Table 4.1 List of Main Assemblies................................................................................17
XLG/XLF MANUAL ii 118020-001 REV E
LIST OF TABLES
Page 8
Chapter 1
INTRODUCTION
1.1 Description of the XLG/XLF
Series
he XLG/XLF series of high voltage power supplies
represent an advanced approach to X-ray generator
T
power requirements. These power supplies provide
all of the power, control, and support functions required
for practically all X-ray applications. The XLG/XLF
series provide high voltage, high current outputs with
very low ripple. Extremely stable voltage and current
outputs result in significant performance improvements
over previously available technology. Low output ripple
provides higher intensity levels, with no increase in tube
loading.
All these advancements are possible only by Spellman’s
long history in X-ray power systems. These series of
power supplies utilize extremely advanced resonant
conversion techniques, along with sophisticated digital
technology.
The XLF series is specifically designed for X-ray tube
application where the high voltage is a negative polarity,
and the filament circuits are referenced to the cathode
high voltage potential, (floating filament). The XLG
series is specifically designed for X-ray tube applications
where the high voltage is a positive polarity, and the
filament circuits are referenced to cathode ground
potential, (grounded filament).
The X-ray tube voltage and tube emission current are all
continuously adjustable via front panel and/or remote
controls.
The power supplies operate from a variety of line
voltages and are convection cooled for 1 – 300W models
and fan cooled for 800 to 1200W models requiring no
water cooling. Custom designed units for single use or
OEM applications are available.
1.2 XLG/XLF Specifications
Output Control: Voltage and current are
continuously adjustable over the entire range from
zero to maximum rating a ten-turn potentiometer
with a lockable counting dial.
Input Voltage: 115Volts AC10%, 50/60Hz, single
phase or 220Volts AC 10%, 50/60Hz, single phase.
1200W models are available with 220 V AC input
only. Specify input voltage at time of order. Other
line voltages are available.
Voltage Regulation:
Load Regulation: 0.005% of full voltage for a no
load to full load change.
Line Regulation: 0.005% of full voltage over the
specified input voltage range.
Current Regulation:
Load Regulation: 0.05% of full current ±100uA
for any voltage change.
Line Regulation: 0.01% of full current over the
specified input voltage range.
Ripple: 0.03%rms below 1kHz,
0.75%rms above 1kHz.
Filament XLG:
HPWR: 9A, 3V LPWR: 3A, 3V
Filament XLF: 5A, 15V.
Stability: 0.01% per hour after 1/2 hour warm up.
0.02% per 8 hours (typical).
Temperature Coefficient: 100 ppm per C. Higher
stability (50 ppm per ºC) available on special order.
Ambient Temperature:
Operating: 0C to +40C
Storage: -40C to +85C
Metering: Digital voltage and current meters are
accurate to 1%.
Weight: 17 to 30 lbs. (7.7 to 14kg) depending on
model.
Physical:
XLG:
30-60kV: 3 ½”H x 19”W x 19”D rack mount.
(89 x 483 x 483mm). 80-130V: 3 ½”H x 19”W x 19”D rack mount.
(89 x 483 x 483mm).
XLF:
3 ½”H x 19”W x 20”D rack mount.
(89 x 483 x 508mm).
XLG/XLF MANUAL 1 118020-001 REV E
Page 9
1.3 Standard Features
The XLG/XLF series incorporates several standard
features designed to optimize user satisfaction and safety.
KV AND MA/FILAMENT CURRENT RAMP
CIRCUITS: This feature provides for a gradual rise for
kV, mA and filament current. This feature is designed to
limit voltage shock and filament shock to the X-ray tube.
The kV ramp rate is approximately 6 seconds. The
filament current is slowly increased until the desired mA
level is achieved. This time is typically 5 seconds for full
mA output. These ramp conditions are started at the
initial HV ON control signal.
ARC DETECT / ARC QUENCH / ARC COUNT:
These features allow the user to tailor the power supply to
meet specific needs in dynamic load applications. If an
arc occurs, the output is inhibited for approximately one
second, then the output is ramped up to the preset level
with the Slow-start circuitry. See Chapter 3 for operating
details and information for user customization for these
features.
REMOTE HIGH VOLTAGE CONTROL: Allows
remote control of the HIGH VOLTAGE ON and HIGH
VOLTAGE OFF functions. Signals are also provided for
remote indication of HV ON or HV OFF status.
EXTERNAL INHIBIT: A circuit that will inhibit the
high voltage output is provided of the 25 pin mini-D
connector on the rear of the chassis. A logic low, ground,
will inhibit the high voltage output and a logic high, open,
will restore the high voltage output to the preset level.
NOTE: The External Inhibit circuit should
NOT be used for protection against injury or for safety
interlock. See External Interlock for this type of safety
control
EXTERNAL INTERLOCK: Interlock connections are
provided on the terminal block on the rear of the chassis
for connection to a safety switch. The unit will not
operate unless the interlock circuit is closed. During high
voltage operation, opening the interlock circuit will cause
the High Voltage to shut off. This circuit should be used
for safety interlock circuits.
INTERNAL FAULT PROTECTION: The XLG/XLF
series continually monitors internal circuits critical to the
proper operation of the power supply. In the event that
one of these circuits does not function correctly, the fault
detection circuit latches the appropriate fault on the front
panel display and turns off the outputs and reverts the unit
to the POWER DOWN mode.
INDICATOR LAMPS: HIGH VOLTAGE OFF and
HIGH VOLTAGE ON indicators.
OUTPUT CABLE: XLG models are provided with a
ten foot shielded high voltage output cable. The cables
are designed with a plug arrangement so that they can be
easily removed from the mating receptacle located on the
rear of the chassis. internal EMI filter and fuse provide
protection against line voltage surges and power supply
faults.
