Yamaha 02R96 Power Supply Repair Manual 电路图.pdf

《Yamaha 02R96 Power Supply Repair Manual 电路图.pdf》由会员分享，可在线阅读，更多相关《Yamaha 02R96 Power Supply Repair Manual 电路图.pdf（16页珍藏版）》请在收音机爱好者资料库上搜索。

1、REPAIR MANUAL HAMAMATSU, JAPAN POWER SUPPLY UNIT PA 011645 CONTENTS ANALYSIS-REPAIR FLOW CHART 2 2H032W AC-DC POWER SUPPLY 10 ABOUT ANALYSIS AND REPAIR OPERATIONS 14 CIRCUIT DIAGRAM 15 PARTS LIST 16 02R96 RadioFans.CN 收音机爱 好者资料库 ANALYSIS-REPAIR FLOW CHART Confirm claim information F1: CERAMIC FUSE 5

2、0CT063H Replacement parts (Including preventive replacements) PKG1 RC1: RBV-1506 R2, 3, 4: A53K-220J 5W 22 ohm J Q1, 2: 2SK2915 R10,11: BPR58 5W 0.02 ohm K R3, 4, 5, 6: AK53K-220J 5W 22 ohm J R10, 11: BPR58 5W 0.02 ohm K Z1: L4981A PKG2 Q15, 16: 2SK2641-01 R64: RSMF2SL 0.22 ohm J R66, 69: RSMF12T 22

3、 ohm 1/2W 22 ohm J R65, 68: RSMF12T 47 ohm J 1/2W 47 ohm J RX10: CR21TR680J R76: CR21TR101J R77: CR21TR101J R75: CR21TR331J Z2: SMA-Z1001A Q19, 20: 2SK2698 R84: RSMF2SL 0.22 ohm J R85, 88: RSMF12T 47 ohm J 1/2W 47 ohm J R86, 89: RSMF12T 22 ohm J 1/2W 22 ohm J RX13 CR21TR390J R96: CR21TR101J R97: CR2

4、1TR101J R95: CR21TR181J Z3: SMA-Z1001A Q22, 23: 2SK2641-01 R102: RSMF2SL 0.33 ohm J R104, 106: RSMF12T 10 ohm J 1/2W 10 ohm J R109: CR21TR152J RX14: CR21TR821J PKG3 Z4: SMA-Z1001A PKG3 R108: CR21TR471J F1 Open RC1: Rectifier R2, 3, 4, 5: Anti-collision resistor Q1, Q2: Main FET R10, 11: Gate resisto

5、r Q15, 16: Main FET R64: Protection resistor R66, 69: Gate resistor Q19, 20: Main FET R84: Protection resistor R86, 89: Gate resistor Q22, 23: Main FET R102: Protection resistor R104, 106: Gate resistor Z5: Control IC 1-4pin, 12-14pin R119: Protection resistor R119: RSFM2SL 0.68 ohm J R133: CR21TR22

6、2J RX16: CR21TR271J PKG3 Z5: SMA-Z1001A PKG3 R132: CR21TR331J NO YES 2 1 Input filter section PFC circuit +5V system circuit +12V system circuit +5V, +/-15V system circuit +48V, +20V system circuit No abnormality 1 2 RadioFans.CN 收音机爱 好者资料库 AC power supply input Confirm output Implement unable-to-re

7、create test items Confirm the start-up condition of each output voltage using OSC. (Overvoltage protective operation, yes/no) Completely no output Check PFC circuit operation Investigate PFC circuit Stop after momentary oscillation FET Vds “H” level Intermittent oscillation Confirm main operation wa

8、veform (refer to page 4) Detection of circuits not outputting Abnormal wave form Secondary side output circuit investigation Inspect whether or not there is output terminal shorting of the secondary side output circuit Operation of protective circuit, mis-operation Control IC Vcc voltage level YES N

9、G YES +/-15A,+/-5A+48, +20, +12A+12D T V 0V +5D, +5LED No output of 1 system Rated voltage Overvoltage detection 1 345 +/-15A,+/-5A Q23 D-S +48, +20, +12A Z5 14-12 +12D Q20 D-S +5D, +5LED Q16 D-S C15: Output terminal voltage (380V) Overvoltage operation ALM Z1 Vcc voltage level “L” 3 RadioFans.CN 收音

