WV. A TROUBLESHOOTING General The "Troubleshooting" section of this manual is written to facilitate maintenance using simple hand tools and a multimeter, such as a Simpson Model 260 or Triplet Model 360. Complete adjustment. requires the use of an oscilloscope. The equipment does come from the factory with all adjustments preset and sealed. Most maintenance problems require only the use of a multimeter, A few simple multimeter checks and use of operator panel meters or tell- tale lamps will generally locate the problem. Many times a mere visual inspection will locate a source of trouble, but an ohnmeter check should thereafter be made to verify all parts are good before reapplying power. ADVICE Do not break the seal on pots of the control board and adjust in troubleshooting. The control can be misaligned such that further damage to the system will result and an oscilloscope setup be required. Avoid the temptation to turn pots in diagnosing a problen. AS previously stated, the majority of problems can be diagnosed by use of a multimeter, panel meters, and indicator amps. How to Use an Ohmneter A simple ohnmeter is a very useful instrument that may be used for the location of circuits. It allows one to make checks with no power on the equipment, thus is the safest instrument for inexperienced personnel. Usually, VOM (volt-chm meter) is used for this purpose as it requires no external power to operate the instrument, making it portable. A VOM of at least 20,000 ohms per volt should be used. A meter like a Simpson 260 VOM is recommended. Other inexpensive meters may be found with the mentioned ohms per volt. Some meter manufacturers may design their meters to read polarity in the reverse direction and must be recognized for this fact when making polarity measurements; for example, diodes read in one direction only when good. Semiconductors are to be checked on the Rx 1 scale of an ohmmeter. Usually a selector switch is provided for selecting this range. With one end of the leads inserted into the meter (see meter instructions) and the.other ends open, the meter will see an infinite resistance and remain at infinity. (Infinity symbol = 00) By touching the leads together, a short or zero ohms is seen by the meter. A control knob is provided on the meter for calibrating the meter to zero ohms. This must be adjustéd before using the meter and checked for zero if moved to a different scale. If the meter cannot be zeroed, it is generally a sign that the battery is weak and needs replacing. See the following "Ohnueter Tests for Semiconductors" and the troubleshooting tests section for other tests that may be performed with an ohmmeterAs mentioned earlier, the ohmmeter may be used to check continuity The leads may be placed across a conductor and measure the resistance between the leads. A copper wire or bus will have a very low resistance and appear to be a short when looking across it. A resistance in the line between the leads will cause the meter to read the value if properly calibrated. Ohaweter Tests for Semiconductors (Out of Circuit Set the multimeter to R x 1 scate. The meter has an internal battery which supplies power when used to measure resistance Determine which lead of the meter is connected to the positive end of this battery. This can be done by checking a diode which is known to be good. Semiconductors almost always fail short. A meter reading of 0 ohms indicates a failed device ‘i 1. Place plus lead on anode and vier minus lead on cathode. Read ANODE >. CATHODE approximately 5 to 10 ohms sj CATHODE : 2. Place plus lead on cathode and minus lead on anode. Read more than 10,000 ohms. Mote: This test is good for both small signal diodes as well as large power diodes. Power diodes are made in both forward polarity and reverse polarity. The stud is the cathode on forward polarity diodes. The stud is the anode on reverse polarity diodes 1. Place plus lead on anode and minus lead on cathode. Read more than 10,000 ohms. ANODE PS CATHOPE 2, Place plus lead on cathode and “GATE. minus lead on anode. Read more than 10,000 ohms. 3. Place plus lead on gate and minus lead on cathode. Read approx- imately 15 to 30 ohms. THYRISTOR (SCR)Ohmmeter test for semiconductors (In Circuit) 1. Remove al) power from cabinet. 2. Set ohmmeter on R x 1 scale 3. Check module diagram for device location. 4. Take ohmmeter readings across each device and check per Table I. 5. If O ohms is read across a device, isolate device and check again 6. Remove failed device 7. Install new device using recommended procedure See Procedure for Removal and Replacement of Power Semiconductors 8. Before discarding failed device, always ohmmeter check it one more time TABLE 1 OHNMETER READINGS DEVICE FORWARD, REVERSE RECTIFIER DIODES 5 to 10 OHMS MORE THAN D1,02,03,04, 05,06 10,000 OHMS BLOCK DIODES 5 TO 10 OHMS MORE THAN 801, B02 10,000 OHMS CLAMP DIODES 5 TO 10 OHMS MORE THAN 01, coz 10,000 OHMS DISCHARGE O100ES 5 TO 10 OMS MORE THAN 07,08 - 10,000 OHMS THYRISITORS 15 TO 30 OHMS MORE THAN SCRI sSCR2 10,000 OHMS SCR3,SCREBasic Power Circuit Check with Ohmmeter These tests should be performed before applying power upon unit installation or after a failure has occurred. If fuses are found to be bad, a power semiconductor check should be made. Making these checks will be time well spent, rather than gambling that everything is proper in applying power to the system. Caution: Ohnmeter checks are to be performed with the power supply de-energized. One should insure that no charge remains on capacitor studs or bus bars before handling. 