Test

Test methods & values taken from a file in IFS - Test Method Main board FP2 482000 HE (J -
2,037,811 to 1 - 11). XLS.

actual value - the value measured using a measuring instrument

Measured Value - The value measured using FP2 Monitor
1,1 Quick Test secondary level

Before going into service mode, test the state secondary power transistors. resistance value of
transistors Q200-201 between G and S should be 4.7 k, the value of the resistance of transistors

Insert 30VDC from an external source on output (AC Voltage 0, no load )( If the the current consumption
is around 100mA (this is our real experience) the rectifier is OK (although in our service manual reads
(20-50mA)).
Higher current consumption (>100mA) means malfunction of the secondary card

Check in the FP2 monitor for can communication & primary & secondary card communication.

1.1.2 Service Mode

- To switch to service mode, connect an external DC voltage source, to connector J100i by Fig. 1

Fig. 1 Connect the external voltage to switch to service mode

- D112 yellow LED on the front panel should be flashing and the rectifier is in service mode .
This mode allows the oscilloscope to check the voltage waveforms of transistors Q200 and Q201.

Fig.2 The terminals of transistors Q200 and Q201

the wave form on transistor Q200 (GS) and Q201 (GS), should be similar to the wave form Fig.3 and
the following values:

voltage: Vp-p = 11.5-16V

alternates: 14-18%
frequency: f = 385-420kHz

Fig.3 the gate voltages of transistors Q200, Q201

Test Boost level

- Apply mains voltage Vin = 3-6Vac

- Using an oscilloscope to check the running voltage transistors Q103

Fig. 4 transistor Q103

- Measuring the momentum of transistor Q103 (GS), conforming to the courses of Fig.5 and the following
values:

voltage: Vpp = 13-19 V

alternates: 5-98%
frequency: f = 90-125 kHz

Fig.5 gate voltage of transistor Q103

Apply input voltage uin = 0Vac, stop the Service Mode (ServiceMode) - Auxiliary power is disconnected
from the connector J100i
1.1.3 Off load and power output

- Disconnect the load and apply 30VDC from an external source (27 - 35V DC) to the output terminals.
(Note the correct polarity!)
- Apply Vin = 75Vac to CON100 D (range: 70 - 75Vac)
- Input current to be in the range iin = 40 to 150 mA
- Status LEDs on the front panel shall be as follows:
RED LED D111 ON
ORANGELED D113 ON
GREENLED D112 OFF

Measure the voltage: VOUT Bleeder (voltage on the collector of the transistor Q202, thus the emitter
and SGND (Attention secondary part of the earth)

Fig 6 measuring point and pin config of transistor Q202- Measured voltage should be in the range:
Output Bleeder = 22 to 26.5 VInternal power source for the primary- Measuring the voltage at: Vstart (vs.
PGND) Vstart = 14.2 - 19V.

Fig.8 Internal auxiliary source on the primary side

Connect the converter via IXXAT converter to PC and run FP2 Monitor- Check communication with
controllers (primary and secondary)- Check the measurement of output (VOUT = 20 to 40 V) and ne(Vin =
60 to 80 Vac), voltage, serial number- Disconnect the connected external 30VDC output.
.1.1.4 Start voltage

- Slowly increase the input power , green LED on the front panel should light up at Vin = 76 - 95Vac-
Output voltage should be in the range: VOUT = 45V - 55V.

Boost the voltage level (between the C114 1 and PGND) should be in the range:+400 V = 300 - 450V-
.Increase the input power supply for: Vin = 230 Vac. (225 to 235 Vac)- LEDs on the front panel to be in
the following states

RED LED D111 OFF

ORANGE LED D113 OFF
GREEN LED D112 ON

Further more measure the following values:

Output voltage should be in the range: VOUT = 52 - 55V

+15 V voltage should be in the range: +15 V = 17 - 21V-

V start = 16 to 19.5

1.1.5 Check operation of fans

try to limit the speed of one fan, rectifier should indicate low speed red LED light lights on the front panel.

1.1.6

Calibration of individual variables is performed if the difference between measured and actual value
greater than the specified tolerance.

actual value - the value measured using a measuring instrument

Measured Value - The value measured using FP2 Monitor
All calibration and adjustment values we enter into the PC rounded to 2 decimal places.

Output current Iout

calibrate ;Lo point, the with load value of 0A

Changer load at 95 ± 5% Iout = 31A (30 - 32A),

Calibrate ;Hi point; value. Output current to be now in the range Iout = 30 - 32A

Measure value of current with the FP2 monitor the deviation should not be greater than: ± 0.3A.

Set Output voltage to: VOUT = 53.5 V

Changer the load to 50%, Iout = 16A (15 - 17A)

using the FP2 monitor, set the output voltage VOUT = 43.51 V, the output voltage should be in the range:
VOUT = 42 - 48V,
calibrate Lo point, the value of voltage

using the FP2 monitor, set the output voltage VOUT = 56V, output voltage should be in the range: VOUT
= 53 - 58V,

calibrate ;Hi point, the value of voltage .

using the FP2 monitor, set the output voltage VOUT = 53.5 V,

the output voltage should be in the range: VOUT = 53.45 to 53.55 V .( ± 0.1 V)

Output Reference Voltage

Apply 50% load output current Iout = 16A (15 - 17A.

using the FP2 monitor, set the output voltage VOUT = 56V, output voltage should be in the range: VOUT
= 53 - 58V,

calibrate ;Hi point,

using the FP2 monitor, set the output voltage VOUT = 43.51 V, the output voltage should be in the range:
VOUT = 42 - 48V.

calibrate Lo point,

using the FP2 monitor, set the output voltage VOUT = 53.5 V,

the output voltage should be in the range: VOUT = 52 - 55V.

Boost (boost calibrated only when the primary repair changed PCBA).

Apply 9% load, current Iout = 3A (2.85 to 3.15 A)

using the FP2 monitor, set the output voltage VOUT = 43.51 V, the output voltage should be in the range:
VOUT = 42 - 53V.

the measured voltage (eg C114 between legs 1 and 2), should be in the range: 348V - 352V,

using the FP2 monitor, set the output voltage VOUT = 56V, real Vout be in the range: VOUT = 54 - 58V.;
the measured voltage (eg C114 between legs 1 and 2), should be 410 - 450Vdc,

calibrate Boost Hi point,

Current limitation-

Set the value of the current limitations of 38A (with FP2 Monitor)

- Output current can be vv interval: Iout = 28 - 48A- Calibrate Hi point "- Current value should be in
intevale Iout = 38 - 46A- Remove the short circuit output1.1.7 Control U / I characteristics- Disconnect the
load Iout = 0A

- Measuring the output voltage VOUT at 0% load and Vin = 230Vac, output voltage should be in the
range: VOUT = 53.6 to 53.85 at current <1A- Set the burden of Iout = 33.5 A (32.5 -34.5 A)- Measuring
the output voltage VOUT at 100% load and Vin = 230Vac, the output voltage at the interval to be: VOUT
= 53.2 to 53.4 Vdc- Disconnect the load Iout = 0A1.1.8 VET - surge protection on output- Connect an
external power supply (output): Uout = 61V (≥ 60.5 Vdc)- Disconnect the converter output voltage status
LEDs is as follows:

REDLED D111 ON
ORANGE LED D113 OFF
GREEN LED D112 OFF
- Disconnect the external voltage connected to the output- Inverter output voltage is restored and the
status LEDs is as follows:

RED LED D111 OFF

ORANGE LED D113 OFF
GREEN LED D112 ON
1.1.10 Stop voltage- Input voltage input to gradually decline to Vin = 65Vac- Inverter is switched off when
the input voltage range: Vin = 60 - 70Vac- Green LED should turn off and the output voltage drop to zero-
Download the input voltage uin = 0Vac1.2 The final test of the whole converterThe final test of the entire
converter after correction (test values taken from a file in IFS - TEST_CBMT Test Method 241115,001
FP2 48V 1800W rev.3 (J - 2,025,285 to 1 - 3). XLS), various steps performed as described in a row.1.2.1
Start voltage- Put you to enter some Vin = 75Vac- Input current should be in the range: iin = 20 to 200
mA- Output voltage should be in the interval: -0.1 VOUT = - 5V- LEDs on the front panel to be in the
following situations:

RED LED D111 OFF

ORANGE LED D113 ON
GREEN LED D112 OFF
- Put you to join Vin = 95Vac (90 - 105V)- Output voltage should be in the range: VOUT = 50 - 54V-
Changer connect to a PC and monitor program FP2Tolerance is measured and skutočnéhoVout at Vin =
95Vac: VOUT = ± 1V- Verify that the program shows the correct serial number, part number and software
version of the primary and secondary control PCBA

1.2.2 Calibration Verification

measured value - the value measured using FP2 Monitoractual value - the value of using a measuring
instrument namrená

Mains input voltage- Set the input voltage at Vin = 230 Vac- LEDs on the front panel to be in the following
situations

REDLED D111 OFF

ORANGE LED D113 OFF
GREEN LED D112 ON
Tolerance measured (FP2 Monitor) and is the real Vin Iout = 0A: Vin = ± 1V

Connect load 160W, Iout = 3A (2.85 to 3.15 A)-

Set the input voltage at Vin = 100 Vac-

Measured voltage (FP2 monitor) should be in the range: Vin = 99.5 to 100.5 Vac

Set the input voltage at Vin = 230 Vac

Measured voltage (FP2 monitor) should be in the range: Vin = 228.5 to 231.5
Mains voltage Calibration

Connect load 160W, Iout = 3A (2.85 to 3.15 A)

Set the input voltage at Vin = 100 Vac (99.5 to 100.5 in)

Calibrate "Lo point"

Set the input voltage at Vin = 275 Vac (274.5 to 275.5 in)

Calibrate Hi point

"Calibration Verification:-

Set the input voltage at Vin = 100 Vac

Measured voltage (FP2 monitor) after calibration should be in the range: Vin = 98.5 to 101.5 Vac

Set the input voltage at Vin = 230 Vac

measured voltage (FP2 monitor) after calibration should be in the range: Vin = 227.3 to 232.3 Vac.

Output Voltage

using the FP2 monitor, set the output voltage VOUT = 53.5 V
Apply 50% load, output current Iout = 16.8 A (16.5 to 17.1 A)
The actual output voltage should be in the range: VOUT = 53.45 to 53.55 V

Measure the value of voltage VOUT via FP2 monitor the deviation should not be more than: ± 0.15 V.
If this difference is greater, follow these 2 steps (more time around)!

Apply 50% load, Iout = 16.8 A (16.5 to 17.1 A)

using the FP2 monitor, set the output voltage VOUT = 45V,

output voltage should be in the range: VOUT = 42 - 48V,

calibrate "Lo point,

using the FP2 monitor, set the output voltage VOUT = 53.5 V,

the output voltage should be in the range: VOUT = 50.5 to 56.5 V,

calibrate "Hi point,

If the voltage measurement is still incorrect, proceed as follows:l

Calibration VoutSet (Output Voltage Setpoint)-

using the FP2 monitor, set the output voltage VOUT = 45V,
output voltage should be in the range: VOUT = 42 - 48V,

calibrate "Lo point,

using the FP2 monitor, set the output voltage VOUT = 53.5 V,

the output voltage should be in the range: VOUT = 50.5 to 56.5 V,

calibrate "Hi point,

using the FP2 monitor, set the output voltage VOUT = 53.5 V,

The voltage should be in the range: VOUT = 53.45 to 53.55

Measured voltage from the FP2 monitor should not be greater than: ± 0.15 V

Output current Iout (Output Current)-

Set the input voltage to Vin = 230 Vac-

apply 50% load, Iout = 16.8 A (16.5 to 17.1 A)

Measure current from the FP2 monitor the should not be greater than: ± 0.2 A

Apply 100% load Iout = 33A (33 to 33.6 A)

Measure current from the FP2 monitor should not be greater than: ± 0.2 A

Disconnect the load, 0%, output current Iout = 0A

Measured current from the FP2 monitor should not be greater than: ± 0.2 A

If any difference of measured and actual values more, follow the subsequent step!

Calibration Iout (Output Current)-

Apply 95% load, Iout = 32A (from 31.7 to 32.3 A),

calibrate "Hi point"

Apply 0% load

, calibrate "Lo point,

Apply 50% load, output current Iout = 16.8 A (16.5 to 17.1 A)

Measuring current from the FP2 monitor, the deviation should not be more than: ± 0.3 A

Apply 100% load Iout = 33A (33 to 33.6 A)

Measure current from the FP2 monitor the deviation should not be more than: ± 0.3 A

Disconnect the load, Iout = 0A

Measure current from the FP2 monitor the deviation should not be greater than: ± 0.3 A
set output voltage to: VOUT = 53.5 V.

Current ceilings for (Current Limit)

Short circuit the load.

Set the input voltage at Vin = 230 Vac-

LEDs on the front panel to be in the following situations:

RED LED D111 OFF

ORANGE LED D113 OFF
GREEN LED D112 ON

The actual short-circuit current should be in the range: Iout = 36.8 to 38.7 and (if necessary calibrate and
verify)-

Set the input voltage at Vin = 145 Vac- The actual short-circuit current should be in the range: Iout = 28 -
34A (if necessary calibrate and verify)

Remove the short circuit output

1.2.3 V / I characteristic

Set the input voltage at Vin = 230 Vac

Disconnect the load, 0%, output current Iout = 0A

The actual value of the output voltage should be in the range: Vout = 53.55 to 53.85 V

Measure VOUT from FP2 monitor the deviation from the true value must not be greater than± 04v

Apply 100% load Iout = 33A (33 to 33.6 A).

The actual value of the output voltage should be in the range: Uout = 53.2 to 53.4 V

Measure VOUT from FP2 monitor, the deviation from the true value must not be greater than:± 0.4 v

Apply 105% load Iout = 36A (from 35.5 to 36.5)

The actual value of the output voltage should be in the range: Uout = 48.5 to 52.5 V

Measure VOUT from FP2 monitor the deviation from the true value must not be greater than:± 0.4 V-

Measuring the output current at 105% load, should be in the range Iout = (35.5 to 36.5 A)

Measure VOUT through FP2 monitor the deviation from the true value must be not greater than:± 0.4 v
1.2.4 Vmax-

Apply load 160W, Iout = 3A (2.8 to 3.2 A)-

Using FP2 Monitor set Vout = 57.6 V- The actual value of the output voltage should be Vout> 57.3 V

Apply load of 95 ± 0.2%, output current Iout = 31.9 A (31.6 to 32.2 A)

The actual value of the output voltage should be in the range: Vout = 57.3 to 57.9 V

1.2.5

Using FP2 Monitor set Vout = 43.51 V

Disconnect the load, 0%, output current Iout = 0A

The actual value of the output voltage should be in the range: Uout = 41 - 44V

Measured (FP2 monitor) output voltage should be in the range: Uout = 41 - 44V