Infratek 106A Manuale utente

SERVICE MANUAL 106A

SINGLE- AND THREE PHASE

POWER ANALYZER

Infratek AG

Weingartenstrasse 6

CH-8707 Uetikon am See

Phone: +41-(0)44-920 50 05

Fax: +41-(0)44-920 60 34

www.infratek-ag.com

E-Mail: info@infratek-ag.com Infratek

CONTENTS

8. Calibration Procedure page 8-1

8.1. Calibration Cycle 8-1

8.2. Equipment needed 8-1

8.3. Preparing for Calibration 8-1

8.4. Offset Adjustment and Calibration 8-1

8.4.1. Voltage Amplifier Calibration 8-2

8.4.2 Current Amplifier offset Adjustment 8-3

8.4.3 Current Amplifier Calibration 8-3

8.4.4 Shunt Input Calibration 8-3

8.4.5 Power Calibration 8-3

9. Maintenance 9-1

9.1 Modular Concept 9-1

9.2 Functional Description of the Assembly Units 9-1

9.2.1 Current Amplifier Assembly 9-4

9.2.2 Voltage Amplifier Assembly 9-4

9.2.3 Processor Assembly 9-4

9.2.4 Option Assembly 9-4

9.2.5 Main Supply Assembly 9-4

9.2.6 DC/DC Converter Assembly 9-5

9.2.7 Display Assembly 9-5

9.2.8 Keyboard Assembly 9-5

9.3. Assembly Removal Procedures 9-5

9.3.1 Removing the Hood 9-5

9.3.2 Removing the Front Panel 9-5

9.3.3 Removing the Separator 9-6

9.3.4 Amplifiers Phase 1 Removal 9-6

9.3.5 Amplifiers Phase 2 and Phase 3 Removal 9-6

9.3.6 Reinstalling Amplifiers 9-7

9.4 Fault Diagnosis, Assembly Level Trouble-

Shooting 9-7

9.5 Supply Voltage Checks 9-10

9.6 Amplifier Input Repair 9-11

9.6.1 Installing a Replacement Amplifier 9-19

9.7 List of Replaceable Assemblies 9-21

8-1 8-2

8. CALIBRATION PROCEDURE

8.1 CALIBRATION CYCLE

We recommend verifying calibration once a year. The user must be aware that

occasional overloads (voltage and current) will degrade accuracy. In such cases,

calibration should be checked more frequently.

8.2 EQUIPMENT NEEDED

A calibrator that will supply voltages 0.3V-600V and currents 15mA-2A at 60Hz with

0.02% accuracy will suffice.

8.3 PREPARING FOR CALIBRATION

Remove the hood of the Power Analyzer by loosening 3 screws on the left and the right

hand side. Slide the hood over the top of the instrument.

Turn Power Analyzer on and allow approximately 30 minutes warm-up time.

8.4 OFFSET ADJUSTMENT AND CALIBRATION

Figure 8.1. shows the locations that have to be adjusted.

The top amplifiers are the voltage input amplifiers with adjustments U1, U2, U3, and U4.

The bottom amplifiers are the current input amplifiers with adjustments IDC, I1, I2, I3, I4,

I5, and I6.

For a 3-phase Power Analyzer above adjustments must be performed for phase 1,

phase 2, and phase 3.

Make sure all scaling factors are set to 1.0000.

NOTE: The shields of the amplifiers are on the potential of the

corresponding Lo-terminal input.

U1I1

Idc

Phase 1 Phase 3Phase 2

current amplifier at

bottom

Power Analyzer Rear Panel

Figure 8.1 Location of Calibration Adjustments

8.4.1 VOLTAGE AMPLIFIER CALIBRATION

Connect the voltage inputs in a 3-phase model in parallel and perform adjustments on

all 3 amplifiers. Apply a 60Hz signal from the calibrator and select voltage

synchronization on the Power Analyzer.

