Phase Loss Protection Upgrade. Phase Loss Protection Upgrade. In this bulletin:

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1 Phase Loss Protection Upgrade In this bulletin: Introduction... 2 Purpose... 2 General... 2 Applicability... 2 HD3070 Phase Loss Protection Upgrade Kit Parts... 2 Preparation... 4 Install the Phase Loss Detection PCB onto Chopper... 6 Chopper Capacitor Bracket Location... 5 Remove the Capacitor Bracket from Chopper... 5 Prepare Phase Loss Detection PCB... 7 Install the Phase Loss Detection PCB... 7 Connect Phase Loss PCB to Chopper and Control Board... 0 Install Firmware... 4 Completion... 6

2 INTRODUCTION Warning Purpose All work must be performed only by qualified personnel! General This field service bulletin will enable a qualified electronics technician to upgrade an HD3070 power supply with a phase loss protection circuit. When the power supply loses one or more input phases, or if the input voltage drops below 85% of the rated voltage for a extended period of time (greater than minute), the choppers may experience a failure. The new phase loss protection circuit will put the power supply in an idle mode when one of these conditions exist, providing protection of the power supply components. Applicability This field service bulletin applies to the following HD3070 power supply serial numbers HD3070 Phase Loss Protection Upgrade Parts (Figure ) Item Part Number Description Qty Bracket: CH30 Cap Mounting Wire Group: Phase Loss Detection PCB Assembly: Phase Loss Detection Firmware: HD3070 Rev. B Tool: All Purpose Chip Extracting Tool: Connector pin extractor Standoff: Locking Circuit Board Support HD3070 Instruction Manual, Revision 3 2

3 Phase Loss Protection Upgrade Figure HD3070 Phase Loss Protection Upgrade Parts 3

4 WARNING SHOCK HAZARD: Always turn off the power, unplug the cord and wait 5 minutes before removing any power supply cover. If the power supply is directly connected to a line disconnect switch, place switch in the OFF position. In the U.S., use a "lock-out / tag-out" procedure until the service or maintenance work is complete. In other countries, follow appropriate local or national safety procedures. PREPARATION. Disconnect power. 2. Wait 5 minutes to allow capacitors to dissipate power. 3. Remove the right side panel and front panel of the power supply. See figure Locate chopper assembly. Front Panel Right Side Panel Chopper Assembly Figure 2 HD3070 Power Supply Front and Side Panels 4

5 Phase Loss Protection Upgrade CHOPPER CAPACITOR BRACKET LOCATION CAUTION Do not install phase loss protection PCB on chopper outer bracket.. Look at the chopper capacitor inner bracket. 2. If the bracket includes four holes (for PCB mounting), skip the next step. NOTE: Some capacitor brackets may be predrilled for PC board mounting. Predrilled brackets will have four holes (not threaded) as shown to the left. Figure 3 Capacitor Bracket Location 5

6 INSTALL THE PHASE LOSS DETECTION PCB ONTO CHOPPER Remove the Capacitor Bracket from Chopper NOTE If the bracket includes four holes (for PCB mounting), skip this step. Remove 4 screws and remove the capacitor bracket from the chopper. Figure 4 Remove Chopper Capacitor Bracket 6

7 Prepare Phase Loss Detection PCB. Plug in the connector of wire group into P of phase loss detection PCB. 2. Move the J jumper at P2 on phase loss detection PCB to the 2V position. P2 P Wire Group J at 2V Figure 5 Prepare Phase Loss Detection PCB Install the Phase Loss Detection PCB. Insert the 4 circuit board supports 0806 into the 4 holes of the chopper capacitor mounting bracket per Figure Bracket 0806 Support, 4 each Figure 6 Circuit Board Support - Install 7

8 2. Snap the phase loss detection PCB assembly onto the circuit board supports. Be certain to orient the PCB per Figure 7. A B C Figure 7 Mounting Phase Loss Detection PCB on Circuit Board Supports 8

9 3. Mount the chopper capacitor bracket onto chopper (Figure 8). Replace these 4 screws to mount the chopper capacitor bracket. Figure 8 Mounting Chopper Cap Mounting Bracket on to Chopper 9

10 Connect Phase Loss Detection PCB to the Chopper and Control Board. Connect wires labeled A, B, C to terminals on the chopper input labeled A, B, C (Figure 9). A B C Figure 9 Connecting Phase Loss Detection PCB to Chopper Input 0

11 Phase Loss Protection Upgrade 2. Route wire group from P of phase loss detection PCB to control board as shown in Figure 0, sheet and 2. Secure to existing harness with tie wraps. Figure 0 Routing Wire Group to Control Board - of 2

12 Phase Loss Protection Upgrade Figure 0 Routing Wire Group to Control Board - 2 of 2 2

13 3. Install Wire Group to Power Supply Control Board (Figure ): a. Remove plug PL and PL0 from the power supply control board. b. Using pin extractor tool 00897: Remove pin 2 from plug PL. Remove pin 3 from plug PL0. c. Insert blue wire from wire group into pin hole 3 of plug PL0. d. Insert white wire from wire group into hole 2 of plug PL. e. Install plug PL and PL0 to the power supply control board. Power Supply Control Board White Wire to Pin 2 Blue Wire to Pin 3 PL PL0 Figure Install Wire Group to Control Board Plugs 3

14 INSTALL NEW FIRMWARE CAUTION Electrical Static Discharge can damage PC boards and firmware chips! Before handling PC boards or firmware, ground yourself to the unit chassis (bare metal) to reduce chance of electrical static discharge. Use of grounding wrist strap is recommended.. Locate control board XPCB3 inside front cover of power supply. See figure Remove firmware cover. 3. Use kit extraction tool (027338) to remove firmware as follows: a. Insert the removal tool into the corner slot. Ensure bend on the removal tool catches on the bottom of the firmware. b. Pull the removal tool straight out until the firmware releases from the socket. c. If the firmware only partially releases, repeat steps a. and b. at the opposite corner. d. Discard old firmware. Control Board Control Board Socket Removal Tool Firmware Firmware Figure 2 Removing 0809 Firmware from Control PCB 4

15 4. Carefully install Rev. B firmware into socket as follows: a. Orient firmware by aligning the dot and bevel on IC (indicating pin ) to the dot on socket. (Some firmware has only a bevel indicating the side where pin is located.) See figure 3. Be careful not to bend any pins during installation. b. Press the firmware into place. When properly installed, the firmware chip will be flush with the top of the socket. CAUTION The firmware cover provides protection from high frequency noise. If cover is not reinstalled, system operation may be erratic or reduced. c. Replace the firmware cover. Pin Identifier Firmware chip Figure 3 Installing Firmware 5

16 COMPLETION WARNING Install all power supply covers before operating the HD3070 system.. Replace all covers to the power supply and secure in place. 2. Discard your copy of the instruction manual, Revision 2, and replace it with Revision 3, included with this bulletin. 6