POWER SUPPLY UNIT 02R96 REPAIR MANUAL PA

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1 POWER SUPPLY UNIT REPAIR MANUAL 02R96 CONTENTS ANALYSIS-REPAIR FLOW CHART 2 2H032W AC-DC POWER SUPPLY 0 ABOUT ANALYSIS AND REPAIR OPERATIONS 4 CIRCUIT DIAGRAM 5 PARTS LIST 6 PA 0645 HAMAMATSU, JAPAN

2 ANALYSIS-REPAIR FLOW CHART 2 Input filter section Confirm claim information Replacement parts (Including preventive replacements) F: CERAMIC FUSE 50CT063H PFC circuit +5V system circuit +2V system circuit YES F Open RC: Rectifier R2, 3, 4, 5: Anti-collision resistor Q, Q2: Main FET R0, : Gate resistor Q5, 6: Main FET R64: Protection resistor R66, 69: Gate resistor Q9, 20: Main FET R84: Protection resistor R86, 89: Gate resistor NO PKG RC: RBV-506 R2, 3, 4: A53K-220J 5W 22 ohm J Q, 2: 2SK295 R0,: BPR58 5W 0.02 ohm K R3, 4, 5, 6: AK53K-220J 5W 22 ohm J R0, : BPR58 5W 0.02 ohm K Z: L498A PKG2 Q5, 6: 2SK264-0 R64: RSMF2SL 0.22 ohm J R66, 69: RSMF2T 22 ohm /2W 22 ohm J R65, 68: RSMF2T 47 ohm J /2W 47 ohm J RX0: CR2TR680J R76: CR2TR0J R77: CR2TR0J R75: CR2TR33J Z2: SMA-Z00A +5V, +/-5V system circuit +48V, +20V system circuit Q22, 23: Main FET R02: Protection resistor R04, 06: Gate resistor Z5: Control IC -4pin, 2-4pin R9: Protection resistor Q9, 20: 2SK2698 R84: RSMF2SL 0.22 ohm J R85, 88: RSMF2T 47 ohm J /2W 47 ohm J R86, 89: RSMF2T 22 ohm J /2W 22 ohm J RX3 CR2TR390J R96: CR2TR0J R97: CR2TR0J R95: CR2TR8J Z3: SMA-Z00A R9: RSFM2SL 0.68 ohm J R33: CR2TR222J RX6: CR2TR27J PKG3 Z5: SMA-Z00A PKG3 R32: CR2TR33J No abnormality Q22, 23: 2SK264-0 R02: RSMF2SL 0.33 ohm J R04, 06: RSMF2T 0 ohm J /2W 0 ohm J R09: CR2TR52J RX4: CR2TR82J PKG3 Z4: SMA-Z00A PKG3 R08: CR2TR47J 2

3 AC power supply input Confirm output Implement unable-to-recreate test items Overvoltage detection NG Confirm the start-up condition of each output voltage using OSC. (Overvoltage protective operation, yes/no) V Rated voltage Completely no output No output of system 0V T YES YES Check PFC circuit operation +/-5A,+/-5A +48, +20, +2A +2D +5D, +5LED C5: Output terminal voltage (380V) Overvoltage operation Z Vcc voltage level L ALM Detection of circuits not outputting Investigate PFC circuit +/-5A,+/-5A Q23 D-S +48, +20, +2A Z D Q20 D-S +5D, +5LED Q6 D-S Confirm main operation waveform (refer to page 4) Stop after momentary oscillation FET Vds H level Intermittent oscillation Abnormal wave form Operation of protective circuit, mis-operation Control IC Vcc voltage level Inspect whether or not there is output terminal shorting of the secondary side output circuit Secondary side output circuit investigation 3

4 Main transistor operating waveform Test Conditions Input voltage: 276 V Load: Rated ) +/-5A, +/-5A series main operating waveform PKG 2 Q23 (Between D-S) 2SK264 CH=00V CH2=0mV DC 00: DC : 2µs/div (2µs/div) NORM:200MS/s 2) +48A, +20A, +2A series main operating waveform PKG 3 Z5 (Between 4-2) STR-Z508 CH=00V CH4=0mV DC 00: DC : µs/div (µs/div) NORM:00MS/s V:00V/Div H:2µs/Div V:00V/Div H:µs/Div 3) +2D series main operating waveform PKG 2 Q20 (Between D-S) 2SK2698 CH=00V CH2=0mV DC 00: DC : 2µs/div (2µs/div) NORM: 200MS/s 4) +5D, +5LED series main operating waveform PKG 2 Q6 (Between D-S) 2SK264 CH=00V CH2=0mV DC 00: DC : 2µs/div (2µs/div) NORM: 200MS/s G V:00V/Div H:2µs/Div V:00V/Div H:2µs/Div 4

