TDK-Lambda 802 Series Operator's Manual

OPERATOR MANUAL FOR

802 Series High Voltage

POWER SUPPLY

Document: 83488001 Rev N

TDK-LAMBDA AMERICAS

405 Essex Road, Neptune, NJ 07753

Tel: [phone]
Fax: [phone]

Web: www.us.tdk-lambda.com/hp

PAGE LEFT INTENTIONALLY BLANK

83-000-005 Rev F

ONE YEAR WARRANTY

TDK-Lambda Americas

, Inc. (405 Essex Road, Neptune, N.J. 07753), warrants that the unit is free from defects in

material or workmanship for a period of ONE YEAR from the date of initial shipment.

TDK-Lambda Americas

Inc.

will

service and,

at its option, repair or replace parts which prove to be defective. This will be done free of charge during

the stated warranty period. This warranty excludes defects resulting from mi

s

use, unauthorized modification,

operation outside the environmental or

safety specifications of the power supply, or improper site preparation or

maintenance. The customer shall contact

TDK-Lambda Americas Inc.

, for warranty service or repair as described in

the RETURNING EQUIPMENT section. The customer shall prepay shipping

charges. If the unit is covered under the

foregoing warranty, then

TDK-Lambda Americas Inc.

shall pay the return shipping charges.

The “WARRANTY”, “CLAIM FOR DAMAGE IN SHIPMENT”, and “RETURNING EQUIPMENT” i

n

formation applies to

equipment purchased directl

y from

TDK-Lambda Americas Inc

. End users receiving equi

p

ment from a third party

should consult the appropriate service organization for assistance with these issues.

THIS LIMITED WARRANTY IS IN LIEU OF, AND

TDK

-

LAMBDA AMERICAS INC.

DISCLAIMS AND EXCLUDES

,

ALL OTHER WARRANTIES, STATUTORY, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ANY

WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, OR OF CONFORMITY TO

MODELS OR SAMPLES.

CERTIFICATION

All test and measuring equipment used by

TDK-La

mbda Americas

Inc.

for Final Acceptance Testing are traceable to

primary standards certified by the National Institute of Standards and Technology.

LETHAL VOLTAGES PRESENT!

All power supplies contain hazardous voltage and energy. The power supply must

only be operated by qualified

personnel who have read this operator’s manual and are familiar with the operation, hazards and application of the

power supply. Proper care and jud

g

ment must always be observed.

1.

Before connecting input AC power, ensure all c

overs are in place and securely fastened. E

n

sure the required

safety ground to chassis is installed and sufficient cooling is su

p

plied.

2.

Proper grounding from the input AC power is required to reduce the risk of electric shock, and to comply with

safety age

ncy and code requirements.

3.

Use extreme caution when connecting input AC power. Only apply the input voltage specified on the rating label.

4.

Use extreme caution when connecting any high voltage cables. Never handle any output c

a

bles when the power

supply is

operating.

5.

After a power supply is switched OFF, its output section will retain a charge which may be lethal. Allow sufficient

time for self

-

discharge before handling anything connected to the output. The di

s

charge time specified in the

Safety Notes does

NOTinclude extra time required to discharge the energy stored in the user’s load.

6.

When user serviceable fuses are present, always replace fuses with the same type and Volt/Amp ra

t

ing.7.Never attempt to operate the power supply in any manner not described in

this manual.

8.

Never remove DANGER or WARNING labels from the power supply. Replace lost or damaged labels

immediately. Contact

TDK-Lambda Americas

Customer Service for replacement labels.

9.

The power supply may be serviced only by

TDK-Lambda Americas Inc.

fa

ctory qualified service personnel.

Breaking the warranty seal will void the warranty. Prior to opening the power supply, contact

TDK-Lambda

Americas

Inc.

Customer Service for a written Service Waiver and a replacement warranty seal.

TDK-Lambda

MANUFACTURER'S PRODUCT DECLARATION

INTENDED PURPOSE (USE)

The Power Supplies described by this manual are defined by TDK-Lambda Americas Inc.
as a component for use in the composition of an apparatus as defined in Article 1 (1) of
the EMC Directive (89/336/EEC). These products, as individual components, do not
perform in themselves a direct function for the user of the end product. They are not
intended to be placed on the market with a direct function to a final user! As such, the
products described by this manual are not subject to the provisions of the EMC Directive
(89/336/EEC, with amendment 92/31/EEC).

