Open Circuit Output Voltage Not Regular - Cebora SYNSTAR 200 M Manual De Servicio

♦ With J1 on supply board (53) connected and
with the power source off, temporarily dis-
connect J9 from power board (45). Power
up the power source and make sure on J9
of power board (45) terminals 2(+) and 1(-),
voltage = +50 Vdc approximately, with start
button pressed.
If not correct:
− check the inverter operation performing,
if necessary, the OPEN CIRCUIT OUT-
PUT VOLTAGE TEST, par. 3.3.8;
− verify efficiency of the diode D30,
capacitor C40 and power transformer TF5
on power board (45) (see Fig. 2.3.1);
− replace power board (45).
If correct, identify defective components on
panel board (48), based on the map connec-
tors of par. 5.5 and replace them.
♦ Replace power (45) and/or supply (53) and/or
panel (48) boards.
SPEED FEED-BACK SIGNAL TEST.
□ Panel board (48), connector J4, terminals 2(+) - 4(-) =
terminals 3(+) - 4(-) = Fig. 5.2.1, three seconds after
pressing the start button (speed feed-back signal from
motor encoder).
NO Correct?
♦ Regular operation.
■ Check the wiring between J13 panel board (48) and
wire feeder motor (25).
■ Make sure there are no mechanical impediments
blocking the motor (25).
■ Check the motor rotation direction. If incorrect, reverse
the wires on connector J13.
■ With the power source off, temporarily disconnect
the wire feeder motor (25) terminals from connector
J13 on panel board (48) and make sure the resistance
between the motor terminals left free. Correct value =
approximately 3 ohm (motor winding resistance). If 0
ohm (short circuit) replace wire feeder motor (25) and
check integrity of mosfet M2, M3, RL1 relay, resistors
R83, R85, R79, R80 and diodes D16 and D17 on panel
board (48) (see connectors map, par. 5.5).
■ Replace the wire feeder motor (25) and/or supply (53)
and /or panel (48) boards.
ENCODER POWER SUPPLY TEST.
□ Panel board (48), connector J4, terminals 1(+) - 4(-),
voltage = +5 Vdc.
3302316/A
YES
ENCODER TEST.
□ With power source off, temporarily disconnect J4 from
the panel board (48) and check resistance between
terminals of the patch connector disconnected from J4:
− terminals 1 - 4 = terminals 2 - 4 = terminals 3 - 4 =
20 Kohm approx.
If short-circuited, replace motor (25) and panel board
(48). If >Mohm replace the motor (25).
3.3.8

Open circuit output voltage not regular.

OPEN CIRCUIT OUTPUT VOLTAGE TEST.
□ Output terminals C(+) and D(-) on power source = ap-
proximately +96 Vdc, depending on polarity reverser
position, with start button pressed.
NO Correct?
♦ Regular operation.
BOOST CONVERTER OPERATION TEST.
□ Power board (45), R32 SHUNT(-) terminal (in proxim-
ity of inductor L3) and dissipater DISS2(+), voltage =
+395 Vdc, with power source powered and after start-
up phase, 5 s approximately.
YES Correct?
♦ Check correct fixing and connections
cleaning of the PFC board on power board
(45) J5 connector.
♦ Check the conditions of the boost converter
power components (L3, U5, U7, R32, D11,
D12, C27, C28, C29) on power board (45).
♦ Replace power board (45).
TF5 TRANSFORMER
VOLTAGE TEST.
□ Power board (45), VITE1 terminal(gnd) and R84
terminal (R83 side) = Fig. 5.2.2, open-circuit voltage
on TF5 power transformer secondary side, with start
button pressed.
NO Correct?
♦ Make sure that in the wiring between termi-
nals VITE1 and VITE2 on power board (45),
polarity reverser and power source output
terminals C and D are not short circuits or
isolation losses towards ground. If you find
loose connections, tighten and replace any
damaged components.
YES
NO
SECONDARY CIRCUIT
YES
25
EN