Keysight RP7900 Series, RP7951AT, RP7952A, RP7953A, RP7961A Advanced Service Manual

...
Keysight RP7900 Series Regenerative Power System
This manual provides the documentation for the following instruments: RP7951AT, RP7952AT, N6991A, RP7951A, RP7952A, RP7953A, RP7961A, RP7962A, and RP7963A
Advanced Service Guide
CAUTION
WARNING
Copyright Notice
© Keysight Technologies 2019 No part of this manual may be repro-
duced in any form or by any means (including electronic storage and retrieval or translation into a foreign language) without prior agreement and written consent from Keysight Technol­ogies as governed by United States and international copyright laws.
Manual Part Number
RP7900-90000
Edition
Edition 1, July 11, 2019
Printed in:
Printed in Malaysia
Published by:
Keysight Technologies Bayan Lepas Free Industrial Zone, 11900 Penang, Malaysia
Technology Licenses
The hardware and/or software described in this document are fur­nished under a license and may be used or copied only in accordance with the terms of such license.
Declaration of Conformity
Declarations of Conformity for this product and for other Keysight prod­ucts may be downloaded from the Web. Go to http://www.keysight.com/
go/conformity. You can then search by
product number to find the latest Dec­laration of Conformity.
U.S. Government Rights
The Software is “commercial computer software,” as defined by Federal Acqui­sition Regulation (“FAR”) 2.101. Pursu­ant to FAR 12.212 and 27.405-3 and Department of Defense FAR Supple­ment (“DFARS”) 227.7202, the U.S. government acquires commercial com­puter software under the same terms by which the software is customarily provided to the public. Accordingly, Keysight provides the Software to U.S. government customers under its stan­dard commercial license, which is embodied in its End User License Agreement (EULA), a copy of which can be found at http://www.keysight.com/
find/sweula. The license set forth in the
EULA represents the exclusive authority by which the U.S. government may use, modify, distribute, or disclose the Soft­ware. The EULA and the license set forth therein, does not require or per­mit, among other things, that Keysight: (1) Furnish technical information related to commercial computer soft­ware or commercial computer software documentation that is not customarily provided to the public; or (2) Relinquish to, or otherwise provide, the govern­ment rights in excess of these rights customarily provided to the public to use, modify, reproduce, release, per­form, display, or disclose commercial computer software or commercial com­puter software documentation. No additional government requirements beyond those set forth in the EULA shall apply, except to the extent that those terms, rights, or licenses are explicitly required from all providers of commercial computer software pursu­ant to the FAR and the DFARS and are set forth specifically in writing else­where in the EULA. Keysight shall be under no obligation to update, revise or otherwise modify the Software. With respect to any technical data as defined by FAR 2.101, pursuant to FAR
12.211 and 27.404.2 and DFARS
227.7102, the U.S. government acquires no greater than Limited Rights as defined in FAR 27.401 or DFAR
227.7103-5 (c), as applicable in any technical data.
Warranty
THE MATERIAL CONTAINED IN THIS DOCUMENT IS PROVIDED “AS IS,” AND IS SUBJECT TO BEING CHANGED, WITHOUT NOTICE, IN FUTURE EDITIONS. FURTHER, TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, KEYSIGHT DIS­CLAIMS ALL WARRANTIES, EITHER EXPRESS OR IMPLIED, WITH REGARD TO THIS MANUAL AND ANY INFORMA­TION CONTAINED HEREIN, INCLUD­ING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MER­CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. KEYSIGHT SHALL NOT BE LIABLE FOR ERRORS OR FOR INCIDENTAL OR CONSE­QUENTIAL DAMAGES IN CONNECTION WITH THE FURNISHING, USE, OR PERFORMANCE OF THIS DOCUMENT OR OF ANY INFORMATION CON­TAINED HEREIN. SHOULD KEYSIGHT AND THE USER HAVE A SEPARATE WRITTEN AGREEMENT WITH WAR­RANTY TERMS COVERING THE MATE­RIAL IN THIS DOCUMENT THAT CONFLICT WITH THESE TERMS, THE WARRANTY TERMS IN THE SEPARATE AGREEMENT SHALL CONTROL.
Safety Information
A CAUTION notice denotes a hazard. It calls attention to an operating proce­dure, practice, or the like that, if not correctly performed or adhered to, could result in damage to the product or loss of important data. Do not pro­ceed beyond a CAUTION notice until the indicated conditions are fully understood and met.
A WARNING notice denotes a hazard. It calls attention to an operating proce­dure, practice, or the like that, if not correctly performed or adhered to, could result in personal injury or death. Do not proceed beyond a WARNING notice until the indicated conditions are fully understood and met.
2 Keysight RP7900 Series Advanced Service Guide