5 3 Confirm RV setting position +5A circuit (RV3) +2A circuit (RV4) +2D circuit (RV2) +5D circuit (RV) 4 Determine RV setting position NG Reset RV or return release setting position to center. Confirm control IC Vcc level +5D circuit Z2 between -4 Approx. 7 V +2D circuit Z3 between -4 Approx. 7 V +/-5D circuit Z4 between -4 Approx. 7 V +48A circuit Z5 between -4 Approx. 7 V 5 Determine control IC Vcc level Confirm part open/short (handy tester) +5D circuit +2D circuit +/-5A circuit +48A circuit Q4,D33,D39,Q7,D40 Q8,D45,D48,Q2 PKG3 Q25,D55 Q47,D75 Confirm whether or not there is output short circuit (secondary side output circuit) +5A circuit CN03 From between pin 9-0 to pin A circuit CN04 between pin D circuit CN02 From between pin - 7 to pin D circuit CN0 From between pin 3-8 to pin A circuit CN03 From between pin 5-6 to pin A circuit CN03 From between pin - 2 to pin A circuit CN03 between pin A circuit CN04 between pin A circuit CN04 From between pin - 2 to pin 3-4 Determine output short circuit NG Circuit short circuit location. Check for items such as part failure. 6 5

6 6 Check CD terminal Confirm control IC CD terminal (2 pin) level ALM "H" CD terminal waveform Circuit diagram Measuring point CD terminal voltage ALM +/-5A circuit +48A circuit +2V circuit Z4 between 2-4 Z5 between 7-3 Z3 between 2-4 ALM operating Approx. 6V +5V circuit Z2 between 2-4 Investigate secondary side output circuit If CD terminal level "H", confirm circuits including control circuit as operation of the overvoltage protection circuit is most likely. Since the failed parts are often semi-conductor parts, it is possible that the failure mode is open or shorted. Confirm part open/short (handy tester) Circuit diagram Over voltage detection circuit Voltage control circuit +5D circuit PKG2 PC3, D79 PC4, Z6 +2D circuit PKG2 PC5, D82 PC6, D65, Q28 +/-5A circuit PKG2 PC7, D88 D9, Q29 +20A circuit PKG2 D A circuit PKG2 PC9, D03 D09, Q38 Photocoupler confirmation Primary side Feedback circuit (PC) operation level confirmation. Is secondary feedback operating normally? Check photocoupler Secondary side Confirm part open/short (handy tester) Circuit diagram +5D circuit +2D circuit +/-5A circuit +2A circuit Control photocoupler PKG2 PC3 PKG2 PC6 PKG2 PC8 PKG2 PC0 Check auxiliary power supply level Are the output voltage waveform for auxiliary voltage winding and power supply voltage normal? Investigate primary side circuit Control IC voltage waveform reference (refer to page 7) Very few part failures are due to the windings on transformers and other parts. (Semiconductor parts are the main cause.) 6

7 Control IC voltage waveform Test Conditions Input voltage: 276 V Load: Rated PKG Z between 9-0 (PFC circuit control IC) PKG2 Z2 between -4 (+5D, +5LED circuit control IC) CH3=5V DC : 500ms/div (500ms/div) NORM:2kS/s CH3=5V DC : 500ms/div (500ms/div) NORM:2kS/s G G V: 5V/div H: 0.5S/div V: 5V/div H: 0.5S/div PKG2 Z3 between -4 (+2D circuit control IC) CH3=5V DC : 500ms/div (500ms/div) NORM:2kS/s PKG3 Z4 between -4 (+/-5A, +/-5A circuit control IC) CH3=5V DC : 500ms/div (500ms/div) NORM:2kS/s G G Investigate secondary side circuit Investigate primary side circuit Abnormal voltage at output connector Failure of primary side part.output voltage is low Confirm VR position for output voltage setting Is secondary side standard voltage abnormal? 2.Confirm pin output of output connector Connector contact or pin damage. 3.Confirm conductivity between secondary output to output connector. 4.Output ripple is big Ripple hunching 5.Confirm secondary side output line of soldering graph, etc..confirm impedance among control IC terminals (Compare with normally operating parts, etc.) 2.Confirm semiconductor impedance (check for shorts, open circuits) 3.Confirm open for resistor parts? 7