Input Range Adjustment

100V

30V

300V

100V

30V

300V

Adjust U1 for 1.0000V rms reading

Adjust U2 for 100.00V rms reading

Adjust U3 for 30.000V rms reading

Adjust U4 for 300.00V rms reading

All other voltage ranges not listed above must now also be within specifications.

8-3 8-4

8.4.2 CURRENT AMPLIFIER OFFSET ADJUSTMENT

Leave the current inputs open. Select 5A input and 15mA current range.

Adjust Idc to obtain a minimal reading for the current average value (AVG mA). The

reading is typically 20uA.

8.4.3 CURRENT AMPLIFIER CALIBRATION

You can connect all three current inputs of a three phase model in series with your

calibrator if your calibrator is capable of driving the 3x0.05Ohm burden of the 5A inputs.

Apply a 60Hz current to the 5A input IN5A or the 30A input IN30A. Make sure you have

selected the correct current input on the Power Analyzer front panel.

Calibrator Output Input Range Adjustment, rms current

2A (3A)

50mA

IN30A

IN5A

50mA

Adjust I1 for 2.0000A (3.0000A)

Adjust I2 for 50.000mA

Repeat above steps at least once

500mA

150mA

1.5A

IN5A

500mA

150mA

1.5A

Adjust I3 for 500.00mA

Adjust I4 for 150.00mA

Adjust I5 for 1.5000A

CAUTION: Drive one current input at a time. Your calibrator may exceed its

maximum burden voltage.

8.4.4 SHUNT INPUT CALIBRATION

Apply 600mV/60Hz to the Power Analyzer Shunt input. Select SHUNT on the front

panel. Adjust I6 for 10.000A rms reading.

8.4.5 POWER CALIBRATION

Select IN5A range 150mA. Apply 15mA to 1A input at shunt input connector. (middle

pin) against current Lo input. (black terminal).

Adjust I7 for 150.00mA.

NOTE: For actual reading of 15mA a scaling factor of 0.1 would be required.

This concludes calibration. Power is the precise product of current and voltage and is

also calibrated with above steps.

9-1 9-2

9. MAINTENANCE

WARNING

These service instructions are for use by qualified personnel only. To avoid electric

shock, do not perform any procedures in this section unless you are qualified to do so.

Starting January 2007 Power Analyzers are equipped with new current amplifiers and

new voltage amplifiers. The DC/DC-Converter Assembly is now longer needed; its

functions are incorporated on each amplifier board.

The descriptions in this manual pertaining to the new amplifier are marked with “New

Amplifier”.

9.1. MODULAR CONCEPT

This Power Analyzer has been designed to make servicing simple and make calibration

after repair unnecessary. The modular concept allows determining the faulty assembly

and allows exchanging this assembly with an exchange unit. You can order an exchange

unit from your supplier of the Power Analyzer.

This procedure does not require special equipment such as calibrators. You simply

replace the faulty assembly and the Power Analyzer is ready again, fully calibrated.

In many cases the amplifier inputs will be damaged due to overloads. If you decide to

repair the input yourself you find the necessary information to do so. Be aware, that in

this case, you must calibrate the Power Analyzer.

9.2. FUNCTIONAL DESCRIPTION OF THE ASSEMBLY UNITS

The block diagram 9.1. shows the assembly units of the Power Analyzer. In the

following the functions of these units are described to support service and repair. Also

shown are the connecting cables. With the help of figure 9.2. you are able to make the

right connections.

Figure 9.2. shows the physical location of the assembly units of the Power Analyzer

looking from the top (with the hood removed).

Also shown is the mounting of the Option Assembly (in front of the Processor

Assembly) and the fixation of the cables going from the Option Assembly to the rear

panel. The cables going to the rear panel are brought over the separator and are held to

the side panel above the main supply by two clips glued to the side panel (cables must

not touch main supply Assembly).

Figure 9.1. Functional Blocks or Assembly units of the Power Analyzer.

Also shown are the flat ribbon interconnecting cables.