Safety Notices

WARNING
WARNING
The following general safety precautions must be observed during all phases of operation of this instrument. Failure to comply with these precautions or with specific warnings or instructions elsewhere in this manual violates safety standards of design, manufacture, and intended use of the instrument. Keysight Technologies assumes no liability of the customer’s failure to comply with the requirements.
The equipment is for industrial use. Equipment operators are subject to all applicable safety regulations. Along with the warning and safety notices in this manual, all relevant safety, accident prevention, and environmental regulations must also be followed. In particular, the operators of the equipment:
– Must be informed of the relevant safety requirements.
– Must have read and understood the operating manual before using the
– Must use the designated and recommended safety equipment.
General
Do not use this product in any manner not specified by the manufacturer. The protective features of this product may be impaired if it is used in a manner not specified in the operating instructions.
equipment.
Keysight RP7900 Series Advanced Service Guide 3
Environmental conditions
Never use the instrument outside of the specified environmental conditions described in the Environmental Characteristics of the RP7900 Series Operating and Service Guide.
WARNING
Heavy weight
WARNING
WARNING
Danger to hands and feet. To avoid personal injury and damage to the instrument, always use a sturdy cart or other suitable device to move the instrument. Do not lift the instrument alone; always use two people to lift the instrument.
SHOCK HAZARD - Ground the instrument
This product is provided with a protective earth terminal. To minimize shock hazard, the instrument must be connected to the AC mains through a grounded power cable, with the ground wire firmly connected to an electrical ground (safety ground) at the power outlet. Any interruption of the protective (grounding) conductor or disconnection of the protective earth terminal will cause a potential shock hazard that could result in injury or death.
Before applying power
Verify that all safety precautions are taken. All connections must be made with the unit turned off, and must be performed by qualified personnel who are aware of the hazards involved. Improper actions can cause fatal injury as well as equipment damage. Note the instrument's external markings described under Safety Symbols and Regulatory Markings.
4 Keysight RP7900 Series Advanced Service Guide
WARNING
SHOCK HAZARD, LETHAL VOLTAGES
WARNING
WARNING
WARNING
WARNING
Many models generate voltages greater than 60 VDC, with some models rated at 950 VDC! Ensure that all instrument connections, load wiring, and load connections are either insulated or covered using the safety covers provided, so that no accidental contact with lethal voltages can occur.
SHOCK HAZARD
Never touch cables or connections immediately after turning off the unit. Depending on the model, lethal voltages can remain at the output terminals for several seconds after turn-off. Verify that there is no dangerous voltage on the output or sense terminals before touching them.
SHOCK HAZARD from external energy sources
Because the instrument can be used as a load to sink current, hazardous voltages from an external energy source such as a battery may be present on the output terminals even with the unit turned off. Provision must be made to disconnect the external energy source before touching the output or sense terminals.
Keysight RP7900 Series Advanced Service Guide 5
Do not operate in an explosive atmosphere
Do not operate the instrument in the presence of flammable gases or fumes.
Do not remove the instrument cover
Only qualified, service-trained personnel who are aware of the hazards involved should remove instrument covers. Always d isconnect the power cable and any external circuits before removing the instrument cover.
WARNING
Do not modify the instrument
WARNING
WARNING
WARNING
Do not install substitute parts or perform any unauthorized modification to the product. Return the product to a Keysight Sales and Service Office for service and repair to ensure that safety features are maintained.
Fuses
The instrument contains an internal fuse, which is not customer accessible.
Cleaning
To prevent electric shock, always disconnect the AC mains before cleaning. Use a dry cloth or one slightly dampened with water to clean the external case parts. Do not use detergent or chemical solvents. Do not attempt to clean internally.
In case of damage
Instruments that are not functioning correctly, appear damaged or defective should be made inoperative and secured against unintended operation until they can be repaired by qualified service personnel.
6 Keysight RP7900 Series Advanced Service Guide