1.3.1 Remote Operating Features
REMOTE PROGRAMMING: Allows remote
adjustment of the output voltage and current via an
external voltage source. The output power is also
remotely controllable when the CPC or APT option is
ordered.
REMOTE MONITOR: Allows remote monitoring of
the tube voltage and tube emission current. NOTE:
Output power remote monitor is included with the CPC
and APT options.
1.3.2 System Status and Fault
Diagnostic Display
“Dead Front” type indicators are provided to give the user
complete indication of system operation and fault
conditions. If a fault occurs the power supply will revert
to the POWER DOWN mode. This is indicated by both
the HV ON and HV OFF lamps turning off. To reset,
depress the HV OFF switch.
VOLTAGE (CONTROL): Indicates the output voltage
regulator circuit is maintaining voltage regulation.
CURRENT (CONTROL): Indicates the output current
regulator circuit is maintaining current regulation.
POWER (CONTROL): Indicates the output power
regulator circuit is limiting tube power (optional).
HV INHIBIT: Indicates the high voltage supply is being
inhibited by either the EXTERNAL INHIBIT or internal
protection circuitry.
INTLK CLSD: Indicates the EXTERNAL
INTERLOCK connections are in the closed position.
This also indicates closure of internal power supply
interlocks.
INTLK OPEN: Indicates the EXTERNAL
INTERLOCK connections are in the open position. This
also indicates opening of internal power supply
interlocks.
XLG/XLF MANUAL 2 118020-001 REV E
Page 10
OVERVOLT: Indicates the overvoltage protection
circuitry has caused the power supply to turn off.
Overvoltage protection is internally set to 110% of rated
output voltage.
OVERCURR: Indicates the output current has exceeded
the programmed current trip level when the AOL
(Adjustable Overload Trip) or the OL (overload Trip)
options are installed.
The options available are listed kin Table 1.1. See
Section 5 for more information on these options along
with operating and set-up instructions. With few
exceptions, these options and modifications can be
retrofitted to your power supply at the factory in a short
time. For price and retrofit arrangements, contact
Spellman’s Sales Department.
OVERPWR: Indicates the output power has exceeded
the internally set level or the remote programmed level if
the optional circuitry is installed.
ARC: Indicates that an arc has occurred within the
previous one second or that the ARC COUNT/TRIP has
shutdown the power supply.
RGLT ERR: Indicates a failure in the voltage, current or
power regulation circuitry. This fault usually occurs
when there is a lack of output power to maintain
regulation.
FILAMENT STANDBY/LIMIT (rear panel):
Indicates the filament is in a standby or limit mode. Also,
when illuminated, this indicates the emission current
regulator is not regulating.
1.4 Options
CODE DISCRIPTION
• AOL Adjustable Overload Trip (0-103%)
• APT Adjustable Power Trip
• AT Arc Trip
1.5 Interpreting the Model
Number:
The model number of the power supply describes its
capabilities. After the series name is:
(1) the maximum voltage (in kV)
(2) the maximum output (in watts)
(3) the option codes for all options that are included.
Custom units have an X number after the option codes.
XL 30 P 1200/ AOL / X(#)
Series
Name
Maximum
Voltage
Polarity
Maximum
Power
Option
Custom
"X" Numb er
• SS(X) Non-Standard Slow Start
• NSS No Slow Start
• IO Instant ON
• ( ) Specify 220V or 100V or 200Vac Single
Phase input with order
• DPM4 4 ½ digit ±1 least significant digit panel mrt
• LL(X) Extra Length Output Cable
• SL Slides
• BFP Blank Front Panel
Table 1.1 XLG/XLF Options
XLG/XLF MANUAL 3 118020-001 REV E
Page 11
Chapter 2
Inspection and Installation
nitial inspection and preliminary checkout
procedures are recommended. For safe
I
operation, please follow the step-by-step
procedures described in Chapter 3, Operating
Instructions.
2.1 Initial Inspection
Inspect the package exterior for evidence of
damage due to handling in transit. Notify the
carrier and Spellman immediately if damage is
evident. Do not destroy or remove any of the
packing material used in a damaged shipment.
After unpacking, inspect the panel and chassis
for visible damage.
Fill out and mail the Warranty Registration card
accompanying the unit. Standard Spellman
XLG/XLF high voltage power supplies and
components are covered by warranty. Custom
and special order models (with an X suffix in the
model number) are also covered by warranty.
2.2 Mechanical Installation
Units in the XLG/XLF series have front panel
holes for standard EIA rack mounting. The rack
must allow rear access for cable connections.
Units are fully enclosed and are suitable for
bench or tabletop operation. Standard unit
dimensions are shown in Figure 2.1. It is
strongly recommended to support the chassis by
guides or slides. Slides are available for ease of
servicing (SL option).
XLG/XLF MANUAL 4 118020-001 REV E
Page 12
Figure 2.1 XLF & XLF DIMENSIONS
XLG/XLF MANUAL 5 118020-001 REV E
Page 13
Chapter 3
Operating Instructions
3.1 Operation
WARNING
THIS EQUIPMENT GENERATES
DANGEROUS VOLTAGES THAT MAY BE
FATAL.
PROPER GROUNDING OF ALL HIGH
VOLTAGE EQUIPMENT IS ESSENTIAL.
WARNING:
Before connecting the power supply to the
AC line, follow this step-by-step procedure.
Do not connect the power supply to the AC
line until Step H is reached.
Failure to follow these procedures may void
the warranty.
A) Insure that the Circuit Breaker is in the OFF
position (0).
