BAUR Prüf- und Messtechnik GmbH Raiffeisenstrasse 8 A-6832 Sulz/Austria T. +43/5522/ F +43/5522/

Transcription

1 BAUR Prüf- und Messtechnik GmbH Raiffeisenstrasse 8 A-6832 Sulz/Austria T. +43/5522/ F +43/5522/ service@baur.at Print date: Service Manual High Voltage Generator PGK 25 Valid from series: service manual pgk 25 page 1/27

2 Contents GENERAL INFORMATION 3 DATA SHEET OF PGK25 4 FEATURES: 4 TECHNICAL DATA PGK25 5 SYSTEM OVERVIEW 6 FUNDAMENTAL CLARIFICATIONS 6 FIRST STEPS TO FIND THE FAILURE 6 SERIAL NUMBER 6 LIST OF IMPORTANT DIAGRAMS 7 ERROR LIST 8 BASIC TESTS 10 FUNCTION TEST 10 FINDING OF THE FAILURE 10 CHECK THE POWER SUPPLY VOLTAGE: 10 EXECUTING TEST 10 SHORT CIRCUIT TEST 10 NO-LOAD TEST 10 DISASSEMBLY OF THE DEVICE 11 PROTECTION AGAINST ELECTROSTATIC DISCHARGES 11 IDENTIFICATION OF IMPORTANT PARTS 12 DESCRIPTION OF SINGLE PLUG-IN CARDS 14 DESCRIPTION OF SINGLE PLUG-IN CARDS 15 PCB POWER, ID PCB TRANSISTOR, ID PCB CONTROL, ID TROUBLE SHOOTING LIST 18 PERFORMANCE TEST PROCEDURE 23 EXAMPLE OF THE BAUR PERFORMANCE TEST REPORT 25 RECOMMEND SPARE PARTS 27 service manual pgk 25 page 2/27

3 General information Observe info signs! For fast finding of important information the corresponding text passages are marked with symbols (symbols not stated here are selfexplanatory). More and special information concerning the respective subject are available from BAUR. Important information about the instrument! In any case, read carefully! Important information text. Copyright by BAUR BAUR Prüf- und Messtechnik GmbH, 6832-Sulz All rights reserved No part of this publication may be reproduced, transmitted, stored in a data processing system or translated into another language without the written permission of BAUR / Sulz, Austria. Subject to modification! In the interest of our customers we reserve the right for modifications due to technical progress. Illustrations, descriptions and delivery content are therefore not binding. Subject to modification! This manual contains all information necessary for the correct service of the system. Before you do it, please read carefully these manual. This document is for BAUR representatives only. Observe all safety rules mentioned in the operating manual of the systems. Any non-authorized changes on hardware, software or parameters may destroy the system and/or may be dangerous for the service technician or an user. Before implementing any changes, please contact BAUR Austria for more detailes. On any questions or problems contact BAUR After Sales Service in Austria Tel: +43 / 5522 / Fax: +43 / 5522 / service@baur.at service manual pgk 25 page 3/27

4 Data Sheet of PGK25 PGK 25 is a compact set for DC voltage testing with negative polarity up to 25 kv. Because of its different power supplies, this instrument can be used anywhere: a) incorporated mains supply unit and charging unit / / 240 V; Hz b) incorporated battery 12 V c) external 12 V DC supply source possible Features: integrated timer 1-30 min (± 1 min) with automatic final disconnection and release of discharge device stepless adjustable output voltage 0-5 kv and 0-25 kv DC voltage measurement is made directly at high voltage output zero interlock of high voltage high voltage plug with control contact current measurement: decade switching in 5 ranges plotter connection for current range mv (for ungrounded input) connection for external battery, 12 V Load characteristic U [kv] ,5 1 1,5 2 2,5 3 3,5 4 I - [ma] service manual pgk 25 page 4/27

5 Technical data PGK25 PGK 25 Connection energy 110 VA Output voltage 0-5 kv and 0-25 kv DC neg. Voltage measuring ranges analogue 5 / 25 kv Current delivery at nominal voltage 1 ma Short-circuit current 3 ma Current measuring ranges analogue 1 µa / 10 µa / 100 µa / 1 ma / 10 ma smallest reading current 50 na Relative humidity not condensing Ambient temperature working: C storage: C Current supply (incorporated battery with charging unit) 12 V; 6,5 Ah Operating time with battery at 2/3 load approx. 30 min Discharge energy: 10 min recovery time between 2 discharges 20 min recovery time between 2 discharges max Ws (9,6 µf / 25 kv) max Ws (16 µf / 25 kv) Dimensions (W x H x D) approx. 415 x 140 x 360 mm Weight approx. 16,5 kg service manual pgk 25 page 5/27