Safety Symbols and Regulatory Markings

Alternating current (AC) Protective earth (ground) terminal
Earth (ground) terminal
Frame or chassis (ground) terminal Caution, risk of electric shock
Standby supply. Unit is not completely disconnected from AC mains when switch is off.
The ETL mark is a registered trademark of Intertek. The text indicates product compliance with the Canadian Interference- Causing Equipment Standard (ICES-001).
Caution, risk of danger (refer to this manual for specific Warning or Caution information)
The CE mark is a registered trademark of the European Community. This CE mark shows that the product complies with all the relevant European Legal Directives.
ICES/NMB-001 - This ISM device complies with the Canadian ICES-001.
Cet appareil ISM est conforme a la norme NMB-001 du Canada.
ISM GRP 1-A - This is an Industrial Scientific and Medical (ISM) Group 1 Class A product.
This product is marked with the ACMA RCM mark for compliance in Australia/ New Zealand. A copy of the Manufacturer's Australia Declaration of Conformity for this instrument can be obtained by contacting your local Keysight Technologies Sales Representative.
This symbol indicates the time period during which no hazardous or toxic substance elements are expected to leak or deteriorate during normal use. Forty years is the expected useful life of the product.
This symbol is a South Korean Class A EMC Declaration. This is a Class A instrument suitable for professional use and in electromagnetic environment outside of the home.
Keysight RP7900 Series Advanced Service Guide 7

South Korean Class A EMC Declaration

Information to the user:
This instrument has been conformity assessed for used in business environments. In a residential environment this equipment may caused radio interference.
This EMC statement applies to the equipment only for use in business environment.
사 용 자 안 내 문
이 기 기 는 업 무 용 환 경 에 서 사 용 할 목 적 으 로 적 합 성 평 가 를 받 은 기 기 로 서 가 정
용 환 경 에 서 사 용 하 는 경 우 전 파 간 섭 의 우 려 가 있 습 니 다 .
사용자 안내문은 " 업무용 방송통신기자재 " 에만 적용한다 .
8 Keysight RP7900 Series Advanced Service Guide

Waste Electrical and Electronic Equipment (WEEE) Directive

This instrument complies with the WEEE Directive marking requirement. This affixed product label indicates that you must not discard this electrical or electronic product in domestic household waste.

Product category:

With reference to the equipment types in the WEEE directive Annex 1, this instrument is classified as a “Monitoring and Control Instrument” product.
The affixed product label is as shown below.
Do not dispose in domestic household waste.
To return this unwanted instrument, contact your nearest Keysight Service Center, or visit http://about.keysight.com/en/companyinfo/environment/takeback.shtml for more information.

Sales and Technical Support

To contact Keysight for sales and technical support, refer to the support links on the following Keysight websites:
www.keysight.com/find/RP7900
(product-specific information and support, software and documentation updates)
www.keysight.com/find/assist
(worldwide contact information for repair and service)
Keysight RP7900 Series Advanced Service Guide 9
THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK.
10 Keysight RP7900 Series Advanced Service Guide