The products described by this manual are intended for incorporation into a final product
by a professional assembler. It is the responsibility of the assembler to ensure that the
final apparatus or system incorporating our products complies with all relevant EMC
standards for that final product.

OPERATING ENVIRONMENT

The operating environment as defined by TDK-Lambda Americas Inc., for the products
described by this manual is stated as follows:

The Power Supplies described by this manual are intended for use in a protected
industrial environment or in proximity to industrial power installations. These locations are
often referred to as industrial locations containing establishments that are not connected
to the low voltage public mains network.

Industrial locations are characterized by the existence of one or more of the following
conditions:

1) industrial, scientific and medical (ISM) apparatus are present;

2) heavy inductive or capacitive loads are frequently switched;

3) currents and associated magnetic fields are high;

4) location supplied by their own transformer.

These components are not intended for connection to a public mains network, but are
intended to be connected to a power network supplied from a high or medium-voltage
transformer dedicated for the supply of an installation feeding manufacturing or similar
operations. They are suitable for use in all establishments other than domestic and those
directly connected to a low voltage power supply network which supplies buildings used
for domestic purposes.

Page: 83-000-006 Rev D

TDK-Lambda

Description of symbols used in product labeling

SYMBOL PUBLICATION DESCRIPTION

EC Council
Directive 93/68/EEC

European Community
Conformity Assessment
Product Mark

IEC 348 Attention, consult

Accompanying documents

IEC 60417-1-5036 Dangerous voltage

IEC 60417-1-5019 Protective earth

(e.g. power line earth ground)

IEC 60417-1-5017 Functional earth

IEC 60417-1-5134 Electrostatic Discharge

(e.g. chassis ground)

(ESD) Sensitive Device

Page: 83-000-007 Rev E

ELECTRICAL STANDARDS

All company primary standards are either certified or are traceable to certification by the
National Institute of Standards and Technology.

CLAIM FOR DAMAGE IN SHIPMENT

This instrument received comprehensive mechanical and electrical inspection before
shipment. Immediately upon receipt from the carrier, and before operation, this instrument
should be inspected visually for damage caused in shipment. If such inspection reveals
damage in any way, a claim should be filed with the carrier. A full report of damage should
be obtained by the claim agent and this report should be forwarded to us. We will then
provide a disposition of the equipment and arrange for repair or replacement.

When referring to this equipment, always include the model and serial numbers.

The “WARRANTY”, “CLAIM FOR DAMAGE IN SHIPMENT”, and “RETURNING
EQUIPMENT” information applies to equipment purchased directly from TDK­Lambda Americas Inc. End users receiving equipment from a third party should
consult the appropriate service organization for assistance with these issues.

RETURNING EQUIPMENT

Before returning any equipment to the factory, the following steps shall be taken.

1.

Notify TDK-Lambda Americas Inc. at 732-918-6888 or follow the instructions at

www.US.TDK-Lambda.com/HP/service.htm. Give a full description of the difficulty

including the model and serial number of the unit in question. Upon receipt of this
information, we will assign a Return Material Authorization (RMA) number and
provide shipping instructions.

2.

The customer shall prepay shipping charges. Equipment returned to us must be
packed in a manner to reach us without damage. The shipping container must be
marked with the RMA number in an area approximate to the shipping label with
numbers that are easy to read. All returned units that do not show the RMA number
on the outside of the container will be refused.

If the equipment is repaired within the warranty agreement, than TDK-Lambda
Americas Inc. shall pay for the return shipping to the customer.

3.

For non-warranty repairs, we will submit a cost estimate for your approval prior to
proceeding. The customer shall pay return shipping charges.

MECHANICAL INSTALLATION

Most power supplies are heavy and, when rack mounted, they should be supported by
rails along the sides of the supply from front to rear. The rails must adequately support the
unit and not block airflow. Do not support the power supply from the front panel only.