1, Fuses - Check the power fuses with the miltimeter conditioned for an ohmmeter test on the R x 1 scale. These are located at the ‘output of the disconnect switch for incoming three phase Tine voltage. A good fuse will read zero ohms. A defective fuse will read more than 1000 ohms. Because of sneak paths through other components in the system, a reading other than zero ohms should be interpreted as defective. The various control fuses will usually be good when checked after most fault conditions. If necessary, they can easily be checked by removing them fron their respective Sockets. If removed, insure that they are returned properly. Contro] fuses will usually relate to obvious problens, such as no control lights, no voltmeter reading (potential transformer fuses), or Tack of operator control with the power dial 2. Power Semiconductors - The power devices (diodes and SCR’s) can be checked without removing them frofl their heat sinks. This is advised in all cases where possible. fach should be checked in the forward and reverse direction as indicated in Table 1. Parallel circuit paths will cause the meter to read an ohm value in one direction on good devices in some instances. A zero ohm reading (short) across a device in both directions is an improper reading. Power devices of this nature usually fail short circuit. Caution: Where devices are in parallel, it may be another part in the system that is bad, which will reflect a short on the device being measured. If a short is observed, the branch circuits should be isolated until a bad device is located. Another Word of Caution: When a semiconductor is removed from the circuit, it may appear open (high reading in both directions) which is caused by no pressure .applied to the pole faces of the device. 3. Capacitors - If a capacitor develops a short, it will usually read near or at zero ohms on the ohmmeter check. - Again, sneak paths of parallel circuit should be watched for when making checks of this nature, If switching leads or polarity 6f the multimeter indicates a different reading on the multimeter (one high - one low), the capacitor is most likely a good capacitor will slowly charge through the batteries of the mltimeter. If a short is observed on themultimeter and the capacitors are in parallel, it will be necessary to isolate the individual section for the short. This should be verified before removing the part. A swollen capacitor in a group would be an obvious candidate for failure. F. General Troubleshooting Outline 1. Visual Cheek Check for bulged, or leaky capacitors Check buswork for any loose connections Examine KS contactor and RI resistor Check for any loose or burnt wiring Check for water leaks or condensation problems Check a1] water-cooled resistor assemblies 2. Ohmmeter Check Line diodes Clamp and block diodes SCR’s (Thyristors) CP capacitors ___ OF capacitors 3. DC Bus Voltage Balance (Breaker on, Unit off) Check positive bus to neutral bus (+ 325 VDC) for 5OKW and up. +175 for 10,20,and 30KW. Check negative bus to neutral bus (- 325 VOC) for SOKW and up. -175 for 10,20, and 30KW. OC bus voltage must be balanced within 20 volts. If not, check the following: Any accumulation of dirt or condensation that may cause leakage. Line voltage. Check phase to phase and phase to ground. One phase may be grounded. (480 .VAC nominal) CF capacitor bleeder resistors, R2 and R3Isolate one CF capacitor at a time on low side, (Must remove one CF capacitor on high side to maintain balance). Isolate or replace on SCR at a time on low side. Isolate other components on low side one at a time (i.e., CP, RC snubbers). Check if any water hose has been replaced. May be conductive. V. CORRECTIVE ACTION AL Circuit breaker will not energize. Check that 211 doors are closed. Check that door switches are operating properly. Check for 24 VOC at breaker undervoltage coil. If voltage is low, replace batteries on 24 volt supply board. Check circuit breaker linkage. May have to reset breaker manually. Power Supply will not start. lL. 2 Check that al] fault lamps are out. Check that “power ready" lamp is on. If not, check that any customer connected interlocks are operating properly. If unit has auto/manual switch and the switch is in the auto position, you mist push the start button to get a power ready Tight. Check control board Pin 2. Pin 2 must go to 420 volts to start. If Pin 3 goes to +20 and unit does not start, replace or troubleshoot control board (single control board units). Check oscillator board pin 3 for +20 volts to start. Fuse Failure. 1 2. 3. Perform visual check of unit Ohmmeter check unit for failed component. Replace failed component. Be careful to observe proper installation procedureD. Fuse Failure with No Bad Parts If failure of fuses occurs with no bad parts found, a number of possibilities arise. On a rare occasion, a capacitor will are or break down internally while operating and cause fuses to fail, then appear good when making tests. This type of failure is difficult to locate, but usually it will not occur too many times before total failure of the capacitor occurs. A visual inspection for a swelled capacitor or listening for the arc while running will sometimes aid in locating the source of failure. A visual inspection may locate where a breakdown has occurred external to components. Such things as coolant leaks, loose connections, foreign material (i.e., dropped pieces of wire, loose hardware, metal filings, discolored or bent bus, tools left in enclosure, etc.) may be the result of intermittent fuse failures The cooling system may relate to fuse failure if it is improper. A minimum of 30 PSI differential pressure is to be maintained across’ the inlet and outlet water manifolds to insure adequate flow in all lines. The inlet water temperature cannot be above a maximum rating of 95°F. Switches in the system monitor the inlet pressure and