10、机爱 好者资料库 4 Main transistor operating waveform CH1=100VCH2=10mV DC 100:1DC 1:1 2s/div (2s/div) NORM: 200MS/s CH1=100VCH2=10mV DC 100:1DC 1:1 2s/div (2s/div) NORM: 200MS/s CH1=100V DC 100:1DC 1:1 CH2=10mV2s/div (2s/div) NORM:200MS/s CH1=100V 1s/div (1s/div) NORM:100MS/sDC 100:1DC 1:1 CH4=10mV 1) +/-15

11、A, +/-5A series main operating waveform 2) +48A, +20A, +12A series main operating waveform 3) +12D series main operating waveform 4) +5D, +5LED series main operating waveform PKG 2 Q23 (Between D-S) 2SK2641 V:100V/DivH:2s/Div PKG 3 Z5 (Between 14-12) STR-Z1508 V:100V/Div V:100V/Div PKG 2 Q20 (Betwee

12、n D-S) 2SK2698 H:2s/DivV:100V/DivH:2s/Div PKG 2 Q16 (Between D-S) 2SK2641 H:1s/Div G Test Conditions Input voltage: 276 V Load: Rated NG OK Confirm part open/short (handy tester) Q14,D33,D39,Q17,D40 Q18,D45,D48,Q21 PKG3 Q25,D55 Q47,D75 OK NG OK 4 Determine control IC Vcc level +15A circuit (RV3) +12

13、A circuit (RV4) +12D circuit (RV2)(RV1) CN103 From between pin 9 - 10 to pin 12 - 14 3 Determine RV setting position Reset RV or return release setting position to center. Confirm RV setting position Confirm control IC Vcc level 6 +5D circuit +5D circuit +5D circuit +5A circuit CN104 From between pi

14、n 1 - 2 to pin 3 - 4 +12A circuit Determine output short circuit Circuit short circuit location. Check for items such as part failure. CN102 From between pin 1 - 7 to pin 8 - 14 +12D circuit CN101 From between pin 3 - 8 to pin 9 - 14 +5D circuit CN103 From between pin 5 - 6 to pin 3 - 4 -15A circuit

15、 CN103 between pin 15 - 16 -5A circuit CN104 between pin 5 - 6 +20A circuit CN103 From between pin 1 - 2 to pin 3 - 4 +15A circuit+48A circuit Z2 between 1-4 Approx. 17 V +12D circuit +12D circuit Z3 between 1-4 Approx. 17 V +/-15D circuit +/-15A circuit Z4 between 1-4 Approx. 17 V +48A circuit +48A

16、 circuit Z5 between 1-4 Approx. 17 V 5 Confirm whether or not there is output short circuit (secondary side output circuit) CN104 between pin 7 - 8 5 Investigate secondary side output circuit Investigate primary side circuit Check CD terminal Confirm control IC CD terminal (2 pin) level ALM H If CD

17、terminal level H, confirm circuits including control circuit as operation of the overvoltage protection circuit is most likely. Feedback circuit (PC) operation level confirmation. Is secondary feedback operating normally? Are the output voltage waveform for auxiliary voltage winding and power supply

18、 voltage normal? Very few part failures are due to the windings on transformers and other parts. (Semiconductor parts are the main cause.) Control IC voltage waveform reference (refer to page 7) Photocoupler confirmation Primary side Check photocoupler Secondary side Check auxiliary power supply lev

19、el 6 OK CD terminal waveform Since the failed parts are often semi-conductor parts, it is possible that the failure mode is open or shorted. OK OK OK Over voltage detection circuit Voltage control circuit Confirm part open/short (handy tester) Confirm part open/short (handy tester) +5D circuit +5D c

20、ircuit +12D circuit +12A circuit +/-15A circuit +12D circuit +20A circuit +12A circuit +/-15A circuit Control photocoupler Measuring pointCD terminal voltageCircuit diagram +5V circuit +12V circuit +48A circuit +/-15A circuit PKG2 PC3, D79PC4, Z6 PKG2 PC5, D82PC6, D65, Q28 PKG2 PC7, D88D91, Q29 PKG2

21、 D101- - - - - - PKG2 PC9, D103D109, Q38 PKG2 PC3 PKG2 PC6 PKG2 PC8 PKG2 PC10 ALM OK Z4 between 2-4 Z2 between 2-4 Z3 between 2-4 Z5 between 7-3 ALM operating Approx. 6V Circuit diagram Circuit diagram 6 Investigate secondary side circuit Abnormal voltage at output connector 1.Output voltage is low

