SoundCraft Power Supply CPS250 User Manual

SOUNDCRAFT CPS250  
CPS275  
Console Power Supply  
User and Technical Manual  
For your own safety and to avoid invalidation of the  
warranty all text marked with these Warning  
Symbols should be read carefully.  
IMPORTANT: please read this manual carefully  
before connecting your Soundcraft console power  
supply to the mains for the first time.  
 
Table of Contents  
Introduction  
1
2
2
3
3
4
Introduction  
Short-circuit Protection  
Mains Voltage Selection  
Replacing Mains Fuse  
Warranty  
Recommendations For Installation  
Recommendations For Installation  
General  
5
6
7
8
8
Dimensions  
PSU Linking (CPS275 Only)  
Technical Specification  
9
Technical Description  
Circuit Diagram (1)  
Circuit Diagram (2)  
Circuit Description  
Servicing  
11  
12  
13  
14  
17  
20  
21  
PCB Layout  
Output Pinouts  
Parts List  
23  
i
 
ii  
 
Introduction  
Introduction  
1
 
Introduction  
WARNING: THIS APPARATUS MUST BE EARTHED  
The CPS250/CPS275 are linear power supplies which, like other linear supplies,  
produce DC voltages by rectifying, smoothing and regulating AC voltages from the  
secondary windings of a mains transformer. Soundcraft mixing consoles employ a  
number of dc voltage supply levels in their operation and these are all provided at the  
output of each supply unit.  
The CPS275 provides higher currents than the CPS250. The CPS275 also has the  
capability of being linked to a second CPS275 to provide automatic power backup in  
the event of one of the units failing.  
In regulating these voltages there is considerable heat generated, the dissipation of  
which is achieved through a substantial internal heat sink. A fan is incorporated which  
draws air over the heatsinks to provide adequate heat dissipation for the regulators  
and reduce the outer case temperature.  
The CPS250/CPS275 is designed for installation in a 19" rack unit, occupying 2U of  
rack height. Refer to the section "RECOMMENDATIONS FOR INSTALLATION"  
on Page 5.  
LED indication is provided on the front panel to show operation of the regulating  
circuits.  
SHORT-CIRCUIT PROTECTION  
The +/-17V rails can withstand a short to ground or each other for up to one second;  
if the short circuit remains for longer than one second then both of the 17V rails will  
be shut down. To reset them the supply must be switched off for 6 seconds and then  
switched on again.  
The +5V and +48V are current limited and will self recover when any short circuit is  
removed.  
2
Introduction  
 
MAINS VOLTAGE SELECTION  
Special attention should be paid to the following information:  
Do not change the voltage setting without first  
turning the unit off and unplugging the mains lead.  
This unit is capable of operating over a range of mains voltages by means of a  
4-position mains input fuse carrier. It is important to ensure that the correct voltage  
setting is selected for the level of local mains voltage supply, for safe, uninterrupted  
operation of the unit. Voltage selection is achieved by positioning the fuse carrier so  
that the required voltage appears next to the arrow which is moulded in the connector.  
In this way the unit is set up for operation at one of the following ranges of mains  
supply:  
NOMINAL VOLTAGE  
OPERATING VOLTAGE RANGE  
(+10/-15%)  
Vrms AC  
Vrms AC  
230  
115  
100  
85  
196 - 253  
98 - 126  
85 - 110  
73 - 93  
To remove the fuse use a small screwdriver to prise the fuse carrier from its location  
in the connector.  
To avoid risk of fire use the correct value fuse, as  
indicated on the unit.  
REPLACING MAINS FUSE  
Switch the ON/OFF switch to the OFF position. Remove the mains lead from the  
connector. Use a small screwdriver to prise the fuse carrier from its location in the  
connector. Check the fuse and replace if necessary; also check that the voltage  
selection is correct for the mains supply level before switching the unit ON again.  
In the event of repeated failure of the mains fuse consult the Soundcraft dealer from  
where the unit was purchased.  
This unit contains no user serviceable parts. Refer  
all servicing to a qualified service engineer, through  
the appropriate Soundcraft dealer.  
Introduction  
3
 