Page: 83-000-011 Rev K

Table of Contents

1. GENERAL INFORMATION ................................................................................. 5

1.1. User Manual Content .......................................................................................... 5

1.2. Introduction ......................................................................................................... 5

1.3. 802 Overview ...................................................................................................... 6

1.4. Capacitor Charging Technology .......................................................................... 6

1.5. Continuous DC Operation ................................................................................... 7

1.6. Additional Features: ............................................................................................ 7

1.7. Safety Precautions .............................................................................................. 7

1.8. Model Number Format ........................................................................................ 8

2. SPECIFICATION ................................................................................................. 9

2.1. Average Charging Power .................................................................................... 9

2.2. Peak Charging Power ......................................................................................... 9

2.3. Average DC Power .............................................................................................. 9

2.4. Output Voltage Range ......................................................................................... 9

2.5. Polarity ................................................................................................................ 9

2.6. HV Output Cable ................................................................................................. 9

2.7. HV Insulating Medium ......................................................................................... 9

2.8. AC Input Voltage ................................................................................................. 9

2.9. AC Input Current ................................................................................................. 9

2.10. AC Connector ...................................................................................................... 9

2.11. AC Line Contactor ............................................................................................... 9

2.12. Power Factor ....................................................................................................... 9

2.13. Efficiency ............................................................................................................. 9

2.14. Front Panel.......................................................................................................... 9

2.15. Stability ............................................................................................................... 9

2.16. Temperature Coefficient ...................................................................................... 9

2.17. Stored Energy ................................................................ ..................................... 9

2.18. Pulse to Pulse Repeatability ................................................................................ 9

2.19. Dimensions - inches (mm) ................................................................................... 9

2.20. Weight - lbs (kg) .................................................................................................. 9

2.21. Ambient Temperature .......................................................................................... 9

2.22. Altitude ................................................................................................................ 9

2.23. Humidity .............................................................................................................. 9

2.24. Protection ................................................................ ............................................ 9

2.25. Remote Control (all models) ................................................................................ 9

2.26. Accessories ......................................................................................................... 9

2.27. Options .............................................................................................................. 10

2.28. Ordering Info ..................................................................................................... 10

2.29. Ordering Examples ............................................................................................ 10

3. OUT OF BOX INSPECTION ............................................................................. 11

3.1. Visual Inspection ............................................................................................... 11

3.2. Electrical Inspection .......................................................................................... 11

3.3. Contacting TDK-Lambda Americas Customer Service ...................................... 12

3.4. Returning Defective Units .................................................................................. 12

4. INSTALLATION ................................................................................................. 13

4.1. 19-Inch Rack Mounting ..................................................................................... 13

4.2. Ventilation Requirements .................................................................................. 15

4.3. Orientation......................................................................................................... 15

4.4. AC Power Connection ....................................................................................... 15

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4.5. Connecting the High Voltage Output ................................................................. 17

5. CONTROLS, INDICATORS, CONNECTORS ................................................... 19

5.1. Front Panel Layout (L Model) ............................................................................ 19

5.2. HV ON Push Button (Ref 1) ............................................................................... 20

5.3. Status LEDs (Ref 2) .......................................................................................... 20

5.4. Local Voltage Set (Ref 3) .................................................................................. 21

5.5. Voltage bar graph (Ref 4) .................................................................................. 21

5.6. Voltage Display (Ref 5) ..................................................................................... 21

5.7. HV OFF Push Button (Ref 6) ............................................................................. 21

5.8. Off/Local/Remote Keyswitch (Ref 7) .................................................................. 21

5.9. View set push button (Ref 8) ............................................................................. 21

5.10. Current bar graph (Ref 9) .................................................................................. 21

5.11. Current Display (Ref 10) .................................................................................... 22

5.12. Power switch (Ref 11) ....................................................................................... 22

5.13. Front Panel Layout (S Model) ............................................................................ 22

5.14. Front Panel Layout (OEM Model) ...................................................................... 22

5.15. Rear Panel Layout (L Models) ........................................................................... 23

5.16. Rear Panel Layout (S Models)........................................................................... 25

5.17. Rear Panel Layout (OEM Models) ..................................................................... 26

5.18. REMOTE CONTROL CONNECTOR PIN DIAGRAM ........................................ 27

6. OPERATING INSTRUCTIONS .......................................................................... 29

6.1. Local Operation (802L only) .............................................................................. 29

6.2. Remote Operation (All models) ......................................................................... 30

6.3. Remote Control Sequence ................................................................................ 33

6.4. Parallel Operation.............................................................................................. 34

7. APPLICATION NOTES ..................................................................................... 39

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List of Figures

Figure 1. 802L Front View ................................................................................................ .................. 13

Figure 2. 802L Rear View .................................................................................................................. 14

Figure 3. 802L Side View ................................................................................................................... 14

Figure 4 AC Input Terminal Block ..................................................................................................... 16

Figure 5 Typical Load Circuit Connection .......................................................................................... 17