B) Check the input voltage rating on the nameplate
of the supply and make certain that this is the rating of the
available power source. Spellman XLG/XLF units
operate on 115VAC (or 220V if 220 V option is ordered),
single phase unless ordered with a different input voltage.
C) PROPER GROUNDING TECHNIQUE: The
chassis of high voltage power supplies must be grounded,
preferably to a water system ground using copper pipe or
other earth ground using the connection terminal at the
rear of the unit.. See Figure 3.1, 3.2 for a typical
operating setup.
The return line from the load should be connected to the
terminal on the rear of the power supply. Using a
separate external ground at the load is not recommended.
The units are provided with a three conductor line cord.
D) Attach the output cable to the load.
E) Plug the high-voltage output cable into the rear
of the supply and hand tighten the knurled collar.
XLG/XLF MANUAL 6 118020-001 REV E
F) Options Note: See section 5 for hook up and
operating instructions for the options on your unit.
Custom models may also require set up changes.
G) For initial turn-on, rotate the KILOVOLT
control fully counter-clockwise to the zero voltage
position.
H) The input power cable may now be connected to
the AC power line.
I) Switch the front panel circuit breaker to the ON
position (1). (If the supply is to be turned off for an
extended period of time the line cord should be
disconnected). The unit is now in the HIGH VOLTAGE
OFF mode. The HIGH VOLTAGE OFF light should be
lit.
J) Depress and hold the HIGH VOLTAGE OFF
switch. The front panel meters will now read the preset
value of the KILOVOLT control dial and the
MILLAMPERES control dial. To preset the desired level
of the current and voltage during operation, hold the
HIGH VOLTAGE OFF switch and rotate the appropriate
control dial while noting its corresponding meter reading.
Release the HIGH VOLTAGE OFF switch.
NOTE: No actual output is being produced at this stage.
K) Depress the HIGH VOLTAGE ON switch. The
light inside the switch should light up and the output will
slow start to the preset level output voltage and/or output
current.
Note: The XLG/XLF series is equipped with a slow start
circuit that ramps the output up to its maximum setting in
approximately 6 seconds after the HIGH VOLTAGE ON
switch is depressed.
L) To terminate the generation of output power,
depress the HIGH VOLTAGE OFF switch. In the HIGH
VOLTAGE OFF mode the power supply’s fault and
interface circuits are still active.
M) To turn off the power supply, turn the circuit
breaker to the off position (0).
NOTE: If a power supply fault, or system monitoring
fault occurs, the power supply will revert to the POWER
DOWN mode. In this mode the output power will be
turned off. The HV OFF lamp will be off. To reset,
depress the HV OFF Switch.
Page 14
WARNING
AFTER TURNOFF, DO NOT HANDLE THE LOAD
UNTIL THE CAPACITANCE HAS BEEN
DISCHARGED!
LOAD CAPACITANCE MAY BE DISCHARGED BY
SHORTING TO GROUND.
WARNING
THE VOLTMETER ON THE POWER SUPPLY
FRONT PANEL DOES NOT
VOLTAGE WHEN THE POWER IS TURNED OFF,
EVEN IF A CHARGE STILL EXISTS ON THE
READ THE OUTPUT
LOAD.
CAUTION
control (front panel control), jumpers are installed on the
connector JB1 in the rear of the chassis between JB1-10
and JB1-11 for voltage control and between JB1-8 and
JB1-9 for current control.
For remote programming, the jumpers are removed and a
positive voltage source, from 0 to 10 volts, is applied to
the appropriate terminals. Programming signals should
be referenced to JB1-1 signal ground. By adjusting the
voltage source from 0 volts (zero output) to 10 volts (full
rated output) the desired output can be selected. See
Figure 3.3A for wiring diagram and specifications.
An alternate method of controlling the output remotely is
by using external resistance such as a potentiometer or a
resistor network. For remote control the jumpers are
removed and the desired resistor configuration is
installed. See Figure 3.3B for wiring diagram.
ALWAYS OPERATE THE UNIT WITH THE COVER
ON.
A fan maintains safe operating temperature in the XLF
power supplies by drawing air over the circuit
components. The cover must be on in order to direct the
air flow over the areas that need cooling. In operation,
the unit must be places so that the air intake and the fan
exhaust are clear of any obstructions that might impede
the flow of air. The XLG units do not use forced air
cooling. Simply maintain ambient temperature
specifications.
3.2 Standard Features
A note on remote interface circuitry and remote signal
grounding. Whenever possible, electrical isolation should
be provided when interfacing with any high voltage
power supply. For power control signals such as
EXTERNAL INTERLOCK, HIGH VOLTAGE OFF and
HIGH VOLTAGE ON isolated relay contacts should be
used. For status signals and control signals such as HIGH
VOLTAGE ON, HIGH VOLTAGE OFF, EXTERNAL
INHIBIT, etc. Opto-isolation should be used. If possible,
analog programming and monitoring signals should be
isolated via analog isolation amplifiers. Spellman
application engineers are available to assist in interface
circuitry design. All interface cables should be properly
shielded. All power supply signals should be referenced
to the power supplies signal ground on the rear terminal
block JB1-1.
REMOTE PROGRAMMING: Allows remote
adjustment of the output voltage and current via an
external voltage source. (Output power is also remotely
controllable with the CPC and APT options). In local
REMOTE MONITOR: Test points are made available
on the rear of the chassis for monitoring the voltage and
current output. (Output power monitor is included with
the CPC and APT option). The test points are always
positive regardless of the output polarity, where zero 0 to
10 volts equals 0-100% of output ±0.5%. Test points
have an output impedance of 5k ohms. See Figure 3.4 for
test point designation.