22、Confirm VR position for output voltage setting Is secondary side standard voltage abnormal? 2.Confirm pin output of output connector Connector contact or pin damage. 3.Confirm conductivity between secondary output to output connector. 4.Output ripple is big Ripple hunching 5.Confirm secondary side o

23、utput line of soldering graph, etc. 1.Confirm impedance among control IC terminals (Compare with normally operating parts, etc.) 2.Confirm semiconductor impedance (check for shorts, open circuits) 3.Confirm open for resistor parts? Failure of primary side part Investigate primary side circuit CH3=5V

24、500ms/div (500ms/div) NORM:2kS/s DC 1:1 G CH3=5V500ms/div (500ms/div) NORM:2kS/s DC 1:1 G CH3=5V500ms/div (500ms/div) NORM:2kS/s DC 1:1 G CH3=5V500ms/div (500ms/div) NORM:2kS/s DC 1:1 G PKG1 Z1 between 19-10 (PFC circuit control IC) PKG2 Z2 between 1-4 (+5D, +5LED circuit control IC) PKG2 Z3 between

25、 1-4 (+12D circuit control IC) PKG3 Z4 between 1-4 (+/-15A, +/-5A circuit control IC) V: 5V/div H: 0.5S/divV: 5V/div H: 0.5S/div 7 Control IC voltage waveform Test Conditions Input voltage: 276 V Load: Rated Unable-to-recreate test items Shipment Such as printed circuit boards, soldering, part mount

26、ing and foreign material. Check output voltage * Check that the output voltage of each circuit is being output normally. Refer to the Voltage Confirmation Table provided on a separate sheet for the measuring points and voltage ranges. (refer to page 9) * As necessary, visual inspection of internal a

27、reas of power supply. * The output at the SW1 on/off should be normal. Refer to the Voltage Confirmation Table provided on a separate sheet for the measuring points and voltage ranges. (refer to page 9) * Operate Power on/off and SW on/off and confirm that there normal signal transmission. Refer to

28、the Voltage Confirmation Table provided on a separate sheet for the measuring points and voltage ranges. (refer to page 9) * Perform the tapping test while monitoring the output voltage waveform by OSC to check the waveform changes. * Check the exterior * The edging test conditions should be impleme

29、nted based on the conditions occurring in the claim. * Check if output operates normally when there is AC input and ON/OFF operation. Refer to the Voltage Confirmation Table provided on a separate sheet for the measuring points and voltage ranges. (refer to page 9) PowerOn/Off SW On/Off Caution sign

30、al Output ripple wave Check the exterior Edging test OK NG 1 8 +5D Circuit name Measuring point From CN104 pin 9 to between pin 3,4 AC input Other output Caution signal 5.0V Rated voltageOutput voltage rangeMeasuring point +12D12.0V10.8V - 13.2V +5A5.0V4.5V - 5.5V -5A-5.0V4.5V - 5.5V +15A15.0V13.5V

31、- 16.5V -15A-15.0V13.5V - 16.5V +12A12.0V10.8V - 13.2V +20A20.0V18.0V - 22.0V +48A48.0V46.08V - 49.92V 95% 4.85V - 5.25V Voltage Confirmation Table Confirm signal sending (AC OFF signal) CN104 Between pin 7-8 CN104 Between pin 5-6 CN104 From between pin 1-2 to 3-4 CN103 From between pin 5-6 to 3-4 C

32、N103 From between pin 1-2 to 3-4 CN103 Between pin 15-16 CN103 From between pin 9-10 to 12-14 CN102 From between pin 1-7 to 8-14 CN101 From between pin 3-8 to 9-14 30 ms or more 10 ms or more 9 2H032W AC-DC POWER SUPPLY 2H032W AC-DC power supply Primary side inverter blockSecondary side control circ

33、uit Input filter section PFC block +12V system circuit +5V, +/-15V system circuit +48V, +20V system circuit +5V system circuit 10 Input filter section F1Input fuse (F1 Ceramic fuse 50CT063H) PFC circuit block R10, 11 R4, 5 Q2Q1 RC1 R2, 3 11 +5V system circuit block +12V system circuit block +5V, +/-

34、15 system circuit block Q16Q15 Z2 Z2 Q19R84Q20 Q23PKG3 Z4 Q22 R64 12 +48V, +20V system circuit block Each setting VR RV1: +5V ADJ RV2: +12D ADJ RV4: +12A ADJ RV3: +15A ADJ RV6: -5A ADJ RV5: +5A ADJ PKG3 Z5 13 14 ABOUT ANALYSIS AND REPAIR OPERATIONS 1.Test Equipment 1-1. Equipment used for analysis a