NOTE: Power Analyzers shipped January 2007 or later do not contain the DC/DC-

Converter Assembly.

9-3 9-4

Figure 9.2. Physical location of Power Analyzer Assembly units.

NOTE: Power Analyzers shipped January 2007 or later do not contain the DC/DC-

Converter Assembly.

9.2.1. CURRENT AMPLIFIER ASSEMBLY

The current amplifiers for phase 1, 2, and 3 have identical functions. The voltage drop

on the 0.2(5A input) and 4.7m(30A input) power resistors are amplified to a voltage

level suitable for analog to digital convection. The gain of the amplifiers is controlled

over the current bus.

Each amplifier output is galvanically isolated (2500Vrms) from its input.

The input section of the amplifiers is supplied by one DC/DC converter output (+10.5V /

-15.5V). Current amplifier phase 1 is supplied by PI1, phase 2 by PI2, and phase 3 by

PI3.

New Amplifier: The voltage drop on the 50m(5A input) and 1m(30A input) power

resistors is amplified to a suitable level for analog to digital conversion.

The amplifier input section is operated by a single 5V supply regulated to 3.3V for

proper operation.

9.2.2. VOLTAGE AMPLIFIER ASSEMBLY

The voltage amplifiers for phase 1, 2, and 3 have identical functions. The voltage on the

voltage input terminals is amplified or attenuated depending on the input voltage level.

The gain of the amplifiers is controlled over the voltage bus.

Each amplifier output is galvanically isolated (2500Vrms) from its input. The voltage

amplifier input section is supplied by a DC/DC converter output, that is, PU1 supplies

voltage amplifier phase 1, PU2 supplies voltage amplifier phase 2, and finally PU3

supplies voltage amplifier phase 3.

New Amplifier: The amplifier input section is operated by a single 5V supply regulated

to 3.3V for proper operation.

9.2.3. PROCESSOR ASSEMBLY

The Processor Assembly controls the gain of the amplifiers, it serves the Option

Assembly, drives the LCD monitor, and does some computing. It also controls the

keyboard entries.

New Amplifier: The brightness adjustment for the LCD is located on the processor

assembly, left corner on top edge.

9.2.4. OPTION ASSEMBLY

The Option Assembly contains the options that are installed in your instrument. From

this assembly the connections to the Power Analyzer rear panel are made.

This assembly can contain the Centronics printer output, RS232- and IEEE-488

interface, 8 analog inputs, and 4 analog outputs.

9-5 9-6

9.2.5. MAIN SUPPLY ASSEMBLY

This switched power supply converts power line voltages 90V-250V AC to 5V/+12V/-12V

DC. The 2AF/250V line fuse is installed on this assembly located near the line power

input. (To exchange the fuse you best unscrew the right hand side panel).

9.2.6. DC/DC CONVERTER ASSEMBLY

This assembly generates isolated DC supply voltages, 2 for the single phase- and 6 for

the three phase version (+10.5V/-15.5V) to deliver supply to the amplifier input section.

It also contains FL driver for the FL Lamp on the display.

Furthermore, this assembly distributes the supply to the processor (J41) and option

assembly (J42).

New Amplifier: DC/DC-Converter Assembly is missing. The individual DC/DC-

Converters are located on the amplifier boards.

The brightness adjustment for the LCD is located on the processor assembly, left corner

on top edge.

9.2.7. DISPLAY ASSEMBLY

The display assembly contains the control logic and memory to write ASCII- and

graphic data to the display. The FL lamp is mounted at the bottom of the display and

can easily be removed.

9.2.8. KEY BOARD ASSEMBLY

This assembly contains 11 switches for the front panel control of the Power Analyzer.

9.3. ASSEMBLY REMOVAL PROCEDURES

In this section we refer to Figure 9.2. for screw location.

9.3.1. REMOVING THE HOOD

Remove 3 screws on the left- and 3 screws on the right hand side of the case and pull

the hood over the top of the instrument. This gives you access to all assemblies of the

Power Analyzer.