6 System overview Fundamental clarifications a) Ask the customer after to a fault description Use for that purpose the official BAUR document Complaint Report.doc First steps to find the failure a) Make an optical check b) Switch on the faulty unit and check all functions c) If possible, check the output voltage d) If the failure (e.g. error code) occurs, see the below trouble shooting list and search for possibilities to solving the problem e) If you need the actual circuit diagrams, send BAUR the claim description (include the serial number) Serial number It is very important to know the serial number, only having this indication, we are able to collect circuit diagrams and drawings for investigation! service manual pgk 25 page 6/27

7 List of important diagrams Drawing number Description Kind of Diagram Circuit diagram complete Summary diagram Power Supply Board Component diagram Transsitor PCB Component diagram Cable diagram Overview PCB control (valid from series 11 up to 33) Component diagram Earth control Circuit diagram Circuit diagram with earth control Circuit diagram Earth control Component diagram Power Off Component diagram Power Off Circuit diagram PCB control (valid from series 34 up to 50) Component diagram service manual pgk 25 page 7/27

8 Error list Error Elimination of error ma display ma meter shows negative numbers and has got in all ranges the same indication ma meter shows a pointer deflection of approx. 70 % after switching on Short-circuit on Zener diode V25 (5,1V) ( ) or Check the connection of ground (printed circuit board) and chassis ground in the instrument No transmission on Zener diode V25 (5,1V) [ ] kv display ma meter shows the same deflection in all ranges ma-meter has got after switch on a indication of 0,4mA ma meter shows the same deflection in all ranges Different output voltage in no-load condition and with nominal load kv-meter deflect in a wrong direction (left!) OP V22 [ ] or Diode V23 [ ] or Inductor L3 [ ] defect Inductor 470 µh (L3) [ ] no operation or Diode 4148 (V24) [ ] short circuit OP V22 [ ] or Diode V23 [ ] or Inductor L3 [ ] defect Check power supply -9,4V or Voltage regulator V6 or Diode V29 (1,5V) is faulty V9 ZD 2,7 defect or Accumulator defect 25kV-range is function, 5kV-range only 2 kv ZD V9 3,6V defect (0,2V operation voltage) By battery operation (idling) the high voltage jumped up to 30kV, regulation is fluctuating Time switch contact has got a high Ri (defect) = voltage drop to high = voltage for the voltage regulator is to less service manual pgk 25 page 8/27

9 Timer Under load the signal lamp is getting dark, no definable response of regulation Timer contact is too high resistive: voltage drop is too high Charging voltage Charging voltage cannot be regulated, it remains at approx. 17V HV-transformer By high voltage ON deactivated K1, It sounds like sparkeover in the HVtransformer For adjustment of the loading voltage an additional load has to be connected (120Ω) or Voltage regulator V3 is faulty C1 defect Adjustment PGK of Impossible to regulate the load voltage for the accumulator No load existence (120 Ohm) service manual pgk 25 page 9/27

10 Basic tests Function test Finding of the failure a) Open the device (unscrew the device bottoms) Check the power supply voltage: Disconnect battery, operate the instrument via the mains cable Check the battery voltage (discharge battery (12Ω / 12W) and measure the voltage) Check voltage at Tp1 (ground) Tp2 = -9,4VDC Check voltage at Tp3 - Tp1: -3,6V Check voltage at Tp4 - Tp1: -5,1V Executing test For all tests: o Connect to correct mains voltage o Connect safety earth connector to safety earth o Connect ground-connector of HV output cable to ground o For voltage tests, insulate the HV output up to the max test voltage o Observe all safety rules o Use the system like describes in the operation manual Check all fuses in the system with multimeter. Resistance should be 0 Ohm. Replace broken fuses only with same type and same technical data. Short circuit test Connect HV output to ground, increase output voltage potentiometer. The output voltage should be approx. 0kV, the output current should be the short-circuit current of the system (see operation manual) No-Load test Insulate the HV output up to the max output voltage, increase output voltage up to the max value. The output current displayed should be approx. zero service manual pgk 25 page 10/27