Warranty  
1
Soundcraft is a trading division of Harman International Industries Ltd.  
End User means the person who first puts the equipment into regular operation.  
Dealer means the person other than Soundcraft (if any) from whom the End User  
purchased the Equipment, provided such a person is authorised for this purpose by  
Soundcraft or its accredited Distributor.  
Equipment means the equipment supplied with this manual.  
2
If within the period of twelve months from the date of delivery of the Equipment  
to the End User it shall prove defective by reason only of faulty materials and/or  
workmanship to such an extent that the effectiveness and/or usability thereof is  
materially affected the Equipment or the defective component should be returned  
to the Dealer or to Soundcraft and subject to the following conditions the Dealer or  
Soundcraft will repair or replace the defective components. Any components  
replaced will become the property of Soundcraft.  
3
Any Equipment or component returned will be at the risk of the End User whilst  
in transit (both to and from the Dealer or Soundcraft) and postage must be prepaid.  
4
This warranty shall only be available if:  
a) the Equipment has been properly installed in accordance with instructions  
contained in Soundcraft’s manual; and  
b) the End User has notified Soundcraft or the Dealer within 14 days of the defect  
appearing; and  
c) no persons other than authorised representatives of Soundcraft or the Dealer  
have effected any replacement of parts maintenance adjustments or repairs to the  
Equipment; and  
d) the End User has used the Equipment only for such purposes as Soundcraft  
recommends, with only such operating supplies as meet Soundcraft’s specifications  
and otherwise in all respects in accordance Soundcraft’s recommendations.  
5
Defects arising as a result of the following are not covered by this Warranty:  
faulty or negligent handling, chemical or electro-chemical or electrical influences,  
accidental damage, Acts of God, neglect, deficiency in electrical power,  
air-conditioning or humidity control.  
6. The benefit of this Warranty may not be assigned by the End User.  
7. End Users who are consumers should note their rights under this Warranty are in  
addition to and do not affect any other rights to which they may be entitled against  
the seller of the Equipment.  
4
Introduction  
 
Recommendations For  
Installation  
FOR UK USERS ONLY  
IMPORTANT WARNING  
THIS APPLIANCE MUST BE EARTHED  
The wires in the mains lead are coloured in accordance with the following code:  
Green and Yellow:  
Blue:  
Brown:  
Earth  
Neutral  
Live  
As the colours of the wires in the mains lead may not correspond with the  
coloured markings identifying the terminals in your plug, proceed as follows:  
The wire which is coloured Green and Yellow must be connected to the  
terminal in the plug which is marked with the letter E or by the earth symbol.  
The wire which is coloured Blue must be connected to the terminal in the plug  
which is marked with the letter N or coloured Black.  
The wire which is coloured Brown must be connected to the terminal in the  
plug which is marked with the letter L or coloured Red.  
Installation  
5
 
Recommendations for Installation  
The CPS250/CPS275 power supply is provided with front panel fixing holes for 19"  
rack-mounting and will occupy 2U of rack space.  
As with any power supply that contains a large mains-voltage transformer, it is  
preferable to provide a degree of physical isolation of the unit from other electronic  
equipment, particularly that which carries low level audio signals, to avoid any  
possible hum pick-up. For this reason the unit is used with a long (7 metres) output  
cable to enable it to be positioned away from the mixing console.  
For the same reason, when rack-mounting it is preferable to avoid locating the unit  
adjacent to signal processing equipment.  
It should be noted that if a complete rack containing a CPS250/CPS275 unit is to be  
operated from a different mains supply level, then the unit should be withdrawn from  
the rack in order to reselect the mains voltage setting, at the same time as resetting any  
other equipment.  
The other important consideration when rack-mounting the unit is the need for natural  
convection of air over the case and an unrestricted air flow through the unit. Note that  
air is drawn in at the rear of the unit and expelled through the front panel.  
Good ventilation BELOW the unit, in the floor or back of the rack, and similarly  
ABOVE the unit, at the top of the rack, will ensure a path for continuous air flow.  
Other equipment in the rack which is known NOT to produce a significant amount of  
heat should be mounted BELOW the unit. Equipment that also relies on good air flow  
within the rack (ie. most power amplifiers and other power supplies) should be given  
due consideration and some space should be provided between such units and between  
these and the CPS250/CPS275 unit. Forced convection, by means of a fan-tray, may  
be desirable in this situation.  
The CPS250/CPS275 will operate as a free-standing  
unit without requiring any special cooling  
arrangement, but should not be allowed to be  
accidentally or deliberately covered over in any way.  
Do not operate the unit with the top cover removed.  
The air intake and outflow holes must be inspected  
regularly and cleaned if necessary to maintain good  
airflow through the unit. This will be particularly  
important if the unit is used in a dusty environment.  
Finally, some consideration should be given to the earthing arrangement of the system  
at the centre of which are the console and the CPS250/CPS275 (and any other  
Soundcraft power supply units). The console chassis is earthed, through the mains  
earth, via the power supply. When rack-mounting the CPS250/CPS275(and any other  
Soundcraft power supply units) care should be taken to avoid any possible ‘ground  
loops’ in the system which would introduce audible hum to otherwise clean audio  
signals. Ground loops may occur where signal processing equipment, patched to the  
console, has its signal earth commoned to the equipment chassis. The ground loop is  
6
Installation  
 