8 Unable-to-recreate test items Such as printed circuit boards, soldering, part mounting and foreign material. * As necessary, visual inspection of internal areas of power supply. Check output voltage NG * Check that the output voltage of each circuit is being output normally. Refer to the Voltage Confirmation Table provided on a separate sheet for the measuring points and voltage ranges. (refer to page 9) PowerOn/Off * Check if output operates normally when there is AC input and ON/OFF operation. Refer to the Voltage Confirmation Table provided on a separate sheet for the measuring points and voltage ranges. (refer to page 9) SW On/Off * The output at the SW on/off should be normal. Refer to the Voltage Confirmation Table provided on a separate sheet for the measuring points and voltage ranges. (refer to page 9) Caution signal * Operate Power on/off and SW on/off and confirm that there normal signal transmission. Refer to the Voltage Confirmation Table provided on a separate sheet for the measuring points and voltage ranges. (refer to page 9) Output ripple wave * Perform the tapping test while monitoring the output voltage waveform by OSC to check the waveform changes. Check the exterior * Check the exterior Edging test * The edging test conditions should be implemented based on the conditions occurring in the claim. Shipment 8

9 Voltage Confirmation Table Circuit name Rated voltage Output voltage range Measuring point +5D 5.0V 4.85V V CN0 From between pin 3-8 to D 2.0V 0.8V - 3.2V CN02 From between pin -7 to A 5.0V 4.5V - 5.5V CN03 From between pin 9-0 to A -5.0V 4.5V - 5.5V CN03 Between pin A 5.0V 3.5V - 6.5V CN03 From between pin -2 to A -5.0V 3.5V - 6.5V CN03 From between pin 5-6 to A 2.0V 0.8V - 3.2V CN04 From between pin -2 to A 20.0V 8.0V V CN04 Between pin A 48.0V 46.08V V CN04 Between pin 7-8 Confirm signal sending (AC OFF signal) Measuring point From CN04 pin 9 to between pin 3,4 AC input Other output 95% Caution signal 30 ms or more 0 ms or more 9

10 2H032W AC-DC POWER SUPPLY PFC block Input filter section 2H032W AC-DC power supply Primary side inverter block Secondary side control circuit +2V system circuit +5V system circuit +5V, +/-5V system circuit +48V, +20V system circuit 0

11 Input filter section F Input fuse (F Ceramic fuse 50CT063H) PFC circuit block RC Q2 Q R2, 3 R0, R4, 5

12 +5V system circuit block R64 Q5 Q6 Z2 +2V system circuit block Q9 Q20 R84 Z2 +5V, +/-5 system circuit block Q22 Q23 PKG3 Z4 2

13 +48V, +20V system circuit block PKG3 Z5 Each setting VR RV6: -5A ADJ RV4: +2A ADJ RV5: +5A ADJ RV3: +5A ADJ RV: +5V ADJ RV2: +2D ADJ 3

