powersoft DigiMod 500 User manual

6/24/02
DigiMod 500
DigiMod 1000
DigiMod 1500
DigiMod 2000HV
DigiMod 1000NPS
Service Manual
COD: MAN-DGM-SERVICE_MAN_V 1.3-EN
MAR 2007
1

Introduction
DigiMod 500/1000/1500/2000HV/1000NPS
This technical document has the aim to be a support guide to solve the most recurrent failures
of DigiMod series.
The troubleshooting will help you to characterize the kind of the fault.
For each failure solving it is explained the recovery method, and it is shown the related
assembly outline particular. The components to be replaced are evidences in red, while the
ones that need to be checked in yellow.
At the end of this guide there is a list showing the description and the related internal
Powersoft code of the parts used in DigiMod series models.
Introduction ____________________________________________________________________ 2
Troubleshooting ________________________________________________________________ 3
Removal of the main PCB_________________________________________________________ 5
Assembly outlines_______________________________________________________________ 8
Replacement of the Control Board (CB) ____________________________________________ 11
Check of the Mosfets short circuit ________________________________________________ 12
Failure of the NTC R10 __________________________________________________________ 14
Failure of the IC U1 _____________________________________________________________ 15
Failure of the varistor RV1 _______________________________________________________ 16
Failure of the IGBTs ____________________________________________________________ 17
Failure of the CH1 output Mosfets_________________________________________________ 18
Failure of the CH2 output Mosfets_________________________________________________ 18
Failure of the resistor R73 _______________________________________________________ 19
Failure of the resistor R79 _______________________________________________________ 19
Failure of the capacitors C51, C52, C53 and\or C54 __________________________________ 20
Failure of the resistor R22 _______________________________________________________ 21
Failure of the resistor R23 _______________________________________________________ 21
Spare Parts List ________________________________________________________________ 22
WE RECOMMEND THAT THE SERVICE OPERATIONS ARE DONE BY A TECHNICIAN.IN
THE CORRECT WAY DESCRIBED IN THIS GUIDE.
CAUTION
RISK OF ELECTRIC SHOCK !
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Troubleshooting
DigiMod 500/1000/1500/2000HV
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Troubleshooting
DigiMod 1000NPS
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Removal of the main PCB
DigiMod 500/1000/1500/2000HV/1000NPS
1- Unscrew and remove the 2 spacers of the Control Board.
2- Unscrew the 6 screws of both the upper lateral sides of the DigiMod.
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Removal of the main PCB
DigiMod 500/1000/1500/2000HV/1000NPS
3- Remove the upper cover and unplug the fan connector inserted in the main PCB.
4- Remove all the lateral screws and then remove the spring clips.
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Removal of the main PCB
DigiMod 500/1000/1500/2000HV/1000NPS
5- Detach the lateral components from the silpads whit the aid of a screw driver
6- Remove the 8 screws that fix the main PCB.
7- Remove the main PCB.
After having repaired the DigiMod it is recommended to replace the silpads with new ones.
This instructions are similar for the DigiMod 1000NPS.
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Assembly outlines
DigiMod 500/1000/1500/2000HV
Assembly outline DGMMAIN17
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Assembly outlines
DigiMod 500/1000/1500/2000HV
Assembly outline DGMMAIN19
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Assembly outlines
DigiMod 1000NPS
Assembly outline DGMNPSMAIN11
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Replacement of the Control Board (CB)
DigiMod 500/1000/1500/2000HV/1000NPS
1- Unscrew and remove the two spacers of the Control Board.
2- Move the two clasps that block the Control Board.
3- Replace the Control Board with a new one.
4- Reinsert and screw the two spacers.
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Check of the Mosfets short circuit
DigiMod 500/1000/1500/2000HV
Through the evidenced fissure of the above picture, it is possible to reach the CN13 and to
check the rail voltage. Check if there is a short circuit with the aid of a tester. Hold one probe
on the pin OUT+1 or OUT-2 of the output phoenix or faston connector, and the other ones on
+Vcc or -Vcc. Then check which of the two channels has at least one mosfet with the drain-
source junction in short circuit.
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Check of the Mosfets short circuit
DigiMod 1000NPS
Check if there is a short circuit with the aid of a tester. Hold one probe on the pin OUT+1 or
OUT-2 of the output phoenix connector, and the other ones on +Vcc or -Vcc. Then check
which of the two channels has at least one mosfet with the drain-source junction in short
circuit.
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Failure of the NTC R10
DigiMod 500/1000/1500/2000HV
Check if the leads of the NTC are interrupted.
Component to be replaced
Resistor NTC R10
After having replaced the resistor R10, put some silicon between R10, C137 and T1.
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Failure of the IC U1
DigiMod 500/1000/1500/2000HV
DGMMAIN17
DGMMAIN19
Components to be replaced
Integrated circuit U1
Zener diodes D2, D27
Zener diodes D29, D30 (From DGMMAIN Version 19)
Bipolar transistor Q8 (From DGMMAIN Version 19)
Component to be checked
Bridge rectifier D1
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Failure of the varistor RV1
DigiMod 500/1000/1500/2000HV
The short circuit of the varistor RV1 and therefore its outbreak, can occure in one of this cases:
- To the DigiMod it has been applied a mains voltage higher than 275VAC.
- To the DigiMod it has been applied a mains voltage of 230VAC with the 115VAC
Operation Selector in short circuit.
- To the DigiMod it has been applied the mains voltage on the 115VAC Operation
Selector.
It is not important to remove the PCB to replace the varistor, thanks to the cover hole under
RV1.
Components to be replaced
Varistor RV1.
Fuse F1
Components to be checked
Bridge rectifier D1
Check if the capacitor from C24 to C29 are swells on the top
IGBTs Q1 and Q2 (Ref. “Failure of IGBTs Q1 and Q2)
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Failure of the IGBTs
DigiMod 500/1000/1500/2000HV
DGMMAIN17
DGMMAIN19
Components to be replaced
IGBTs Q1 and Q2
Resistor R20 and R21
Integrated circuit U1
Components to be checked
Zener diodes D2, D27
Zener diodes D29, D30 (From DGMMAIN Version 19)
Bipolar transistor Q8 (From DGMMAIN Version 19)
Diode D3
Fuse F1
Bridge rectifier D1
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Failure of the CH1 output Mosfets
DigiMod 500/1000/1500/2000HV/1000NPS
Components to be replaced
Mosfet Q3 and Q4
Resistor R58 and R59
Integrated circuits U7 and U8
Components to be checked
Diode D22 and D23
Failure of the CH2 output Mosfets
Components to be replaced
Mosfet Q5 and Q6
Resistor R60 and R61
Integrated circuits U9 and U10
Components to be checked
Diode D24 and D25
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Failure of the resistor R73
DigiMod 500/1000/1500/2000HV/1000NPS
Components to be replaced
Resistor R73
Components to be checked
Capacitor C67
Failure of the resistor R79
Components to be replaced
Resistor R79
Components to be checked
Capacitor C68
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Failure of the capacitors C51, C52, C53 and\or C54
DigiMod 500/1000/1500/2000HV/1000NPS
Check if the capacitor from C51 to C54 are swells on the top. Change the capacitors if they are
swells and check if the load impedance is inferior respect to the minimum nominal load.
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