887-47

6024-6109-0 FILAMENT MODULE, CV-XS (1-GUN VERSION)

D-2-855-2198

6024-6109-1 FILAMENT MODULE, CV-XS (1-GUN VERSION) D-2-855-2511

6024-6110-0 FILAMENT MODULE, CV-XS (2-GUN VERSION)

D-2-2350-225

6024-6111-0 2-GUN CONVERSION KIT, CV-XS (BOCCT) D-2-855-2072

6024-6112-1 HV OUTPUT CABLE, CV-XS (20 FT)

C-2-371-257 (W-105A)

6024-6113-0 FILAMENT MODULE CABLE SET, CV-XS BOC (20 FT) C-2-371-166 (Includes 2 cables)

6024-6114-0 CONTROL PANEL CABLE SET, CV-XS (10 FT)

C-2-371-165 (Includes 2 cables)

6024-6115-0 GUN-2 CONTROL PANEL CABLE, CV-XS (10 FT) C-2-371-256

6024-6116-0 HV OUTPUT LEAD SET, CV-XS (3 FT)

B-2-371-224

6024-6117-0 POSITION CONTROL INTERCONNECT CABLE (BOC 10 FT) B-2-371-179

6024-6117-1 POSITION CONTROL INTERCONNECT CABLE (SATIS 20 FT)

B-2-371-179A

6024-6118-0 OPERATORS MANUAL, CV-XS 85-2-855-2078

6024-6119-0 CUSTOMERS SPARES KIT, CV-XS (* Note 3)

6024-6120-0 SERVICE SPARES KIT, CV-XS (380V BOC) (* Note 4)

6024-6120-2 SERVICE SPARES KIT, CV-XS (208V BOC) (* Note 4)

6024-6121-0 INVERTER ASSEMBLY, CV-6S (208V)

D-2-855-2105

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6024-6122-0 INVERTER ASSEMBLY, CV-6S (380V)

D-2-855-2077

6024-6123-0 HV REGULATOR PCB, CV-XS D-3-1899-85A

6024-6124-0 HV CONTROL REMOTE INTERFACE CABLE (10 FT)

D-2-371-185 W-107

6024-6124-1 HV CONTROL REMOTE INTERFACE CABLE (20 FT) D-2-371-226 W-107A

6024-6125-0 GUN CONTROL REMOTE INTERFACE CABLE (10 FT)

D-2-371-184 W-106

6024-6125-? GUN CONTROL REMOTE INTERFACE CABLE (20 FT) D-2-371-225 W-106A

NOTE 2: 2-GUN CONVERSION KIT, CV-XS INCLUDES:

* FILAMENT SUPPLY PCB, CV-XS (W/OUT POSITION SUPPLY) * HV METERING PCB, CV-XS * FILAMENT MODULE, CV-XS (2-GUN VERSION) * HV OUTPUT CABLE, CV-XS (20 FT) * FILAMENT MODULE CABLE SET, CV-XS (20 FT) * GUN-2 CONTROL PANEL CABLE, CV-XS (10 FT) * HV OUTPUT LEAD SET, CV-XS (3 FT)

NOTE 3: CUSTOMER SPARES KIT, CV=XS INCLUDES:

* FUSES * LAMPS

NOTE 4: SERVICE SPARES KIT, CV-XS INCLUDES:

* CONTROL PANEL PCB, HV CONTROL CV-XS * CONTROL PANEL PCB, GUN CONTROL CV-XS * FILAMENT SUPPLY PCB, CV-XS (W/OUT POSITION SUPPLY) * HV OUTPUT PCB, CV-XS * FILAMENT MODULE, CV-XS (1-GUN VERSION) * INVERTER ASSEMBLY, CV-6S * HV REGULATOR PCB, CV-XS

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