REMOTE CONTROL: Remote control of the POWER
ON, HIGH VOLTAGE ON and HIGH VOLTAGE OFF
can be accomplished via the rear panel interface. The
POWER ON control is an on-off toggle contact. HIGH
VOLTAGE OFF and HIGH VOLTAGE ON are
controlled by momentary normally closed normally open
contacts, respectively. See Figure 3.5 for recommended
interface.
EXTERNAL INHIBIT: Allows the user to inhibit the
power supply output without switching HIGH
VOLTAGE OFF control. This circuit can be used to
generate fast slewing output waveforms or control high
voltage generation as in Laser and Capacitor discharge
applications. The maximum inhibit rate should not
exceed 5Hz. Consult factory for higher repetition rates or
high pulse load applications. See Figure 3.6 for the
recommended interface circuit.
WARNING
It is extremely dangerous to use this
Inhibit circuit to inhibit high voltage
generation for the purpose of servicing
or approaching any area of load
considered unsafe during normal use.
XLG/XLF MANUAL 7 118020-001 REV E
Page 15
EXTERNAL INTERLOCK: Interlock connections are
provided on the terminal on the rear of the chassis for
connection to a safety switch. The unit will not operate
unless the interlock circuit is closed. If the interlock is
not being used, the jumper installed on the terminals
before shipping must be in place. If the jumper is
missing, or there is an open between the interlock
terminals the unit’s high voltage inverter will be disabled.
During high voltage operation, opening the interlock
circuit will cause the unit to revert to the HIGH
VOLTAGE OFF mode. Subsequent closing of the
interlock circuit will NOT return the unit to HIGH
VOLTAGE ON mode, this must be accomplished by
depressing the HIGH VOLTAGE ON switch. See Figure
3.7 for the recommended interface circuit.
ARC DETECT / ARC QUENCH ARC COUNT: The
ARC DETECT circuit senses dynamic arcing or
discharge conditions present at the output load. If an arc
occurs, the output is inhibited for one second. After the
one-second period, the output is ramped up to the
previous set level. This ramp is based on the standard
six-second slow start feature. The ARC DETECT ramp
circuit may be disabled by removing CR32 on the
Control/Power PWB. Caution should be observed if this
feature is disabled. Discharge rates of greater than 1 Hz
may cause excessive power dissipation in the power
supply’s output limiting resistors.
The ARC COUNT feature will allow the user to program
the ARC fault parameters. The ARC indicator on the
front panel will illuminate for approximately one second
after each arc has occurred. The power supply can be
programmed to trip to the POWER DOWN mode if an
arc occurs. The standard feature is programmed to trip
the power supply if 8 arcs occur within a twenty second
period.
REMOTE HIGH VOLTAGE ON & REMOTE HIGH
VOLTAGE OFF: Signals are provided for remote
monitoring of the HIGH VOLTAGE ON/OFF status. See
Figure 3.8 for recommended interface.
REMOTE MODE INDICATORS: Signals are
provided for remote indication of the control mode status,
voltage control, current control and power control. See
Figure 3.9 for the recommended interface.
Figure 3.1 Typical Operating Setup XLG
XLG/XLF MANUAL 8 118020-001 REV E
Page 16
Figure 3.2 Typical Operating Setup XLF
XLG/XLF MANUAL 9 118020-001 REV E
Page 17
JB1 SIGNAL SIGNAL PARAMETERS
1 Power Supply Common Signal Ground
2 External Inhibit Ground = Inhibit, Open = HV ON
3 External Interlock +15V at Open, <15mA at Closed
4 External Interlock Return Return for Interlock
5 Current Monitor 0 to 10V = 0 to 100% rated output
6 KV Test Point 0 to 10V = 0 to 100% rated output
7 + 10V Reference +10.24V, 1mA max.
8 Remote Current Program In 0 to 10V = 0 to 100% rated output
9 Local Current Program Out Front Panel Program Voltage
10 Remote Voltage Program In 0 to 10V = 0 to 100% rated output
11 Local Voltage Program Out Front Panel Program Voltage
12 Power Monitor 0 to 10V = 0 to 100% rated output
13 Remote Power Program In (Optional)
14 Local HV OFF Out +15V at Open, <25mA at Closed
15 HV OFF Connect to HV OFF for FP operation.
16 Remote HV ON +15V, 10mA max = HV ON
17 Remote HV OFF Indicator 0 = HV ON, +15V, 10mA max = HV OFF
18 Remote HV ON Indicator 0 = HV OFF, +15V, 10mA max = HV ON
19 Remote Voltage Mode Open Collector 50V max, 10mA max,
20 Remote Current Mode On = Active
21 Remote Power Mode
22 Remote PS Fault 0 = Fault, +15V, 1mA max = No Fault
23 + 15V Output +15V, 100mA max
24 Power Supply Common Signal Ground
Table 3.1 Rear Panel Interface
XLG/XLF MANUAL 10 118020-001 REV E
Page 18
Voltage Source 0-10V = 0-100% of Rated Output
It is recommended that analog signals be isolated
via isolation amplifiers.
JB1
1
PS Common
All cables should be shielded with the shields
being returned to the chassis ground of the
High Voltage Power Supply.
Remove jumpers for
remote programming
Figure 3.3A Wiring Diagram for Remote Programming Via Voltage Source
Fully Counterclockwise = Zero Output
Fully Clockwise = 100% of Rated Output
JB1
1
2
3
4
5
6
7
8
Z in = 10M Ohms
9
10
Z in = 10M Ohms
11
PS Common
v
Remote
Current
Program
V
Remote
Voltage
Program
10
11
2
3
4
5
6
7
8
9
20k Ohm
CW
+10.32V
1mA max.
Z in = 10M Ohms
Z in = 10M Ohms
Remote
Current
Control
All cables should be shielded with the shields
being returned to the chassis ground of the
High Voltage Power Supply.