11 Disassembly of the device Protection against electrostatic discharges Open of BAUR devices is only allowed for authorize people (BAUR employees or BAUR partners)!! Never touch parts inside of the unit without being earthed (earth-wristlet)!! a) Take out the device of the leather bag b) Unscrew the marked screws and remove the front cover Front cover ID: c) Remove the four rubber feet on the back side of the device Rubber foot ID: service manual pgk 25 page 11/27

12 d) Pull out the rack of the housing Identification of important parts 1. View front panel a o n m l k j p b c d e f g h i Name Description Identify number a) Voltmeter b) Nonlocking key S ; c) Stepping switch S ; ; ; service manual pgk 25 page 12/27

13 Name Description Identify number d) Potentiometer R8 with 2 switches ; ; ; e) Stepping switch S ; ; ; f) Timer S ; ; ; g) Fuses F1 and F h) HV socket 30kV i) Earth connector ; j) Power input block k) Banana socket black l) Banana socket red m) BNC socket n) Indicator lamp H ; o) Ammeter p) Front panel Inside view below of the device PCB Power ID: PCB Transistor ID: Accumulator ID: Transformer ID: Rectifier ID: service manual pgk 25 page 13/27

14 3. Inside view above of the device Ammeter ID: Voltmeter ID: Resistor R31 ID: Inside view back side of the front panel of the device PCB Control ID: Resistor R30 ID: service manual pgk 25 page 14/27

15 Description of single plug-in cards PCB Power, ID Documents: Schematic: -> hardware overwiew PCB layout Function Power supply PCB Picture Mains input Check mains input voltage F3 F4 X14-X16 X15-X17 Check fuse Check fuse 12 VDC (mains) 12 VDC (battery) service manual pgk 25 page 15/27

16 PCB Transistor, ID Documents: Schematic: -> hardware overwiew Component diagram: Function DC supply voltage is alternated (push-pull) by transistors service manual pgk 25 page 16/27

17 PCB Control, ID Documents: Schematic: -> hardware overwiew Component diagram: Function Main control PCB for controlling power transistors and adjusting voltage and current indication on front panel. TP3 TP2 TP1 TP4 Test point TP 1 TP 2 TP 3 TP 4 GND -8-9,5 VDC to GND. If not: check V6 and V VDC to GND. If not: check V9 5.2 VDC to GND. If not: check V25 service manual pgk 25 page 17/27

18 Trouble shooting list INSTRUCTION TO EXCHANGE TIMER-CONTACT 1. Unscrew the instrument hood 2. Loosen the 4 instrument feet ( ATTENTION: take care about the tooth lock washers) 3. Take the instrument out of the housing 4. Pinch off the plus-pole (red) from the battery 5. Loosen the hood of the control knob of the timer with knife: it is only sticked 6. Loosen the central fixing with a screw driver and take away the control knob from the timer 7. Loosen both fixing screws of the timer at the front panel 8. Unsolder the two lines from the contacts of the timer 9. Mark the position of the switching-cam ( white plastic), that it can be built-in at the same position afterwards 10. Loosen both threaded bolts in the white switching-cam 11. Mark the timer and the hard-paper- hood, that that they can be assembled as before afterwards 12. Unscrew the hard-paper-hood from the timer ( 2 screws), at the same time move the switching-cam to a position that the second screw appears 13. Strip away 8 downwards) the timer from the hard-paper-hood and the switching-cam 14. The timer contact can now be exchanged Please pay attention to the pressurespring! 15. Now the timer has to be sticked and screwed together ( from below) with the hardpaper-hood and the switching cam again 16. Fix the switching-cam at the correct position 17. Solder on the two lines again 18. Fix the timer with the 2 screws at the front panel 19. Mount the control knob 20. Check the position of the control knob by turning the same to the right hand side until the stopper: the marketing of the control knob must show to 30. service manual pgk 25 page 18/27

19 21. Checking of the discharge device: in idle-state (zero position) the HV- output must have contact with the discharge resistor 22. Stick the cap onto the control knob 23. Pinch on the plus-pole to the battery again 24. Slide the instrument into the housing and fix it with the instrument feet: Don t forget the tooth lock washers! Modification required =>Destruction of diode V25 (PCB Control / ) In some cases the plugging / unplugging the HV cable can destroy the inductor L3 ( ), the IC V22 ( ) and/or the diode V25 ( ). This problem include all PGK25 units up series 33 to enclose 49. To eliminate proceed like described below: 1. Change R32 (right side of V25) from 1kOhm (old / ) to 10kOhm (new / ) (same type of resistor) 2. Remove wire bridge (left side of V25) and put in Resistor 1kOhm ( ) (same type of resistor) 3. If necessary change V25 ( ) (same type) service manual pgk 25 page 19/27