Figure 6 802L Front Panel Controls and Indicators ........................................................................... 19

Figure 7 Front Panel Controls and Indicators (S Model) .................................................................... 22

Figure 8 802L Rear Panel Connections ............................................................................................ 23

Figure 9 802S Rear Panel ................................................................................................................. 25

Figure 10 802OEM Rear Panel ......................................................................................................... 26

Figure 11 Remote Interface Connector and Signals. ......................................................................... 27

Figure 12 Suggested external remote interface circuit. ..................................................................... 31

Figure 13 Typical remote Interface waveforms .................................................................................. 34

Figure 14 802L Parallel System Control Connections. ...................................................................... 35

Figure 15 802L and 802S/OEM Parallel System control Connections. .............................................. 36

Figure 16 Parallel Operation Connections for 802S/OEM Supplies ................................................... 37

List of Tables

Table 1 :802 Model Description Format . ............................................................................................. 8

Table 2 Recommended AC Input Cable ............................................................................................. 16

Table 3 Front Panel Controls and Indicator Functions (L Model) ........................................................ 19

Table 4 Front Panel Controls and Indicators (S Model) ...................................................................... 22

Table 5 802L Rear panel Functions ................................................................................................... 23

Table 6 802 Remote Interface Description ........................................................................................ 31

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Notes

4

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1. GENERAL INFORMATION

1.1. User Manual Content

This User’s Manual contains the operating instructions, installation instructions and
specifications for the ALE 802 series high voltage power supply. The instructions refer to
standard power supply models, and include checkout, installation, and operation of the 802
series. Suggestions and requirements for connecting AC power, load cables and signal
cables are given. Various operating modes and programming modes are described.

The model 802 is just one model in a broad family of HV power supplies covering the power
range from 500J/sec to 30kJ/sec in a single package, and to 1MW and beyond in parallel
systems. For more information please visit our web site at:

http://www.us.tdk-lambda.com/hp/product_html/high_volt.htm.

This manual contains information, instructions and diagrams which apply to standard

constructions. If special features or modifications have been installed, the instructions

specific to that modification are contained in Addenda and take precedence if conflicts

exist. Please take care to refer to the correct information for your unit.

NOTE

1.2. Introduction

TDK-Lambda Americas ALE model 802 are state of the art constant current switch mode
high voltage power supplies, designed to rapidly and efficiently charge capacitors in laser
systems, modulators, pulse forming networks, and a broad range of pulse generator circuits,
without the need for a series current limiting resistor. They can also be used in many
continuous DC applications including beam power for RF devices such as magnetrons,
gyrotrons, klystrons and electron beam loads.

The 802 series utilize a high frequency IGBT based series resonant inverter topology which
operates as a constant current source. This makes the supply perfect for rapidly charging
capacitors which represent a challenging load for conventional HV DC supplies using
multiplier designs.

The 802 series is available with a choice of three different front panel configurations
designed to suit different applications and end uses. All models feature the same
comprehensive remote control interface which is detailed in Section 6.2.

The 802L Model is fully instrumented with front panel meters displaying output voltage and
current, status LEDs, a key switch for OFF, LOCAL or REMOTE operation, HV ON/OFF
push-button switches, and a 10 Turn output voltage control. The rear panel features external
interlock, inhibit, remote control and slave (parallel operation) control connections.

The 802S Model can only be operated by remote control and features only status LEDs and
a power switch on the front panel. The "S" Models have been designed to operate as a slave
unit to the "L" Models or in systems where local control is not a requirement.

The 802OEM features a blank aluminum front panel and can only be operated by remote
control.

As many 802 supplies as required, can be connected in parallel to provide greater output
power.

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1.3. 802 Overview

1.3.1. Features

 8kJ/sec capacitor charging power, 8kW in continuous DC applications.
 Output voltages from 0-1kV to 0-50kV.
 Rep rates from single shot to kilohertz.
 Local (L Model) or remote operation with comprehensive control interface.
 Cost effective blank front panel version for OEM applications.
 Constant current topology for rapid efficient charging.
 Parallel operation (master/slave) for high power applications.
 Compact Air Cooled design.
 Passive Power Factor Correction reduces RMS current draw.

1.3.2. Benefits

 Lightweight switchmode design.
 Rack mount chassis configuration.
 Low stored energy provides greater safety.
 Constant current design eliminates series current limit resistance in charge circuit.
 Immunity to external EMI.