formed if this chassis and the power supply chassis are in electrical contact through  
the fixing rails they share in the rack. To avoid this situation, standard isolating  
washers may be employed when fixing the power supply (or supplies) or any other  
unit into the rack.  
W A R N I N G : THIS APPARATUS MUST BE  
EARTHED. Under no circumstances should the  
mains earth be disconnected from the  
CPS250/CPS275 power supply unit.  
GENERAL  
As with all electrical/electronic equipment care should be taken when handling this  
unit. Avoid general mishandling and do not drop. Avoid storage and operation in  
dusty locations and do not expose to corrosive atmospheres.  
To avoid risk of fire do not expose this unit to rain  
or moisture.  
Retain all packaging for transportation in the event of the unit requiring servicing.  
Retain this manual safely, along with all other relevant documents.  
For touring/mobile transportation it is advisable to install the CPS250/CPS275 in a  
flight case to provide mechanical protection. Refer to your Soundcraft dealer for a  
suitable case.  
Where the CPS250/CPS275 is enclosed in a touring case, provision must be made for  
adequate ventilation to the rear of the unit to ensure unrestricted supply of air for the  
cooling fan.  
Use only the high-current mains lead supplied, not  
the more common 5A type supplied with other  
equipment.  
Installation  
7
 
PSU Linking (CPS275 Only)  
The output voltages from the CPS275 are fed via diodes  
as shown in the adjacent diagram. This allows a standby  
CPS275 to automatically takeover in theevent of a power  
rail failing.  
Link  
When a spare CPS275 is ordered it comes with a 1metre  
linking cable. This should be connected between the link  
connectors as shown in the diagram.  
Console  
(Only one rail shown.)  
Standby CPS275  
Link  
Console  
(Only one rail shown.)  
Main CPS275  
To Co n so le  
Dimensions  
350.50mm  
482.60mm  
427.56mm  
5.95mm  
88.10mm  
5.95mm  
9.52mm  
8
Installation  
 
Technical Specification  
Technical Specification  
9
 
Technical Specification  
MAINS INPUT VOLTAGE RANGE:  
85/100/115/230 V AC +10%/-15% @ 50/60Hz  
RATED INPUT POWER (Max):  
CPS250 - 350 WATTS  
CPS275 - 450 WATTS  
MAINS FUSE RATING:  
Use T3.15A/250V (slow-blow) for 230V  
Use T6.3A/250V (slow-blow) for 85/100/115V  
OUTPUTS  
DC. VOLTAGE RAIL  
MAX. OUTPUT CURRENT  
CPS250  
CPS275  
+17.5V  
-17.5V  
4.00 AMPS  
4.00 AMPS  
5.25 AMPS  
5.25 AMPS  
+5V  
1.00 AMPS  
0.30 AMPS  
1.00 AMPS  
0.30 AMPS  
+48V  
All voltage and current measurements are to be  
taken at the console-end of the power supply cable.  
OPERATING TEMPERATURE RANGE (Ambient):  
-10 TO +40°C.  
HUMIDITY:  
Similar unit tested at 0-90% RH non-condensing +/-5% Relative Humidity  
at 40 °C for 16 hours. Load switched between 20% and 100% at regular  
30 minute intervals.  
OVERALL DIMENSIONS:  
HEIGHT: (exc. feet)  
88.10mm. (2U)  
WIDTH: Chassis  
427.56mm.  
482.60mm.  
Front panel  
DEPTH: (excl. connectors)  
350.50mm.  
WEIGHT:  
(Excl. packing): 11Kg  
10  
Technical Specification  
 