Table of Contents

Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety Symbols and Regulatory Markings . . . . . . . . . . . . . . . . . . . . . . . .7
South Korean Class A EMC Declaration . . . . . . . . . . . . . . . . . . . . . . . . .8
Waste Electrical and Electronic Equipment (WEEE) Directive . . . . . . . .9
Product category: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Sales and Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1 Troubleshooting
Safety Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Before, During, and After Troubleshooting . . . . . . . . . . . . . . . . . . . . . .15
Introduction to the Titan HV (RP7900 Series) Architecture . . . . . . . . .16
Titan HV architecture: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
General Troubleshooting Information . . . . . . . . . . . . . . . . . . . . . . . . . .26
List of Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Hardware Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Required equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Hardware trouble shooting procedure . . . . . . . . . . . . . . . . . . . . . . . 32
2Disassembly
Electrostatic Discharge (ESD) Precautions . . . . . . . . . . . . . . . . . . . . . .40
Disassembly Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Disassembly Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Removing/Installing flat flexible cables (FFC) or ribbon cables . . . .42
Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Removing the top chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Removing the PFC control board . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removing the digital personality module PCA . . . . . . . . . . . . . . . . .48
Removing the isolation and isolation attic board (top and bottom) from
the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Keysight RP7900 Series Advanced Service Guide 11
Removing the regulation magnitcs PCA from the regulation PCA . 55 Removing the isolation partition, insulator regulation, and chassis
module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removing the output and back plane assembly . . . . . . . . . . . . . . . 59
Removing the bias bracket from the chassis . . . . . . . . . . . . . . . . . . 62
Removing the constellation and P600 assembly from the chassis . 63
Removing the GPIB board from the chassis . . . . . . . . . . . . . . . . . . . 65
Removing the IO board from the chassis . . . . . . . . . . . . . . . . . . . . . 66
Removing the front panel from the chassis . . . . . . . . . . . . . . . . . . . 67
Removing the front frame vent from the chassis . . . . . . . . . . . . . . . 70
Removing the fan bracket assembly from the chassis . . . . . . . . . . . 71
3Replaceable Parts
RP7900 Replaceable Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
12 Keysight RP7900 Series Advanced Service Guide
Keysight RP7900 Series Regenerative Power System Advanced Service Guide

1 Troubleshooting

Safety Precaution 14 Before, During, and After Troubleshooting 15 Introduction to the Titan HV (RP7900 Series) Architecture 16 General Troubleshooting Information 26 List of Error Codes 27 Hardware Troubleshooting Guide 31
This chapter lists the possible errors and their description and discusses the procedures for troubleshooting the Keysight RP7900 Series Regenerative Power System.
13
1 Troubleshooting
WARNING
CAUTION

Safety Precaution

A WARNING notice denotes a hazard. It calls attention to an operating procedure, practice, or the like that, if not correctly performed or adhered to, could result in personal injury or death. Do not proceed beyond a WARNING notice until the indicated conditions are fully understood and met.
A CAUTION notice denotes a hazard. It calls attention to an operating procedure, practice, or the like that, if not correctly performed or adhered to, could result in damage to the product or loss of important data. Do not proceed beyond a CAUTION notice until the indicated conditions are fully understood and met.
Read the information in the “Safety Notices” on page 3 and the “Safety Symbols
and Regulatory Markings” on page 7 before proceeding with the rest of this
chapter.
Ensure that all safety precautions are observed during all phases of operation of this instrument. Failure to comply with these precautions or with specific warnings or instructions elsewhere in this manual or in the RP7900 Series Operating and Service Guide violates safety standards of design, manufacture, and intended use of the instrument. Keysight Technologies assumes no liability of the customer’s failure to comply with the requirements.
This manual serves as a complement to the RP7900 Series Operating and Service
Guide. Only qualified, service-trained personnel who have read the Operating and Service Guide prior to this should attempt the procedures listed in this manual.
14 Keysight RP7900 Series Advanced Service Guide

Before, During, and After Troubleshooting

1 Before turning on the unit under test (UUT):
– Make sure all connections are done correctly.
– Connect the 3-phase power cord to the UUT before connecting the plug to
3-phase main power trunk.
2During test:
– DO NOT probe any area of the UUT as there is HIGH RAIL VOLTAGE present
while the UUT is powered ON.
– If you wish to measure any test points, always ensure that the DMM probes
stay on the measurement area before powering on the UUT.
3 After test:
– Turn off the UUT and all other testing equipment.
– Unplug the 3-phase power cord immediately.
– DO NOT touch any location of the UUT as the HIGH RAIL VOLTAGE is slowly
discharging (the RAIL LED is RED).
– Wait 5 minutes or until the RAIL LED is OFF before performing any
disassembly procedure.
Troubleshooting 1
Keysight RP7900 Series Advanced Service Guide 15
1 Troubleshooting