If connections to external potentiometers are
excessively long (>10 ft), motorized
potentiometers are recommended.
Remove jumpers for
remote programming
Figure 3.3B Wiring Diagram for Remote Programming Via External Resistance
XLG/XLF MANUAL 11 118020-001 REV E
20k Ohm
Remote
Voltage
Control
CW
Page 19
It is recommended that analog signals be isolated
via isolation amplifiers.
All cables should be shielded with the shields
being returned to the chassis ground of the
High Voltage Power Supply.
Figure 3.4 Remote Monitor Test Point Designations
It is recommended to use relay contacts for S1 and S2.
Relays should be located as close as possible to the high
voltage power supply. Coils should be driven form
JB1
1
2
3
4
5
6
7
PS Common
Current
M
Monitor
Z out = 4.99k ohms ±0.1%
Z out = 4.99k ohms ±0.1%
isolated sources. Signals are at ¢ 15Vdc, 25mA max, and
are only to be used for contact closure.
S1 must be closed to enable HIGH VOLTAGE ON.
M
Voltage
Monitor
Remove jumper for remote
high voltage control
All cables should be shielded
with the shields being returned
to the chassis ground of the
High Voltage Power Supply.
Figure 3.5 Remote Control of High Voltage ON and High Voltage OFF Interface
JB1
14
15
16
17
S1
S2
S1=Remote High
Voltage Off
S2=Remote High
Voltage On
XLG/XLF MANUAL 12 118020-001 REV E
Page 20
Transistor should be located as close as possible
to the power supply.
All cables should be shielded with the shields
being returned to chassis ground of the
High Voltage Power Supply.
+15V
JB1
1
2
2.2K
3
High Voltage Power
Supply Internal inhibit circuitry.
4
Figure 3.6 External Inhibit Interface Circuit
It is recommemded to use relay contacts for S1. The relay
should be located as close as possible to the power supply.
Signals are ~15Vdc, 25mA max and are only to be used
for contact closure.
JB1
PS Common
Transistor
ON
Inhibits
High
Voltage
1
2
Remove jumper
for remote
external interlock
All cables should be shielded with the shields being returned
to chassis ground of the High Voltage Power Supply.
3
4
5
S1
S1 Open = Interlock Open
S1 Closed = Interlock Closed
Figure 3.7 External Interlock Interface
XLG/XLF MANUAL 13 118020-001 REV E
External Safety
Interlock Control
Page 21
12Vdc lamps or relay coils may replace opto-couplers.
Opto-couplers, lamps or relays should be located as close
as possible to the high voltage power supply.
All cables should be shielded with the shields being returned
to chassis ground of the High Voltage Power Supply.
JB1
PS Common
1
2
3
4
General Purpose
Opto-Coupler
5
To High Voltage
6
7
OFF Indicator
General Purpose
Opto-Coupler
8
To High
Voltage
ON
Indicator
P/O High Voltage
Power Supply
1K Ohm
1/4 W
1K Ohm
1/4 W
9
10
11
12
13
14
15
16
R Limit
17
R Limit
18
Signals are 15Vdc, 10mA max.
R Limit must be > 500 Ohms.
Figure 3.8 Remote High Voltage ON and Remote High Voltage OFF Indicator Circuit
XLG/XLF MANUAL 14 118020-001 REV E
Page 22
JB1
+15V, 100mA max.
23
Voltage Control
R1
R2
R3
19
20
21
R Limit
10mA max.
R Limit
10mA max.
R Limit
10mA max.
R limit must be > 1k Ohm
R1-R3=680 Ohm, 1/4W
Indicator
Current Control
Indicator
Power Control
Indicator
Figure 3.9 Remote Mode Indicators Interface
XLG/XLF MANUAL 15 118020-001 REV E
Page 23
Chapter 4
PRINCIPLES OF OPERATION
he XLG/XLF series of high voltage power supplies
utilizes sophisticated power conversion technology.
T
A variety of analog, digital and power conversion
techniques are used throughout. The intention of the
Principles of Operation is to introduce the basic function
blocks that comprise the XLG/XLF power supply. For
details on a specific circuit, consult Spellman’s
Engineering Department.
See Table 4.1 for a list of the main assemblies found in a
typical XLG/XLF power supply.
* Due to the many variations within the XLG/XLF series,
drawing numbers may differ from unit to unit.
The XLG/XLF power supply is basically an AC to DC
converter. Within the power supply, conversions of AC
to DC, then high frequency AC, then to high voltage DC
take place. By reviewing further the sub-assemblies, a
basic understanding of the process can be gained.
4.1 Chassis
The XLG/XLF is a compact, high efficiency, high voltage
power supply. The power supply can supply up to 600
watts of DC power. (Output power capability may be
higher or lower depending upon model ordered). Output
voltages of up to 130kV can be generated.
WARNING
The energy levels used and generated by the
power supply can be lethal! Do not attempt to
operate the power supply unless the user has a
sufficient knowledge of the dangers and hazards
of working with high voltage. Do not attempt to
approach or touch any internal or external
circuits or components that are connected or
have been connected to the power supply. Be
certain to discharge any stored energy that may
be present before and after the power supply is
used. Consult IEEE recommended practices for
safety in high voltage testing #510-1983.
4.2 Line Rectification and Filtering
Basic single phase rectification provides the DC voltage
for the high frequency inverter. The line input voltage
can vary from 90 up to 242 volts within the XLG/XLF
series.
In general, the following variations can be ordered:
100Vac ±10%, 50/60Hz, single phase.
115Vac ±10%, 50/60Hz, single phase.
200Vac ±10%, 50/60Hz, single phase.
220Vac ±10%, 50/60Hz, single phase.