Technical Description  
Servicing should only be carried out by a competent  
service engineer.  
SEE THE WARNINGS STARTING ON PAGE 17.  
Technical Description  
11  
 
Circuit Diagram (1)  
12  
Technical Description  
 
Circuit Diagram (2)  
Technical Description  
13  
 
Circuit Description  
The CPS250 and CPS275 power supplies provide +/-17V at 4 Amps and 5.25 Amps  
respectively. Both give +5V at 1 Amp, and +48V at 0.3 Amp. The PCB is SC3803.  
THE +/- 17V RAILS.  
This consists of two identical +17V supplies connected together to give +/-17V.  
Each 17V supply is a linear regulator with conventional fullwave rectification and  
20,000uF reservoir capacitors. This is combined with a second power supply that sits  
on top to power the driver transistors and the control IC; this reduces the minimum  
voltage drop across the series-pass device and so improves efficiency.  
The main series-pass element is a 250W discrete bipolar transistor mounted on a  
fan-cooled heatsink. The voltage reference and servo control amplifier are provided  
by a 723 regulator IC.  
The circuitry of the +17V regulator is described in detail below:  
The +17V Supply.  
The transformer secondary is fused by F1. Secondary fuses will normally only blow  
in the event of serious failure, such as a major short in the AC wiring or a failed bridge  
rectifier.  
The fullwave bridge rectifier is mounted on the heatsink, at the hottest end as it is the  
most heat-tolerant of the semiconductors. For safety reasons, the reservoir capacitor  
is discharged by bleeder resistors R39,40 at switchoff; this takes about 10 seconds.  
The unregulated DC voltage is approx +26 to +29V.  
The 723 IC contains a 7.15V nominal Zener diode, defining the voltage that appears  
at Pin 6. R5 is in series with the positive input of the servo opamp (Pin 5) and is made  
roughly equal in resistance to the feedback divider R7,11 etc to minimise bias-current  
offsets.  
The feedback divider R7,8,11, & PR1 derives a fraction of the output voltage and  
delivers it to the negative input of the servo opamp. (Pin 4) The negative feedback  
keeps this point also at 17.15V, so the actual output voltage is determined by the  
feedback divider ratio, which is trimmed over a narrow range by PR1.  
The output of the servo opamp controls the output through TR1, an emitter follower  
driving the series-pass device TR3. The power supply to TR1 is taken from the +12V  
supply developed across C23. This has its 0V side connected to the positive  
unregulated DC supply of 26 - 29V, (at nominal mains) giving a total voltageof approx  
38 - 41V for the driver; this also powers the 723 IC via R1. This subrail markedly  
reduces the minimum drop across the pass elements and therefore increases the  
efficiency.  
10 Amp Schottky diode D25 on the output allows supplies to be paralleled for  
redundancy. This is only fitted for the CPS275 option.  
Overcurrent Protection.  
The power supply is protected against short-circuits and overload by a dual-mode  
protection system; brief overloads are dealt with by constant-current protection, while  
prolonged overload causes both 17V rails to shutdown. Reset is by turning the mains  
power off for not less than 6 seconds.  
14  
Technical Description  
 