20 4. Circuit diagram neck before modify: 5. Circuit diagram neck after modify: 6. If exchange is necessary pay attention to following identify number => (new) service manual pgk 25 page 20/27

21 Replacing of the clock timer 1. Parts needed: ( Schaltuhr mit Erdungsarm PGK 25 ) 2. Remove the cap and unscrew the screw to dismount the timer s button. 3. Unscrew the 4 footers at the back of the PGK. Now you can get the system out of it s housing. 4. Disconnect the cables going to the timer inside the PGK. Mark which one has to be plugged where later. service manual pgk 25 page 21/27

22 5. Disassemble the cable going from the discharge part of the timer to the discharge resistor. 6. Dismount the clock timer from the front panel (4 screws on the front panel) and exchange it. 7. Reassemble the unit in reverse order! External resistor to reduce ripple on output current If you have variations between the voltage range 1kV up to 5kV, you can reduce it with using of this additional 33kOhm resistor! Part no.: Connections: Left side: PGK 25 HV-line, right side: load Limitations when using this optional resistor with PGK 25: - Voltage indication is subject to additional systematic error of max. 2% (0.4%) at shortcircuit current, 5kV-mode (25kV-mode) - Necessary discharge time is increased to 130% of values written in operation manual service manual pgk 25 page 22/27

23 Performance test procedure Set timer and check discharge unit Set milliammeter and kv meter mechanically to zero Check fuses F3 (2A 90) and F4 (8A slow-blow) on the power board insulate X 17 (battery + ) with rubber sleeve!! Connect instrument o ground line o clamp amperemeter (10A DC) between rectifier bridge o + and X16 o HV cable o mains cable Test o HV lamp o switch-on interlock (pole in position 0 ) Set U max to approx. 27kV Set pulse duty factor o Charge output with 25MΩ and change with R 20 to U max o Short-circuit output and change with R 18 to ma Check short-circuit current: I sek = mA Set limitation of U max with R 15 to 26.1kV Check current consumption at nominal load (rectifier bridge X 16 ); I = 6-7A Check kv meter i. set U sek extern to 20kV ii. adjust kv meter with R 14 to 20kV iii. switch over to the 5kV range and check U extern at 4kV Adjust milliammeter: o Set I sek extern to 0.800mA and adjust internally with R 40 o Check the other ranges (80µA, 8µA, 0.8µA) Set charging voltage: o Disconnect battery + and charge voltage (loading voltage) with 120Ω o Adjust to 13.8V. Reconnect plug to battery service manual pgk 25 page 23/27

24 Check plotter output: o Set I sek to 1mA (measuring instrument = 100%) o Set plotter output with R 41 to 200mV 2 min. arcing at 20kV mains operation 10 min short-circuit test with mains operation Check soldering joints, clamped joints and screwed joints, secure plug with silicone Operation with external battery (charging unit) Fix instrument in rack 30 min. operation at full load, with internal battery Check the different mains voltages (according to order), exchange fuses F1 + F2 if necessary Measure leakage current without connection cable Check current consumption from mains at nominal load Description, type plate, damage on lacquer Controll card view solder side S4 S3 S5 R 14 R 15 R 18 R 20 R 41 R 40 U max kv-meter frequency impulse / second ma-meter graph recorder output Recommendation The guarantee the testing accuracy it is recommended to calibrate the PGK25 and/or your test equipment once a year and starting two years after purchase. service manual pgk 25 page 24/27

25 Example of the BAUR Performance Test Report service manual pgk 25 page 25/27

26 service manual pgk 25 page 26/27

27 Recommend Spare Parts In trying to offer our BAUR partners a rapid and efficient repair service we have ensured that this section contains a compilation of the most important spare parts. These are spare parts which in our experience are exposed to increased wear and tear or corrosion and these are also assemblies (PCBs) which support rapid repairs. This is why these spare parts should be kept in stock at each service location. The given number of pieces per device is for information only. service manual pgk 25 page 27/27