Other input voltages can be accommodated. If the user is
unsure which input voltage option is supplied, check the
serial tag on the rear of the power supply or consult
Spellman’s Sales Department
Circuit protection is provided by CB1 (SYSTEM BLOCK
DIAGRAM CHASSIS XLG/XLF SCHEMATIC). CB1
is a fast acting magnetic trip type circuit breaker. The
line input is connected directly to the line side of CB1.
The load side of CB1 is connected to the
CONTROL/POWER PWB. The load side of CB1 is also
connected to T1. T1 is a step-down type line transformer.
T1 provides voltage for housekeeping and control circuit
power.
WARNING
LINE VOLTAGE IS PRESENT WHENEVER THE
POWER SUPPLY IS CONNECTED TO EXTERNAL
LINE VOLTAGES. BE SURE TO DISCONNECT
THE LINE CORD BEFORE OPENING THE UNIT.
ALLOW 5 MINUTES FOR INTERNAL
CAPACITANCE TO DISCHARGE BEFORE
REMOVING ANY COVER.
When CB1 is ON, voltage is applied to CR10. CR10 is
an isolated diode rectifier bridge that contains the rectifier
diodes used for line voltage rectification. The output of
CR10 is connected to a capacitor filter (C7 through C10).
Capacitors are initially charged through NTC type or
resistive inrush limiters.
Approximately 1 second after CB1 is turned on, a relay is
energized to short the NTC or resistor limiters. This relay
is K1. This DC voltage is supplied to the high frequency
inverter.
The DC rails are connected to the high frequency rail
capacitors. These capacitors are high frequency, low loss
type. Capacitors C11, C12, C54, and C55 provide the
energy storage for the high frequency inverter.
The inverter is a series resonant, series/parallel loaded
topology. A proprietary control scheme is used for
regulating the power generated from the inverter. Q2,
Q3, Q4, and Q5 are high speed Mosfets. These devices
provide high frequency switching to control the resonant
current flow. The typical resonant operating period is
approximately 10uSeconds. The gate control for the
switching devices is provided by T2 on the
CONTROL/POWER PWB. The CONTROL/POWER
PWB also provides circuitry for sensing shoot thru and
over current conditions in the inverter. U10 and its
associated circuitry automatically shutdown the inverter.
U18 provides for the gates high current pulse
requirements. T2 provides line voltage isolation
4.4 High Voltage Transformer
The output of the High Frequency Resonant Inverter is
connected to the primary of the High Voltage
Transformer. The High Voltage Transformer is a step-up
type. Typically secondary voltages are in the range of
1kV to 4.5kV depending upon output voltage ratings.
4.5 High Voltage Assembly
The High Voltage Assembly will vary depending upon
the model ordered. The circuitry typically consists of a
full wave, full bridge. The higher voltage ranges utilize
various parallel, series arrangements of a full wave
voltage doubler.
Output filtering is typically provided by an R-C type
filter. Voltage feedback for regulation and monitoring is
provided by a high bandwidth resistive/capacitiv e divider.
Current feedback for regulation and monitoring is
provided by a sense resistor connected at the low voltage
end of the High Voltage Rectifier/Multiplier Circuit.
4.6 Control/Power PWB
The majority of control circuits for power supply controls
are located on the CONTROL/POWER PWB.
+15VDC, -15VDC, and +10VDC is generated on the
CONTROL/POWER PWB. High Voltage On/Off control
is accomplished by K3, and its associated circuitry.
Interlock control is provided by K4.
Voltage feedback from the high voltage divider is sent to
U6. Gain adjust is provided on the HV PWB. The KV
feedback signal is sent to the front panel DVM and to the
REAR PANEL TERMINAL BLOCK for remote
monitoring. K2 provides switching between feedback
and program signal for the front panel DVM’s. This
allows the user to preset the desired output before
energizing high voltage.
Program voltages are typically ramped up to set level by
the slow start circuits of U7.
Arc sense circuits U14 and U23 provide sensing, quench
and indication of arc conditions. Consult operation
manual for a detailed description of the arc sense control.
Current feedback from the high voltage rectifier is sent to
sense resistors located on the High Voltage Assembly.
Calibrated feedback is then sent to U4.
An overvoltage protection circuit provides protection in
the unlikely event of a main control loop failure. U9
provides gain adjustments for the overvoltage protection
(OVP) control.
XLG/XLF MANUAL 17 118020-001 REV E
Page 25
U12 and U13 circuits provide visual indication of the
control mode, which is in operation. These signals are
sent to the FRONT PANEL ASSEMBLY for front panel
status indication.
The resonant control circuitry consists of a voltage to
pulse width converter. U17 generates all frequency and
pulse width control signals. U16 provides specific
control functions for the resonant control.
Power supply inhibit circuits are provided by U22 and
K3. System Fault Control and Indication is provided by
U19m U20, and U21 and associated circuitry. Diagnostic
signals are latched and then sent to the FRONT PANEL
ASSEMBLY for status indication.
4.7 Front Panel Assembly
Front Panel control meters, and status indications are
connected to the FRONT PANEL PWB. The FRONT
PANEL PWB interfaces directly to the
CONTROL/POWER PWB.
4.8 Filament Supply PWB
The power for the X-ray tube is provided by the filament
inverter. The filament inverter is a high frequency, series
resonant inverter. The inverter provides regulated current
to the primary of the filament transformer. The filament
isolation transformer is then connected to the output
connector.
4.9 Options
Due to the many variations of models and options
provided in the XLG/XLF series, details of actual circuits
used may differ slightly from above descriptions. Consult
Spellman’s Engineering Department for questions
regarding the principles of operations for the XLG/XLF
series.