9.3.2. REMOVING THE FRONT PANEL

The front panel contains the display - and keyboard assembly. To detach it remove 2

screws A, B along the left hand front edge, 2 screws E, F along the right hand front

edge, and 2 screws C, D along the bottom front edge. Disconnect the two flat ribbon

cable connectors (J21 and J20). Now you can put the front panel face down between the

side panels. The white cable from the FL lamp to the FL driver is still connected. In this

position you could install the option assembly. If you need to completely detach the front

panel detach the FL driver cable on the DC/DC converter board (J43). In a 3 phase unit

you may not be able to get to this connector. To disconnect tilt the separator by first

removing screw H on the left side panel, screw G on the right side panel, and screw I at

the bottom inside the case. Now move the separator towards the back panel to slide the

bolt (at location of screw I) out of its hole.

New Amplifier: It is possible to remove amplifiers without removing the separator first.

Start by unscrewing the left hand side panel to get access to amplifiers phase 1, etc.

9.3.3. REMOVING THE SEPARATOR

The separator is the central piece of the Power Analyzer and must be removed

whenever you want to remove amplifiers of phase 2 or phase 3, the Processor

Assembly, or the DC/DC Converter Assembly. Proceed as follows: Remove screw H on

the left side panel, remove screw G on the right side panel, and loosen screw I at the

bottom inside the case. The bolt that is fastened by screw I can be moved out of its hole

by moving the separator towards the back panel. Now disconnect those cables that

prevent removal.

New Amplifier: It is possible to remove amplifiers without removing the separator first.

Start by unscrewing the left hand side panel to get access to amplifiers phase 1, etc.

9.3.4. AMPLIFIERS PHASE 1 REMOVAL

CAUTION: Before removing an amplifier put a tag on it such as I Ph1, or U

Ph1 and make sure to reinstall it at its original location.

Amplifiers are coded for phase 1, 2, 3.

In a 3-phase unit you must first remove the separator.

To detach the voltage amplifier (on top) remove screws K, L, M on the left hand side

panel. Disconnect the plugs at the rear panel binding posts. Disconnect the flat ribbon

cable on the amplifier, disconnect the supply cable at connector PU1 and unscrew the

grounding cable at the DC/DC Converter Assembly.

Similarly you proceed to remove the current amplifier at the bottom: you remove screws

N, O, P first, then you disconnect the input binding posts. The shunt input cable is best

removed from the rear panel connector using pliers.

9-5 9-6

9-7 9-8

9.3.5. AMPLIFIERS PHASE 2 AND PHASE 3 REMOVAL

CAUTION: Before removing an amplifier put a tag on it such as I Ph2, U Ph2,

I ph3, or U Ph3 and make sure to reinstall it at its original

location.

In a 3-phase unit you must first detach the separator.

Phase 3 amplifiers are simple to remove. Remove 2 screws T, U on the rear panel and

loosen screw V at the bottom of the case. Now you can slide the bolt at screw V out of

the hole, disconnect the cables and remove the metal plane holding both phase 3

amplifiers. If you need to remove the amplifiers of phase 2 you should first remove the

three screws holding amplifiers phase 3. This way you can gain more working space.

To detach amplifiers phase 2 remove screws Q, R on the rear panel and screw S at the

bottom of the case. Detach all cables and connectors as already discussed above and

remove the metal plate holding phase 2 amplifiers.

9.3.6. REINSTALLING AMPLIFIERS

Amplifiers are coded for each phase, Make sure to install it in its original location. For

amplifier coding refer to section 9.6.

9.4. FAULT DIAGNOSIS, ASSEMBLY LEVEL TROUBLE-

SHOOTING

It is good practice to try to locate the faulty assembly, if possible at all.

This section lists a number of malfunctions that can occur. Before you go to any details

check if all connectors are tight and in place!