1.3.3. Applications

 Charging capacitors and capacitor banks.
 Powering pulse forming networks/modulators.
 Powering lasers: Excimer, flashlamp pumped dye, Yag, CO2, etc.
 Continuous power for RF tubes – magnetron, gyrotron, TWT, klystron etc.
 Electron beam applications.
 DC power source for pulsed hard-tube and solid state modulators.

1.4. Capacitor Charging Technology

Capacitor charging applications require a power supply designed specifically for the task.
The 802 series supplies allow capacitors to be charged in pulse forming networks and
modulators in a very fast, efficient and controllable manner.

The units are compact high power constant current sources that can linearly and rapidly
charge a capacitive load to high voltage. Once the load capacitor is charged to the
programmed voltage, the supply will switch over to a voltage regulation mode and maintain
the load voltage at the programmed level until it is discharged.

The flexible design of the 802 allows the unit to be ordered with (L model) or without (S and
OEM model) the front panel controls and meters. Front panel controls are ideal in
applications where local control and read backs are necessary, such as R&D, laboratory
use and diagnostics. All front panel controls and indicator signals are available at the rear
panel remote control connector regardless which panel option (L, S, or OEM) is selected.

The unit is self-contained, requiring only AC power and appropriate controls. Several units
may be connected in parallel for higher power operation. There is no theoretical limit to the
number of units that may be paralleled. Typically one master unit and one or more slave or
OEM units may be used to obtain as much output power as necessary. The 802 is also
ideally suited to charge reservoir capacitors in resonant charging circuits where high rep
rates (several kilohertz) are required, such as in metal vapor lasers or solid-state
modulators.

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All 802 power supplies are designed to minimize the risk of fire or shock
hazard. This instrument received comprehensive mechanical and
electrical inspection prior to shipment. Nevertheless, certain safety
precautions must be observed. Only TECHNICALLY QUALIFIED
SERVICE PERSONNEL familiar with the principles of electrical safety
should operate this supply. The power supply SHOULD NOT BE
EXPOSED TO WATER OR MOISTURE OR DUSTY ENVIRONMENTS.
Electrical safety must be maintained at all times.

Lethal voltages are developed within the power supply's enclosure and
at the output cable. Therefore, the cover may not be removed by the
user (see Warranty in preamble section for variance). Also, the large
capacitors in the supply may store power even after the AC input line is
removed. ALLOW AT LEAST 40 SECONDS DISCHARGE TIME
between removing the AC input line and opening the cover. ALSO,
ALLOW AT LEAST 40 SECONDS between switching the AC power off
and switching it on again.

1.5. Continuous DC Operation

Although the 802 series has been designed for capacitor charging applications, they can
also be used as a continuous DC High Power Source for RF tubes such as klystrons,
TWTs, or other DC loads such as DC-DC converters. The DC option must be specified
when ordering, and the supply will be factory setup and tested with a continuous DC load.
When 802 supplies are operated in continuous DC applications it is often necessary to add
an external capacitor between the load and ground to improve the ripple performance of
the unit. Our online Application Note 505 describes operating capacitor charging supplies
in DC applications, and gives guidance in determining the size of any additional external
filter capacitance required. App Note 505 can be found at:

http://www.us.tdk-lambda.com/hp/pdfs/application%20notes/93008505rC.pdf

Consult the factory before connecting parallel units in continuous DC applications.

1.6. Additional Features:

 Internal contactor and fuses for AC disconnect and protection
 Standard AC power and control connectors
 Documentation Manual Including -
 Installation, check out, suggested remote interfaces and control circuits
 10 ft (3m). Output cable is standard, other lengths are optional.

1.7. Safety Precautions

1.7.1. This product is designed for Indoor use.

1.7.2. This product is designed for pollution degree 2.

1.7.3. This product is designed for Transient Overvoltage Category II

1.7.4. Ensure all covers are in place and securely fastened before switching ON the AC
power.

1.7.5. Proper grounding from the input AC power is required to reduce the risk of electric
shock. Ensure that the AC Protective Earth Ground connection has at least the same
gauge wire as the supply leads shown in Table 2.

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7

1.7.6. Use extreme caution when connecting AC input power, and never apply the incorrect
input voltage, refer to ratings label.

1.7.7. Use extreme caution when connecting the high voltage output cable to the load.

1.7.8. Ensure all load capacitors are completely discharged prior to connection. Never
handle the output cable when the power supply is operating.