XLG/XLF MANUAL 18 118020-001 REV E
Page 26
Chapter 5
OPTIONS
He options available for this power supply are
described in this section. Interface diagrams are
T
shown where required. Options are specified by
including the option code in the model number as
described in Section 1.5.
5.1 Adjustable Overload Trip
AOL
The overload trip protection feature rapidly shuts down
the high voltage output when the load current exceeds the
limit set by the current control dial on the front panel. A
fast acting circuit inhibits the generation of high voltage
and reverts the unit to POWER DOWN mode,
illuminating the OVER CURRENT indicator. When
adjustable overload trip is provided, it replaces the
standard current regulation feature.
5.2 220V AC Single Phase Input
220
XLG/XLF power supplies with the 220 V AC input
option will operate from an input voltage of 220VAC rms
±10%, 50-60hZ, single phase.
5.3 No Slow Start NSS
The no slow start option causes the output voltage of the
power supply to rise (within 50 msec) to the rated voltage
upon depressing the HIGH VOLTAGE ON Switch.
5.4 Non-Standard Slow Start
SS(x)
5.6 Adjustable Power Trip
APT
The power control options allow monitoring and control
of the power supply output power. The APT option
allows the user to remotely adjust the power limit for the
power supply. If the power limit is exceeded, the unit
will shut down with an OVERPOWER fault. See Figure
5.2 or remote interface.
5.7 Arc Trip Option AT
When this option is ordered, the ARC Count circuit is set
so the unit trips to Standby after 1 count.
One of the applications for this option is for sensing
material breakdown under an applied high voltage.
5.8 Instant On IO
When the Instant On option is ordered, the High Voltage
is enabled as soon as line voltage is applied when the
circuit breaker is in the ON position.
To enable Instant ON, keep the jumper between JB1-14
and JB1-15 attached. Connect an additional jumper from
JB1-15 to JB1-16 as shown in Figure 5.1
CAUTION
The Power Supply will generate programmed High
Voltage whenever the circuit breaker is in the ON
position, and line voltage is applied.
The non-standard slow start option allows the gradual rise
time of the output voltage to be different from the
standard of six seconds. To order the option, place the
time desired in seconds after the suffix letter; i.e. SS(10)
denotes a 10 second rise time.
5.5 Extra Length Output Cable
LL(ft)
Standard output cable is 10’ of shielded high voltage
cable. Other lengths may be specified in multiples of 10
feet.
XLG/XLF MANUAL 19 118020-001 REV E
5.9 Custom Designed Models X(#)
Units built to customer specifications are assigned an X
number be the factory. If this unit is an X model,
specification control sheet is added at the end of this
instruction manual.
Spellman welcomes the opportunity to tailor units to fit
your requirements or to develop new products for your
applications. Contact Spellman Sales Department with
your needs.
Remove internal
jumper, JP1 ON
Control/Pwr Pwb
for remote programming.
(Jumper connects internat
pot factory set at 103%
of max power).
1
2
12
13
3
4
5
6
Z in = 10M ohms
7
Remote
Power
Monitor
M
0-10V=0-100%
power output
Zout=4.99k Ohms, 0.1%
V
Figure 5.2 Adjustable Power Remote Interface
Remote
Power
Program
20k Ohm
min.
Remote Pwr
Program
potentiometer
XLG/XLF MANUAL 20 118020-001 REV E
Page 28
Chapter 6
MAINTENANCE
his section describes periodic servicing and
performance testing procedures.
T
WARNING
THIS POWER SUPPLY GENERATES VOLTAGES
THAT ARE DANGEROUS AND MAY BE FATAL.
OBSERVE EXTREME CAUTION WHEN
WORKING WITH HIGH VOLTAGE.
6.1 Periodic Servicing
Approximately once a year (more often in high dust
environments), disconnect the power to the unit and
remove the top cover. Use compressed air to blow dust
out of the inside of the unit. Avoid touching or handling
the high voltage assembly. Be sure that the fan is not
obstructed and spins freely. The fan has sealed bearings
and does not need lubrication. Be sure to replace the top
cover before operating for proper cooling.
6.2 Performance Test
WARNING
HIGH VOLTAGE IS DANGEROUS.
ONLY QUALIFIED PERSONNEL SHOULD
PERFORM THESE TESTS.
High voltage test procedures are described in Bulletin
STP-783, Standard Test Procedures for High Voltage
Power Supplies. Copies can be obtained from the
Spellman Customer Service Department. Test equipment,
including an oscilloscope, a high impedance voltmeter,
and a high voltage divider such as the Spellman HVD100 or HVD-200, is needed for performance tests. All
test components must be rated for operating voltage.
6.3 High Voltage Dividers
High voltage dividers for precise measurements of output
voltage with an accuracy up to 0.1% are available from
Spellman. The HVD-100 is used for voltages up to
100KV. The HVD-200 measures up to 200KV. The
Spellman divider is designed for use with differential
voltmeters or high impedance digital voltmeters. The
high input impedance is ideal for measuring high voltage
low current sources, which would be overloaded by
traditional lower impedance dividers.
XLG/XLF MANUAL 21 118020-001 REV E
Page 29
Chapter 7
REPLACEMENT PARTS
7.1 Replacement Parts
otact the Spellman Customer Service Department for
parts lists for specific models.
C
Spellman provides parts and subassemblies for its high
voltage power supplies but recommends that only
qualified personnel perform the repair. High voltage is
dangerous; even minor mistakes in repairs can have
serious consequences.
When requesting parts please give the model number and
serial number of the power supply
7.2 Correspondence and
Ordering Spare Parts
Each Spellman power supply has an identification label
on the rear of the chassis that bears its model and serial
number.