Fault 1: The display monitor stays dark blue when line Power is turned on.

Action: Turn display monitor towards bright light with line power turned on. If you can

see numbers then the cause of the fault is a defective FL lamp or a defective FL driver

mounted on the DC/DC Converter Assembly.

If you can not see any numbers then you have most likely no dc supply in your

instrument. Check fuse on the Main Supply Assembly, if o.k. check the voltages on

connector J7, To do this turn power off, disconnect J7, turn power on again and check

voltages 5V/12V-12V (Refer to Supply Voltage Check).

Warning: Do not touch any part of the main supply. High voltages are

present.

Fault 2: The display lights up but there are no numbers displayed.

Action: The fault lies on the display itself or on the Processor Assembly. The simplest

action would be to exchange the display monitor to determine the faulty assembly.

Fault 3: The instrument runs normal. Current or voltage readings of any one

phase are drastically off specifications.

Action: The fault is on the input amplifier. If it is a current input, the input measuring

resistor may be burnt. Refer to the section „Amplifier Input Repair“. Keep in mind that

making amplifier repairs requires calibration.

Fault 4: The instrument runs normal. Current or voltage readings of all three

phases are drastically off specification when ranges are altered.

Action: The fault is most likely on the Processor Assembly. There is a remote chance

that ULN2003L or 74HC04 near connector J33 on the Option Assembly is defective.

(The ranges are not switched properly).

Fault 5: The instrument runs normal. Current or voltage readings of one phase

are noisy, zero, or at a constant value not equal zero.

Action: The malfunction is caused by the particular Amplifier Assembly. Check the

supply voltage on the DC/DC Converter Assembly for this amplifier (refer to the section

„Supply Voltage Checks“). Check the supply voltage on the faulty amplifier.

Fault 6: The display shows erratic symbols or just garbage.

Action: This malfunction is caused by the Processor Assembly or the display itself.

Fault 7: The instrument initializes properly by displaying all zero values for 1

sec and then locks up.

Action: This is the worst case because there are several reasons why this can

happen. The error can be on any one or several assemblies. The following steps may

help to determine the faulty part.

Step 1: Check all supply voltages on the DC/DC Converter. If one or several supplies

fail the test the error is on the DC/DC Converter Assembly.

Step 2: Check the supply voltages on the amplifier board itself (Refer to „Amplifier

Input Repair“). If one voltage fails the test the fault is on that particular

amplifier.

9-9 9-10

Step 3: Check signals on amplifier connectors J1 through J6.

Separator is on ground potential

pin 3 : 5MHz square wave 3Vptp

pin 4 : 5MHz square wave 4Vptp

pin 2 : 0 to 4V pulse, 200ns wide

pin 7 : 3Vptp pulse

pin 13: 3Vptp pulse (3 phase only)

pin 14 : 3Vptp pulse (3 phase only)

New Amplifier

pin 2: periodic pulse 4Vptp

pin 4: square wave 5mHz

pin 6: continuous transitions 0 to 4V

pin 5/14 Ground

pin 9: +5V

Connectors J1-J6 from solder side

If signal at pin 3 is not present the fault is on the Processor Assembly.

If signals at pin 2 and pin 4 are not present the fault is on any one of the 6 input

amplifiers.

If the pulses at pin 7 are not present, the error is on the Processor Assembly.

If the pulses at pin 13 or 14 are not present the fault is on the Option Assembly.

Note: The pulses on pin 13 and 14 are only valid for 3 phase instruments.

Fault 8: One of the option inputs or outputs is not working properly.

Action: Check cables at the rear panel connectors. If the cables are in order the fault

is on the Option Assembly.

9.5. SUPPLY VOLTAGE CHECKS

Figure 9.3. shows the location where the supply voltages can be measured.

J43 is the high voltage connector to the display FL lamp (non polarized). Do not touch!

Figure 9.3 Power Analyzer Supply Voltages

Amplifier Assembly

16 pol connector from

solder side

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