1.7.9. Never attempt to operate the power supply in any manner not described in this
manual.

1.7.10. Never remove DANGER and WARNING labels from the power supply. Replace lost
or damaged labels immediately.

1.7.11. The power supply should only be serviced by factory authorized personnel.

1.7.12. No user maintenance is required.

1.8. Model Number Format

The model numbering system for the 802 Series power supply includes symbols for features
and options. They are separated by dashes.

Examples are: 802L-10kV-POS-400VAC and 802S-20kV-POS-DC.
The 802 is available with three front panel configurations, the L, S, and OEM. The choice of

panel configuration is dependent upon the installation and system requirements. See section
5 for further details.

Table 1 shows a partial listing of the model description format for the 802 Power Supply
family. For additional options, the customer may contact the Sales Department at TDK­Lambda Americas. Special options are typically shown as a four-digit suffix to the model
number.

Table 1 :802 Model Description Format .

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2.1. Average Charging Power

8,000 Joules/sec (½CV2 x Rep Rate)

2.2. Peak Charging Power

9,000 Joules/sec (½CV

2 ∕

t

charge

)

2.3. Average DC Power

8,000 Watts

2.4. Output Voltage Range

1, 2, 4, 5, 10, 15, 20, 30, 40, 50kV, variable from 10-100% of rated.
Other voltages on request, please contact the factory.

2.5. Polarity

Available as fixed Positive or Negative. Please specify at time of ordering

2.6. HV Output Cable

1-39kV Models - DS2124 Coaxial cable with proprietary HV connector

40-50kV Models - DS2214 Coaxial cable with proprietary HV connector

2.7. HV Insulating Medium

Exxon Mobil Univolt N61B or equivalent insulating oil

2.8. AC Input Voltage

200-240VAC (180-264), 3Ø or 380-440VAC (340-460), 3Ø + N, 50-60Hz
Please specify at time of ordering

2.9. AC Input Current

40A for 200-240VAC Input / 25A for 380-440VAC input

2.10. AC Connector

UL/CSA approved terminal block. 3Ø + GND for 200-240VAC, 3Ø + N +
GND for 380-440VAC

2.11. AC Line Contactor

UL/CSA approved AC line contactor (standard on 802L and 802S, option for
802OEM)

2.12. Power Factor

Passive PFC pf = 0.85 at full load and nominal AC line

2.13. Efficiency

Better than 85% at full load

2.14. Front Panel

802L - Voltage Control, Voltage & Current Meters, Status Indicators

802S - On/Off Switch, Status Indicators

802-OEM - Blank front panel

2.15. Stability

0.2% per hour after 1 hour warmup

2.16. Temperature Coefficient

100ppm per °C typical

2.17. Stored Energy

Less than 0.3J all models

2.18. Pulse to Pulse Repeatability

±2% to 1000Hz, consult factory for higher rep rates

2.19. Dimensions - inches (mm)

19 (483) W x 8.75 (222) H x 17 (432) D

2.20. Weight - lbs (kg)

80 (37)

2.21. Ambient Temperature

Storage: -20 to +70°C. Operating: -20 to +45°C

2.22. Altitude

Storage: 40,000ft (12,000m), Operating: 9,900ft (3,000m)

2.23. Humidity

10-90%, non-condensing

2.24. Protection

Open/short circuits, Overloads, Arcs, Overtemp, Overvoltage, Safety
Interlock

2.25. Remote Control (all models)

Via 25-pin D-sub connector on rear of unit, Signals include, Vprogram (0­10V), HV Enable/Reset, Inhibit, Summary Fault, Load Fault, Vanalog, Vpeak

2.26. Accessories

10ft HV cable, operating manual

2. SPECIFICATION

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9

2.27. Options

EN - Low Enable. Replaces standard high enable

5V - 0-5V Analog programming. Replaces standard 0-10V programming.

LP - Latching Overload Protection, requires HV reset after overload fault

DC - Continuous DC operation

CT - AC line contactor (option for 802-OEM only, standard on 802L and
802S)

Double terminated HV cable, and mating bulkhead connector

2.28. Ordering Info

Model - XXkV - POS (or NEG) - YYYVAC - ZZ (options)

2.29. Ordering Examples

802L-10kV-POS, 802S-1kV-NEG-DC, 802-OEM-50kV-POS-400VAC

All specifications subject to change without notice

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3. OUT OF BOX INSPECTION

3.1. Visual Inspection

Prior to shipment, this instrument was inspected and found to be free of mechanical and
electrical defects. As soon as the unit is unpacked, inspect for any damage that may have
occurred in transit. Verify the following:

a) Check the operation of the front panel control (knob should rotate smoothly).
b) Confirm that there are no dents or scratches on the panel surfaces.
c) Check front panel meters and LEDs for any broken or cracked lenses.