The constant-current protection system works in the standard way; when an attempt  
is made to draw excessive current, the output voltage is reduced so that no more than  
a fixed maximum can be drawn. However, the high current capability of this PSU  
means that long-term constant-current protection alone is not practical as the  
dissipation in the pass devices is too high for the cooling system to deal with, and in  
time they will overheat.  
The constant-current system measures the output current by sensing the voltage drop  
across resistors R18,19 in parallel. When it reaches approx 0.60 V the internal  
protection transistor in IC1 is turned via R41, and the output voltage on pin 10 pulled  
down to limit the current supplied.  
If this condition persists for longer than one second, then both rails of the +/-17V  
supply are shut down by the Mutual Shutdown System, described below.  
The Mutual Shutdown System.  
Equipment containing some kinds of op-amp is vulnerable to damage when only one  
of the +/-17V rails fails, as in this case excessive supply currents can be drawn,  
damaging fuse resistors on the modules.  
When both 17V supplies are working normally, DZ1,DZ2 are conducting, LED1 is  
on and opto-couplers OP1,2 have their photo- transistors conducting. Therefore TR5  
does not conduct, and the supply works normally.  
If the -17V rail collapses, there is no longer enough voltage to keep DZ1,DZ2 on, and  
OP1 switches off. TR5 is turned on by R16, with R28,30 and C40 providing a  
time-delay to prevent spurious operation on transients, or brief overloads which are  
dealt with by the constant-current protection system . TR5 now pulls down an internal  
node of IC1 via pin 13, and the +17V supply is shut down.  
In the same way, if the +17V supply fails, OP2 switches off, TR6 is turned on by R17,  
and the -17V supply is shut down.  
The -17V Supply.  
This is identical in operation to the +17V section described above.  
The +48V Supply.  
Max current rating is 0.3 Amps. The +48V phantom supply is based on the special  
high-voltage regulator TL783C. (REG1) The AC input is fused by F3 and fullwave  
rectified by D15-18; C31 is the reservoir capacitor. C32 ensures HF stability of REG1.  
The TL783C maintains a fixed 1.27 V between its ADJ and OUT pins, so the  
adjustable voltage-divider R22-PR3-R23 gives an output of approx 48V. This can be  
finely adjusted by PR3. C33 minimises output ripple. Rail indicator LED2 is powered  
through DZ3,4, which total 30V, so even a partial fall in rail voltage will extinguish  
it.  
Two protection diodes are included. D13 protects the regulator from reverse voltage  
if there is a charged capacitor across the output but the voltage on C31 has collapsed.  
D20 prevents the ADJ pin from rising above the OUT pin (due to the charge on C33)  
if the output is shorted.  
Diode D22 on the output (CPS275 only) allows supplies to be paralleled for  
redundancy.  
Technical Description  
15  
 
The +5V Supply.  
Max current rating 1.0 Amps. This supply is primarily intended for powering console  
internal computers; it also powers the cooling fan.  
The AC input is fused by F4 and fullwave rectified by D9-12, with C36 as the reservoir  
capacitor. The LM340 regulator has a fixed 5.0V output. C35 ensures regulator  
stability.  
A protection diode is included; D14 protects the regulator from reverse voltage if there  
is a charged capacitor across the output but the voltage on C36 has collapsed.  
Diode D23 on the output (CPS275 only) allows supplies to be paralleled for  
redundancy.  
16  
Technical Description  
 
Servicing  
SAFETY.  
These safety notes are directed to those testing and repairing this power supply.  
Legal requirements mean that we must not encourage untrained personnel to  
take the lid off.  
Servicing should only be carried out by a competent  
service engineer.  
This supply contains mains voltages on the voltage select PCB, the mains switch,  
etc, and the usual precautions must be taken.  
The main reservoir capacitors have a capacity of 20,000 uF, and are charged to  
+26V.  
THIS CAN BE DANGEROUS.  
The danger lies not in the voltage, but in thelarge currents that will flow if the capacitor  
terminals are shorted. A small screwdriver will simply disappear in a violent  
explosion. The main bodily danger is from metal watchstraps, etc. Serious burns are  
very likely if these contact the capacitor.  
For safety reasons, the reservoir capacitors are discharged by bleeder resistors at  
switchoff; this takes about 10 seconds.  
The unregulated supply to the +48V regulator can reach +90V on high mains,  
and should be treated with some respect.  
Initial operational tests on the power supply can be carried out by switching the unit  
ON and checking the voltages present on the output connectors on the back of the unit.  
While the unit remains disconnected from the mixing console some of the DC voltage  
rails are floating with respect to each other, that is they do not all have a common  
reference within the unit. When connection is made to the mixing console various  
output pins become earthed to a common star-point, which has a mains earth return  
in the power supply cable itself.  
An indication of obvious fault condition is the failure of one or more of the front-panel  
LED’s to light.  
Any fault condition, with the exception of simple mains fuse failure due to underrating  
or an unusual mains input condition, will require removal of the top cover to enable  
fault correction. This is achieved using a cross-head screwdriver to remove the six  
retaining screws and washers. Carefully lift the cover to avoid the earth connecting  
lead to the cover from snagging. Place the cover face down behind the unit.  
WARNING: At the front of the unit just behind the  
front panel is the MAINS SWITCH, which carries  
HIGH VOLTAGES directly from the mains input.  
Similarly on the rear panel is the MAINS INPUT  
SOCKET/MAINS VOLTAGE SELECTOR.  
Care MUST be taken when carrying out any  
servicing operation with the top cover removed.  
Technical Description  
17  
 