When requesting engineering or applications information,
please state the model and serial number of the power
supply. If specific components or circuit sections are
involved in the inquiry, it is helpful to indicate the
component symbol number(s) shown on the applicable
schematic diagram.
When ordering spare parts, please specify the part’s
description, the part’s reference designation or part
number, and the model and serial number of the unit.
XLG/XLF MANUAL 22 118020-001 REV E
Page 30
Chapter 8
FACTORY SERVICE
8.1 Warranty Repairs
During the Warranty period, Spellman will repair all units
free of charge. The Warranty is void if the unit is worked
on by other than Spellman personnel. See the Warranty
in the rear of this manual for more information. Follow
the return procedures described in Section 8.2. The
customer shall pay for shipping to and from Spellman.
8.2 Factory Service Procedures
Spellman has a well-equipped factory repair department.
If a unit is returned to the factory for calibration or repair,
a detailed description of the specific problem should be
attached.
For all units returned for repair, please obtain an
authorization to ship from the Customer Service
Department, either by phone or mail prior to shipping.
When you call, please state the model and serial numbers,
which are on the plate on the rear of the power supply,
and the purchase order number for the repair. A Return
Material Authorization Code Number (RMA Number) is
needed for all returns. This RMA Number should be
marked clearly on the outside of the shipping container.
Packages received without an RMA Number will be
returned to the customer. The Customer shall pay for
shipping to and from Spellman.
A preliminary estimate for repairs will be given by phone
by Customer Service. A purchase order for this amount is
requested upon issuance of the RMA Number. A more
detailed estimate will be made when the power supply is
received at the Spellman Repair Center. In the event that
repair work is extensive, Spellman will call to seek
additional authorization from your company before
completing the repairs.
8.3 Ordering Options and
Modifications
Many of the options listed in Chapter 5 can b e retrofitted
into Spellman power supplies by our factory. For prices
and arrangements, contact our Sales Department.
8.4 Shipping Instructions
All power supplies returned to Spellman must be sent
shipping prepaid. Pack the units carefully and securely in
a suitable container, preferably in the original container, if
available. The power supply should be surrounded by at
least four inches of shock absorbing material. Please
return all associated materials, i.e. high voltage output
cables, interconnection cables, etc., so that we can
examine and test the entire system.
All correspondence and phone calls should be directed to:
Spellman High Voltage Electronics Corp.
475 Wireless Boulevard
Hauppauge, New York 11788
TEL: (631) 630-3000 FAX: (631) 435-1620
E-Mail: sales@Spellmanhv.com
http://www.spellmanhv.com
XLG/XLF MANUAL 23 118020-001 REV E
Page 31
SPELLMAN HIGH VOLTAGE ELECTRONICS
WARRANTY
Spellman High Voltage Electronics (“Spellman”) warrants that all power supplies it manufactures will be
free from defects in materials and factory workmanship, and agrees to repair or replace, without charge, any
power supply that under normal use, operating conditions and maintenance reveals during the warranty
period a defect in materials or factory workmanship. The warranty period is twelve (12) months from the
date of shipment of the power supply. With respect to standard SL power supplies (not customized) the
warranty period is thirty-six (36) months from the date of shipment of the power supply.
For all Spellman LPX products that incorporate an X-Ray Tube, the standard Spellman Warranty does not apply to
the X-Ray tube for which the orig inal manufacturer’s warra nty applies. Spellman specifically disclaims any direct
warranty for such tubes. In the event of a tube failure within one year from shipping date, provided there is no
evidence of misuse or abuse, the tube will be replaced according to the terms of the original tube manufacturer’s
warranty to Spell m an.
This warranty does not apply to any power supply that has been:
Disassembled, altered, tampered, repaired or worked on by persons unauthorized by Spellman;
subjected to misuse, negligent handling, or accident not caused by the power supply;
installed, connected, adjusted, or used other than in accordance with the original intended application and/or
instructions furnished by Spellman.
THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
THOSE OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
The buyer’s sole remedy for a claimed breach of this warranty, and Spellman’s sole liability is limited, at
Spellman’s discretion, to a refund of the purchase price or the repair or replacement of the power supply at
Spellman’s cost. The buyer will be responsible for shipping charges to and from Spellman’s plant. The
buyer will not be entitled to make claim for, or recover, any anticipatory profits, or incidental, special or
consequential damages resulting from, or in any way relating to, an alleged breach of this warra nty.
No modification, amendment, supplement, addition, or other variation of this warranty will be binding unless
it is set forth in a written instrument signed by an authorized officer of Spellman.
For an authorization to ship contact Spellman’s Customer Service Department. Please state the model and
serial numbers, which are on the plate on the rear panel of the power supply and the reason for return. A
Return Material Authorization Code Number (RMA number) is needed from Spellman for all returns. The
RMA number should be marked clearly on the outside of the shipping container. Packages received without
an RMA Number may delay return of the product. The buyer shall pay shipping costs to and from Spellman.
Customer Service will provide the Standard Cost for out-of-warranty repairs. A purchase order for this
amount is requested upon issuance of the RMA Number (in-warranty returns must also be accompanied by
a “zero-value” purchase order). A more detailed estimate may be made when the power supply is received
at Spellman. In the event that the cost of the actual repair exceeds the estimate, Spellman will contact the
customer to authorize the repair.
Spellman will warrant for three (3) months or balance of product warranty, whichever is longer, the repaired
assembly/part/unit. If the same problem shall occur within this warranty period Spellman shall undertake all
the work to rectify the problem with no charge and/or cost to the buyer. Should the cause of the problem be
proven to have a source different from the one that has caused the previous problem and/or negligence of
the buyer, Spellman will be entitled to be paid for the repair.
For a complete listing of Spellman’s Global Service facilities please go to: