Maintenance and Troubleshooting
Spirit200a User’s Manual Rev J
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7-12
Chopper Test Procedure
WARNING: Only qualified maintenance personnel should perform
the chopper test procedure. The system utilizes potentially fatal A.C.
and D.C. voltages. All maintenance should be performed with safety
in mind.
Use extreme caution when working near the power conversion
module (i.e., chopper). The large electrolytic capacitors store large
amounts of energy even after power has been removed from the
system. Wait at least five minutes after turning off power, and then
use a voltmeter to verify that the capacitors are fully discharged
before touching the power conversion module.
Capacitor failure can injure and/or cause property damage. If
troubleshooting requires the system to be powered with the
enclosure panels removed, remain clear of the capacitors. Failure of
a capacitor can result in a sudden release of stored energy causing
rupture of the capacitor case.
Note: A chopper troubleshooting flow chart can be found at the end
of this section
.
1. Turn off all power to the Spirit power supply.
2. Open the RHF console door and disconnect the black primary wires
of the high frequency transformer from the 120 VAC line filter. Close
the RHF console door to activate the door interlock switch.
3. Remove the front and left side panels from the power supply to
expose the output terminal block and the microprocessor p.c. board.
4. Remove the Electrode and Nozzle leads from the
bottom
connections of the output terminal block (#59 & #79, page 8-5).
5. Apply three phase power to the unit and check the primary power on
the input terminal block TB5.
6. Depress the ON button to energize the Spirit system, and then apply
a start signal to the unit.
Note that the unit will only energize for
approximately two seconds each time a start signal is applied.
When making the following readings, be sure the red DC Power
light is illuminated on the front control panel of the unit
. After
applying the start signal, check the three phase voltage input to the
chopper at the diode bridge terminals (three right side screws on the
chopper assembly) for 208 VAC. If the voltage is not present, check
for primary voltage on the main contactor CON and on the primary
side of the power transformer.
7. With a start signal applied, check for 300 VDC at the Spirit output
terminal block between Electrode and Work. If 300 VDC is present,
the chopper is working properly.