35、nd inspection Measuring equipment and equipment required during analysis 1) Input equipment:Input insulation transformerEnsuring safety during investigation Input autotransformerEnsuring safety during investigation (Implementing analysis while raising the input from 0V to the rated capacity.) 2) Loa

36、d equipment: Simple inspection equipmentFor checking output and performance operation confirmation 3) Measuring equipment: Synchroscope, DMM, Tester, etc.For confirming waveform Since the synchroscope input performs the primary circuit measuring, the insulation of the input line requires a 1:1 insul

37、ation transformer. In addition, it is recommended that a autotransformer be used for secondary damage prevention during analysis. 1-2. Part replacement and assembly jig preparation Since this power supply uses a through-hole type printed circuit board, conventional soldering is difficult and an elec

38、tric suction type tool is required. Moreover, a torque driver or similar equipment that can control tightening torque is required to control the torque during the mounting of the semiconductor and the assembly operations. 1-3. Confirming function and operation after repair After repair and analysis,

39、 it is necessary to electrically confirm the repaired parts and the faulty locations that have been repaired as well as check that the operating functions have been completely repaired. Well it is possible to make the confirmation using the inspection jig for the analysis, simple testing equipment i

40、s probably required. While the items to be confirmed will vary according to the areas that failed and the conditions of repair, it is necessary to confirm the general characteristics and function operations by introducing a simple checker. 1-4. Confirmation items for soldering operations accompanyin

41、g the replacement of parts The skill required for the soldering should not be a problem for an experienced soldering technician. However, temperature will have to be controlled during the soldering process (to prevent thermal stress to the parts) and steps must be taken to prevent the effects of sta

42、tic electricity on the IC, FET and other such parts (including the storage conditions as well). 1-5. Confirming the function of the insulation after assembly Insulation and withstand voltage testing is required prior to re-shipping the product to ensure that secondary defects (such as foreign object

43、s or the wire damage) from the re-assembly after repair do not cause insulation impediments, insulation and withstand voltage testing is required prior to re-shipping the product. Insulation and withstand voltage testing equipment, testing jigs and preparation of the environment for the operation ar

44、e indispensable requirements for the implementation of these tests. At the very minimum, checking the insulation resistance is required to prevent the secondary defects shown above. This test requires a device for measuring the resistance of the insulation and cable for connecting to the product for

45、 easy inspection. 1-6. Pre-shipment inspection Use an inspection jig to inspect and check the general characteristics and operating functions. Sanken Electric Company can prepare the documentation for the inspection procedures, etc. 1-7. Steps for products where symptoms could not be recreated We ar

46、e investigating the establishment of rules and inspection guidelines for products for which the symptoms could not be recreated on the results of the primary diagnoses based on the complaint information of the final user. 1-8. Managing historical data about repair parts It is necessary to record and

47、 manage historical data about the conditions surrounding the failure, symptom treatment, lot number of the failed parts and replacement part numbers. Commerical power supply Insulated transformer + Variable autotransformer A InputOutput Load resistance : AC ammeter : AC voltmeter : DC ammeter : DC v

48、oltmeter or digital voltmeter A VV R Supply test power supply N L A V A V CIRCUIT DIAGRAM PKG1 PKG2 PKG3 15 16 PS UNIT PARTS KIT Circuit Board Ceramic Fuse FET FET FET FET FET FET FET FET Cement Resistor Cement Resistor Cement Resistor Cement Resistor Cement Resistor Metal Oxide Film Resistor Rectif

49、ier IC IC IC Circuit Board Metal Oxide Film Resistor Metal Oxide Film Resistor Metal Oxide Film Resistor Metal Oxide Film Resistor Carbon Resistor (chip) Carbon Resistor (chip) Carbon Resistor (chip) Metal Oxide Film Resistor Metal Oxide Film Resistor Metal Oxide Film Resistor Metal Oxide Film Resistor Metal Oxide Film Resistor Carbon Resistor (chip) Carbon Resistor (chip) Carbon Resistor (chip) Metal Oxide Film Resistor Metal Oxide Film Resistor Metal Oxide Film Resistor Carbon Resistor (chip) Carbon Resistor (chip) Metal Oxide Fi