temperature for safe operation. Caution Tampering with these devices can only lead to trouble and will void the warranty. Outlet temperature switches are utilized to insure safe operating temperatures of individual lines. Any improper performance of water Tines should be checked out and corrected. The cooling system is important for protection of the water-cooled components. Kinked hoses or restrictions from deposits will lead to eventual failure. Targets as described earlier in the maintenance section are used for electrolysis protection and should be watched until the rate of decay is determined. A more elusive and complex problem may result from radio frequency "noise." This can result from improper or poor wiring practices where radiated or conducted electrical transients are fed into the control and disturb its normal operation. This can usually be completely eliminated or avoided if a few simple rules are followed. If none of the previous usual problems have been found, then it is advised that the following questions be answered. ‘Are control wires and power cables separated between the load station and power supply? ii Are wires twisted or shielded as indicated on drawings, particularly where Tong runs are used? Verify that no cut or frayed wires exist.iii Oo all relays associated with control or connected to the power supply 115 VAC line have snubber protection around their solenoid coils? iv If the equipment has been running up to now, has any new circuitry been added to the control about he time trouble started? v Is there proper clearance and insulation at the work station for bus bars and coil? If very severe arcing has occurred, disturbances may be getting back to the power supply even though there is isolation between the power supply and load. The power supply is capable of operating into shorts or open circuits at the work station Protective circuitry in the power supply will stop the unit if a continuous short exists at the Toad. An open will usually result in the power supply operating in voltage Vimit Intermittent Iripping Intermittent tripping can be caused by a part failing under oad, noise problems, a control board problem (false tripping), or a malfunciion in the load circuit 1 Part failing under load The most common part to fail under load would be an SCR. Next would be a capacitor. The only way to find a part that is failing under load is through a process of elimination. A Monitor OC bus voltage with respect to neutral while running unit. If a part is failing under load, either the positive or negative bus voltage will collapse to 0 volts and then recover to normal levels after the unit has tripped Turn unit on. Turn power up slowly while watching voltmeter. If positive bus voltage collapses to zero, then part failure is in the positive section. If negative bus voltage collapses Lo zero, then part failure is in the negative section. If bus voltage collapse is only partial (100-150 VDC), then it is probably a control board problem (misfiring). Change or troubleshoot control board. If bus voltage stays constant at point of trip, then problem is either load related (i.e., tank capacitor breaking down, severe arching at work coil) or a control board problem (false tripping)0. If bus voltage collapses to zero then: 1. Replace SCR's one at a time on side that collapses 2. Swap CP capacitors. The idea is then to try to get the bus collapse to move to the opposite side. 3. Swap other inverter components untiT bus collapse moves to the opposite side > CAUTION: When using the oscilloscope to monitor waveshapes in the power section, high voltages will exist on the chassis if the ground Vead of the probe is connected into the power circuit. Care must be used in handling the oscilloscope. A good insulating material should be placed between the operator of the oscilloscope and earth or frame ground. The oscilloscope must always be isolated from the line! This may be accomplished by using an isolation transformer between the 115 VAC Vine and oscilloscope or by not connecting the ground of the three prong plug. Failure to operate the oscilloscope in this manner will result in damage to the instrument or probe. Before looking at any waveshapes of the equipment, it is always necessary to compensate the probe. Without doing this first, some distortion of the observed wave will exist. The oscilloscope manual will explain how to perform this function, but generally a square wave should be observed at the calibrator terminal of the oscilloscope. The x 10 probe would be the most, convenient for monitoring waveshapes. A x 1 probe should be avoided. A x 100 probe will be useful for some of the waveshapes in the power circuit, however, the x 10 probe will suffice for most measurements. As mentioned previously, the scope chassis may have high potentials on it when monitoring the power circuit with the ground lead attached to the high frequency bus. This may be overcome by looking at a signal using both channels of a dual channel -oscilloscope to monitor a waveshape. 8y setting the gain for each channel equal {both probes need to be the same "X" value), ihverting one channel, establishing a common reference for each channel, and monitoring the signal with one probe acting as a ground, a waveshape may be observed using the scope amplifiers for isolation_WrvE FORMS OsciLtLoscor MONITOR AY FIRING CONTROL BOARD PIN IB REE: PIN IT POSITIVE WAVEFORM SHOW” NEGATIVE WAVEFORM INNERTED orm SCR Wav PEAK REVERSE VOLTAGE -S™ +600 PIN IS REED PIN IT Wes aye BaaS G. (teas fES> 08 DI-daS tous | ON TIME 280 ( NOTE 1. ON-TIME - 20 To 25 ~ SEC. NOMINAL 2. TURM-OFF-TIME — 10 USEC. MINIMUM 3B. PEAK REVERSE VOLTAGE - S00 VouTS Maximum CAUTION! OSCILLOSCOPE MuST BE UNGROUNDED