If any damage is found, follow the instructions in Section 3.3.

3.2. Electrical Inspection

Before the power supply is installed in a system, verify that no internal damage occurred
during shipping. A set of simple preliminary electrical test can be performed if desired. These
tests are described below.

The sequences described are for L model supplies with local controls, for S and OEM

models the corresponding signals must be applied and monitored through the remote control

NOTE

interface.

3.2.1. Test 1

Purpose: Verify general logic operation, generate maximum output current, and check

overload protection circuits. With AC power "OFF" and disconnected, short the HV
output by connecting the center conductor of the output cable to its return shield
(braid). This dead short will allow the unit to generate full output current at zero voltage.

1. Set the output voltage control to zero. Connect AC power to the unit. Turn "ON" the
AC power front panel switch.

2. Turn the front panel keyswitch to the LOCAL position (if applicable). Press the HV
"ON" button and turn up the HV control until the power supply is generating output
current into the dead short. The current meter will indicate max. current. The
voltage meter will read zero and the power supply will intermittently turn on and off
indicating the "overload" condition. The unit should continue to indefinitely cycle in
this mode with a 1 second period. (The power supply will go into overload when
max. current is drawn for more than half a second). If the LP option is installed, the
unit will shut down and indicate a fault after delivering full current for 500milliS.

3. Turn off the HV and AC power switches.

This test indicates the inverter section is generating maximum current and the logic and
overload circuitry works correctly.

3.2.2. Test 2
Purpose: Verify that the power supply generates maximum rated voltage, and the

regulation and feedback circuits are functioning.

1. With AC power OFF and disconnected, connect an appropriate load capacitor to

the power supply output cable. Select the capacitor size so the charge time is
several milliseconds or more.

2. Prepare to charge the capacitor. NOTE: Operating a 802 power supply into an open

circuit (no load operation) will instantly damage the power supply's HV output

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diodes. Make sure the load (capacitor) is connected and the HV output cable is
securely inserted and connected.

3. Turn the voltage control on the front panel all the way down to zero (counter

clockwise), apply AC power, turn the front panel keyswitch to the LOCAL position (if
applicable), and press the HV ON button. By turning up the HV control knob the
capacitor will charge to the voltage indicated on the front panel voltmeter. The
power supply may be turned all the way up to its max. output voltage provided the
load capacitor is sufficiently rated.

4. By turning the voltage control down or depressing the HV OFF button, the capacitor

will slowly "bleed" down through the internal voltage divider resistors used for
regulation feedback. Use an external discharge wand to ensure the capacitor is fully

discharged.
Test #2 indicates the HV section is working correctly. Tests 1 and 2 generally indicate
the unit is functioning as designed. Although 100% power had not been generated,
these two tests give greater than 90% confidence that the unit is not damaged.

If any inconsistency from the above test procedure is noted, do not hesitate to call TDK­Lambda Americas Customer Service for assistance.

3.3. Contacting TDK-Lambda Americas Customer Service

When contacting customer service locate the product description, part number and serial
number from the label located on the rear of the unit, and have this information available.

Phone: [phone] E-mail: [e-mail]
Fax: [phone]

Customer Service, or an approved Service Center, should be contacted if:

 The power supply is mechanically or electrically damaged.
 The power supply requires on-site calibration, or replacement warning decals.
 The customer has questions about a special application that is not described in this

manual.

Normally, the customer may NOT open any chassis covers that have a warranty seal.
Breaking a seal will void the warranty.

At the discretion of TDK-Lambda Americas, the customer may be granted permission to
break the warranty seal and open the chassis covers. Customer Service shall confirm the
permission by sending a replacement seal. Once the unit has been serviced, the customer
shall close the cover and apply the replacement seal adjacent to (not on top of) the broken
seal.

3.4. Returning Defective Units

If a unit needs to be returned to the factory for repair, the factory must first assign an RMA
number. Please complete and send the online RMA request form at http://www.us.tdk-

lambda.com/hp/RMA_request.htm and an RMA number will be assigned. Follow the return

instructions on the form or at http://www.us.tdk-lambda.com/hp/returns.htm.