14 ABOUT ANALYSIS AND REPAIR OPERATIONS. Test Equipment Commerical power supply Insulated transformer + Variable autotransformer A Input L Output V Supply test V R power supply N A Load resistance A V A V : AC ammeter : AC voltmeter : DC ammeter : DC voltmeter or digital voltmeter -. Equipment used for analysis and inspection Measuring equipment and equipment required during analysis ) Input equipment: Input insulation transformer Ensuring safety during investigation Input autotransformer 4 Ensuring safety during investigation (Implementing analysis while raising the input from 0V to the rated capacity.) 2) Load equipment: Simple inspection equipment For checking output and performance operation confirmation 3) Measuring equipment: Synchroscope, DMM, Tester, etc. For confirming waveform Since the synchroscope input performs the primary circuit measuring, the insulation of the input line requires a : insulation transformer. In addition, it is recommended that a autotransformer be used for secondary damage prevention during analysis. -2. Part replacement and assembly jig preparation Since this power supply uses a through-hole type printed circuit board, conventional soldering is difficult and an electric suction type tool is required. Moreover, a torque driver or similar equipment that can control tightening torque is required to control the torque during the mounting of the semiconductor and the assembly operations. -3. Confirming function and operation after repair After repair and analysis, it is necessary to electrically confirm the repaired parts and the faulty locations that have been repaired as well as check that the operating functions have been completely repaired. Well it is possible to make the confirmation using the inspection jig for the analysis, simple testing equipment is probably required. While the items to be confirmed will vary according to the areas that failed and the conditions of repair, it is necessary to confirm the general characteristics and function operations by introducing a simple checker. -4. Confirmation items for soldering operations accompanying the replacement of parts The skill required for the soldering should not be a problem for an experienced soldering technician. However, temperature will have to be controlled during the soldering process (to prevent thermal stress to the parts) and steps must be taken to prevent the effects of static electricity on the IC, FET and other such parts (including the storage conditions as well). -5. Confirming the function of the insulation after assembly Insulation and withstand voltage testing is required prior to re-shipping the product to ensure that secondary defects (such as foreign objects or the wire damage) from the re-assembly after repair do not cause insulation impediments, insulation and withstand voltage testing is required prior to re-shipping the product. Insulation and withstand voltage testing equipment, testing jigs and preparation of the environment for the operation are indispensable requirements for the implementation of these tests. At the very minimum, checking the insulation resistance is required to prevent the secondary defects shown above. This test requires a device for measuring the resistance of the insulation and cable for connecting to the product for easy inspection. -6. Pre-shipment inspection Use an inspection jig to inspect and check the general characteristics and operating functions. Sanken Electric Company can prepare the documentation for the inspection procedures, etc. -7. Steps for products where symptoms could not be recreated We are investigating the establishment of rules and inspection guidelines for products for which the symptoms could not be recreated on the results of the primary diagnoses based on the complaint information of the final user. -8. Managing historical data about repair parts It is necessary to record and manage historical data about the conditions surrounding the failure, symptom treatment, lot number of the failed parts and replacement part numbers.

15 CIRCUIT DIAGRAM PKG PKG2 PKG3 5

16 PARTS LIST REF NO. F Q Q2 Q5 Q6 Q9 Q20 Q22 Q23 R2 R3 R4 R0 R R64 RC Z Z2 Z3 PART NO. AAX40870 DESCRIPTION PS UNIT PARTS KIT Circuit Board Ceramic Fuse FET FET FET FET FET FET FET FET Cement Resistor Cement Resistor Cement Resistor Cement Resistor Cement Resistor Rectifier IC IC IC 02R96 PKG AC250V 6.3A 2SK295 2SK295 2SK SK SK2698 2SK2698 2SK SK W 22 ohm 5W 22 ohm 5W 22 ohm 5W 0.02 ohm 5W 0.02 ohm 2W 0.22 ohm RBV-506 L498A SMA-Z00 SMA-Z00 REMARKS QTY RANK R65 R66 R68 R69 R75 R76 R77 R84 R85 R86 R88 R89 R95 R96 R97 R02 R04 R06 R08 R09 R9 R32 R33 RX0 RX3 RX4 RX6 Z4 Z5 Circuit Board IC IC PKG2 /2W 47 ohm /2W 22 ohm /2W 47 ohm /2W 22 ohm /0W 330 ohm /0W 00 ohm /0W 68 ohm 2W 0.22 ohm /2W 47 ohm /2W 22 ohm /2W 47 ohm /2W 22 ohm /0W 80 ohm /0W 47 ohm /0W 68 ohm 2W 0.33 ohm /2W 0 ohm /2W 0 ohm /0W 470 ohm /0W 820 ohm 2W 0.68 ohm /0W 330 ohm /0W 470 ohm /0W 2.2 ohm - k ohm /0W 2.2 ohm - k ohm /0W 0 ohm -0k ohm /0W 0 ohm -0k ohm SMA-Z00 STR-Z508 *: New Parts RANK: Japan only 6

DLVP A OPERATOR S MANUAL

DLVP A OPERATOR S MANUAL DLVP-50-300-3000A OPERATOR S MANUAL DYNALOAD DIVISION 36 NEWBURGH RD. HACKETTSTOWN, NJ 07840 PHONE (908) 850-5088 FAX (908) 908-0679 TABLE OF CONTENTS INTRODUCTION...3 SPECIFICATIONS...5 MODE SELECTOR