I'd appreciate views on this annoying fault I have with a programmable power supply. Overall a very complex beast to which the interweb will not yield a schematic. Sorensen XG series - user
manuals here . It has digital control and USB/RS-485 interfaces. The general design is fairly clear and it can be seen in
.
Initially, the TOP224YN switching regulator IC which provides power for the internal circuits was intermittently faulty. I’ve replaced this, and the internal supplies are now good. However, although the unit is showing many signs of life, it is a
Zombie!
a) The front panel display is dead and controls inoperative
b) The OVP protection (?) MOSFET is sinking some currentAt least the behaviour is not intermittent, but I’m not so sure which route to take debugging this now. I had been focusing my attention on why the OVP MOSFET is conducting, but having gone through that circuit extensively I’m not sure the fault is there (I can post more details of the circuit). I’m wondering if its more useful to look into the microcontroller and digital circuits.
Any view on this, or how to proceed debugging the digital side would be appreciated.I have checked all supply rails, used diode-test where possible and tried to look for physical damage or heat dissipation. The unit has suffered some abuse as it had dirt and moisture blown in through the fans. There was some corrosion visible on bolts across the whole PCB and on metal part of transistors etc. However, the visible damage was not too much after cleaning. It seemed like it had been operating somewhere damp from the pattern left by the air flow.
Here are my observations:
Observed Behaviour:• Fans come on immediately, but front panel display and LEDs blank. Controls have no effect. The LED displays should show 8888-8888 at startup.
• After a couple of seconds the inrush relay can be heard and
14.00V is present at the main output• Checking the rear analog programming ports, the voltage monitor readback is 4.2482v, which scales to 14.1v if 10.0v readback = 100% of 33v (max o/p). The status pin (J2_13) goes high indicating there is apparently not a fault condition.
• There is one MOSFET, Q25 2SK2837 which is placed across the main rails, I guess for OVP. This is heating up noticeably, sinking about 3-4W. I haven’t left it on for a long time, but it fairly quickly reaches 40-50C.
Circuit description and detailed observation:Here is a description of the main sections and what I observe in each:
1) mains filter with inrush protection relay
• relay comes on after a few seconds as normal
2) PFC controller based on L4981AD (
https://www.st.com/resource/en/datasheet/l4981.pdf)
• replaced a corroded cap which would prevent it oscillating, now probably OK. Output is about 390V DC
3) Main PSU Switcher based on M51995AFP(
https://pdf1.alldatasheet.com/datasheet-pdf/view/115167/RENESAS/M51995AFP.html• Havent checked this circuit, but we do have stable output voltage from the main PSU output
4) Internal Supply using a TOP224YN (
https://www.farnell.com/datasheets/2059937.pdf) switcher. This has multiple outputs, all of which are good now:
• a main +5V supply from an LM2940 which seems to supply the main logic circuits and front panel
• +/- 15V from 7*L15 8-pin ICs for the Op-Amps (LM324, OP2177) – good
• +18v VCC to the L4981AD and M51995AFP – good
• Feeds to other isolated supplies for USB, RS232 etc. – not checked
5) Logic section with a
microcontroller (not sure what type, as it has version sticker on it. See pic. Update - I think 80C51 variant, given location of VCC, GND pins), provided RS232, RS485, USB. Socketed PLCC44 pin design with 22.1184 MHz clock.
• VCC and clock signal present.
• Some other signals can be seen, but I don’t know what I’m looking at…
• Has a MAX1232 watchdog – this is giving initial reset pulse as expected.
• Tried USB with FTDI driver. Windows recognises the USB port being plugged in but I can’t open a connection with Putty.
6) Front panel with I2C PCA9555 GPIO (
https://www.nxp.com/docs/en/data-sheet/PCA9555.pdf) and MC14489 display drivers. Power for this board comes from the main +5v.
7) ADC
https://www.analog.com/media/en/technical-documentation/data-sheets/AD7708_7718.pdf) and multiple MAX5441 DACs, MAX6225 v ref.
Between these sections there are about 30 (!) opto couplers, mostly NEC 2561 type(
https://www.farnell.com/datasheets/89573.pdf. I’ve checked the diodes but not done the harder check of transistor on-resistance.