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Never install the 802 so its weight is supported only by the front panel

screws!

8.72”

(222mm)

19” (483mm)

4. INSTALLATION

4.1. 19-Inch Rack Mounting

This power supply is intended for mounting in a conventional 19-inch equipment rack. It’s

8.75 inch height makes it a “5U” size instrument. The rack should enclose the sides, top and
back to protect the operator from electrical shock and protect the supply from environmental
contamination.

The 802 must never be installed without support in the back or sides of the unit. The 802
should be mounted on support rails or chassis slides –such as General Devices CTS-124- or
on a suitable shelf or supports inside the rack.

The mechanical outline of the 802 is shown in Figures1 through 3.

Figure 1. 802L Front View

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4.5”

(114mm)

2.15”

(55mm)

19” (483mm)

17” (432mm)

1.875”

(48mm)

17” (432mm)

Figure 2. 802L Rear View

Figure 3. 802L Side View

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For 200-240VAC models, the maximum voltage allowed between any

two AC input terminals is 264VAC. For 380-440VAC models, the

maximum voltage allowed between any two AC input terminals is

460VAC. If this voltage is exceeded, catastrophic damage will result,

that is not covered by TDK-Lambda Americas standard warranty.

The Protective Earth Ground must be connected before applying

AC Line Power to the 802.

4.2. Ventilation Requirements

This instrument is fan cooled. Sufficient space must be allocated so that a free flow of
cooling air can reach the back and sides of the instrument when it is in operation. Ensure
these clearances are met for adequate air flow:

 4 inches (10 cm) rear
 1 inch (2.5 cm) on each side.

Cooling air exits through the rear of the unit, and enters through the side panels and around
the HV tank. This power supply should not be operated with its cover removed since the
cover directs the flow from the internal fan.

When operating in an enclosed system, care must be taken to ensure the ambient inlet air to
the power supply does not exceed the maximum operating temperature of 45°C. This may
require addition of a system heat exchanger.

4.3. Orientation

The power supply must be operated in a level horizontal orientation. More than a quarter of
an inch (6.25mm) difference in height in any direction could potentially cause an arcing
condition in the high voltage tank and should be avoided.

4.4. AC Power Connection

The customer’s AC power line connects to the 802 via a UL/CSA approved 5 position
terminal block on the rear panel of the unit (see Figure 1). Only use a power cable with the
correct voltage and current rating (see Table 2). The ground wire must be equal to or larger
than the recommended gauge. Secure grounding of the input AC power is required to reduce
the risk of electric shock. The metal chassis of the power supply is grounded through the
earth wire at the input AC power terminal block. Use extreme caution when connecting input
AC power and never apply the incorrect input power.

An external switch or circuit breaker with the following parameters must be used as means of
disconnection:

a) Rated voltage not less than maximum rated voltage of the power supply
b) Rated current not less than 150% of the power supply rated current
The switch or circuit breaker must be located in proximity to the power supply and within

easy access of the operator. The switch or circuit breaker must be marked as disconnecting
device for the equipment.

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AC INPUT VOLTAGE

MODE

RECCOMENDED AC INPUT CABLE

SIZE & RATING

200-240VAC

(180-264VAC), 50-60 Hz, 3

Cap Charging

9mm2/8 AWG, 600V

Continuous DC

9mm2/8 AWG, 600V

380-440VAC

(340-460VAC), 50-60 Hz, 3

Cap Charging

6mm2/10 AWG, 600V

Continuous DC

6mm2/10 AWG, 600V

Connect the three lines of the input power to the L1, L2, L3 terminals and the earth ground to
the terminal marked with the ground symbol ( ). No neutral connection is required for the
200-240VAC configuration. For models with the 380-440VAC input configuration (340­460VAC) the neutral wire must be connected to terminal marked N. The power connections
are not phase rotation sensitive, so any phase can be connected to any of the AC inputs.

Figure 4 AC Input Terminal Block

If the power supply was purchased with the 400VAC input configuration, in
addition to the three phases, the neutral wire must be connected to terminal
marked N. Failure to connect the Neutral wire in a 400VAC unit may result in
damage to the supply.

Table 2 Recommended AC Input Cable

The AC input rating is marked on the rear terminal of the power supply. The rating is also
part of the unit’s model description shown in Table 1.

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