FAULTFINDING NOTES.  
+/- 17V RAILS.  
If one side of the +/-17V supply is not working, the mutual shutdown system will  
close down both sides of the supply. This makes faultfinding difficult as it is often not  
obvious which side has failed. The mutual shutdown can be disabled by linking pins  
4 and 5 on BOTH opto-isolators  
IT IS ESSENTIAL THAT THIS IS REMOVED AFTER SERVICING IS  
COMPLETED! FAILURE TO DO THIS MAY CAUSE SEVERE CONSOLE  
DAMAGE IF ONLY ONE 17V RAIL SHUTS DOWN.  
If there is no power to the 723 IC (eg if R1 or R2 is open- circuit) the output will  
remain low, but no damage occurs.  
+8V SUPPLY.  
This is a completely standard IC regulator circuit. The regulator REG3 is the only part  
that is likely to fail.  
REPLACING COMPONENTS  
Replacement of any components should be  
undertaken only after switching the power supply  
unit OFF and disconnecting the mains supply lead  
from the power supply unit.  
Replacement of any of the fuses in the power supply units is possible without the  
removal of the circuit board.  
The fuses are held in open fuseholders on the top of the board. These can be carefully  
removed by hand. Ensure that the insulating fuse covers are replaced with the new  
fuses.  
Various components are mounted along the heatsink extrusion. The extrusion/pcb  
assembly must be removed from the case to gain access to the underside of the pcb in  
order to unsolder and/or undo the appropriate component. They can be removed by  
desoldering the pins, where appropriate, and unscrewing the fixing nuts or the fixing  
screws, taking care to retain the small insulating bush(es).  
Retain carefully the mounting pads and plastic insulating bushes where fitted.  
THESE MUST BE CORRECTLY REFITTED TO AVOID DAMAGE TO THE  
UNIT.  
The correct high efficiency mounting pad must be used, and this should be replaced  
if it appears to be damaged (see the Parts Lists for the relevant Soundcraft Part  
Numbers). When refixing or replacing the device, it is important to screw the device  
down before resoldering the pins to avoid stressing the pads on the circuit board.  
NOTE : The heatsink bracket is earthed through  
its mechanical contact with the rest of the chassis  
and so a faulty mounting pad may cause the output  
of its regulator to be connected to earth.  
Take care not to bend the pins on the regulators, or  
to strain the corresponding pads on the circuit board  
18  
Technical Description  
 
Reassembly is simply a reverse of the procedure above. Particular care should be  
taken when fixing the regulators, ensuring that the pins are not bent or the circuit board  
pads strained when the fixing screws are tightened. The regulator screws are tapped  
into a relatively soft aluminium heatsink. DO NOT OVER-TIGHTEN or you will  
strip the thread in the heatsink. High performance mounting pads must be fitted  
between the regulators and the heatsink. The regulators must be checked for isolation  
from the heatsink using a multimeter.  
Re-dress cable forms in their original positions and secure where applicable with cable  
ties.  
OUTPUT VOLTAGE ADJUSTMENTS  
The +/-17V and +48V rails are adjustable via trimpots on the pcb. After any repair  
these should be checked on load and adjusted if necessary. Set the 17V rails to 17.5V  
+/- 0.1V, and the 48V rail to 48.3 +/- 0.1V. The 5V rail is not adjustable.  
GENERAL  
Before replacing the top cover on the unit, carefully remove any dust from surfaces  
within the unit.  
Carefully check all wiring connections and ensure  
that there are no loose parts lying around inside the  
unit.  
Technical Description  
19  
 
PCB Layout  
20  
Technical Description  
 
Output Pinouts  
Technical Description  
21  
 
22  
Technical Description  
 

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