Introduction to the Titan HV (RP7900 Series) Architecture

Listed below are the Titan HV models (RP7900 Series):
– RP7951AT, RP7952AT, N6991AT
– RP7951A, RP7952A, RP7953A: Using AC input 208 Vrms
– RP7961A, RP7962A, RP7963A: Using AC input 400 Vrms
Specification RP7951A/RP7961A RP7952A/RP7962A RP7953A/RP7963A
DC ratings
Voltage source: Current source and sink: Power:
A Titan HV unit consists of:
– 3-phase AC/DC front end
– DC/DC isolation stage
– Non-isolated DC/DC regulation stage
– Control board and digital personality module (DPM)
[1]
: Using AC input 208 Vrms
0 to 500 V 0 to ±20 A
5 kW
0 to 500 V 0 to ±40 A
10 kW
0 to 950 V 0 to ±20 A
10 kW
– Output board
–Bias board
– Customer interface board (P600 and carrier)
[1] Limited distirbution/customers only. Not available for sale to the public on www.keysight.com.
16 Keysight RP7900 Series Advanced Service Guide

Titan HV architecture:

Shown below is the block diagram for a Titan HV unit.
– Titan HV 5 kW models (RP7951A/RP7961A): One pair of isolation board and
regulation board.
– Titan HV 10 kW models (RP7952A/RP7962A/RP7953A/RP7963A): Two pairs of
isolation board and regulation board.
Troubleshooting 1
Keysight RP7900 Series Advanced Service Guide 17
1 Troubleshooting
Power Good (PG) signal: If the PG signal is not detected, the input board can
Power Fault (PF) signal: If the PF signal is detected, the input board asserts
shut down the isolation boards and bias board and create a “Channel Fail” error code at display.
this signal when it determines if the output power should be inhibited to preserve rail charge in the event of a line fault.
3-phase AC/DC front end:
The 3-phase AC/DC front end consists of the Power Factor Correction (PFC) bias-control board, PFC driver board, and PFC inverter board. Its main function is to convert the 3-phase AC input voltage to the require DC voltage as shown in table below.
The AC front end will assert a PF signal to the secondary FPGA when the line conditions are severe enough that the output power should be restricted or if the rail voltage dips below a ‘power fault’ level. The purpose of this signal is to quickly notify the regulation board to temporarily latch its output in the event of a brief line drop out.
Model AC 3-phase input DC output
RP7951A, RP7952A, RP7953A 208 Vrms 425 Vdc
RP7961A, RP7962A, RP7963A 400 Vrms 980 Vdc
18 Keysight RP7900 Series Advanced Service Guide
Troubleshooting 1
PFC inverter board operation
– The inverter boards consists of fuses, relay, big relay, and hall current sensors.
– The AC 3-phase input will go through the fuses. By turning on the bias, the AC
input will go through a small relay with a resistor path in order to have a soft charge on the capacitor in the driver board. After that, the big relay will be turned on when you hear the second clicking sound.
– The current passes through the hall sensor into the choke followed by the IGBT
and output capacitors.
PFC driver board operation
– The PFC driver boards consists of photo-detectors and big capacitors. The
gate driver output is influenced by signals from the photo-detector circuitry. During normal operation, if the supply voltage is above the UVLO threshold, the output of the photo-detector will drive the IGBTs of the output stage.
Keysight RP7900 Series Advanced Service Guide 19
1 Troubleshooting
PFC bias control board operation
– The PFC bias control board consists of AC/DC current sensing, instantaneous
– The main purpose of the PFC control board is to provide the protection when
– The DC bus voltage monitors the output capacitor voltage. The center tap
– The function of the dead time circuit is to make sure that the gates will not be
– The triangle wave generator function acts as a reference signal, which
– The IPEAK_fault signal (peak current latch signal) will go into the inhibit logic
current protection, IGBT DESAT and PEAK current latch circuitry, AC/ DC voltage sensing circuitry, current control loop, DC voltage error amplifier, and dead circuitry.
abnormalities are detected on the peak current and to control and adjust the DC output voltage.
monitors voltage across one capacitor whereas the DC bus monitors voltage across the output cap. The main function of the center tap sensing is to ensure that the voltage across is balanced.
turned on at the same time. It allows certain delays to prevent a short circuit.
compares the IMON signal, which eventually determines the PWM gate duty cycle. This is a triangle waveform with a frequency of 33 kHz.
circuitry. In normal mode, IPEAK_latched and OC_latched must always stay high whereas the Inhibit_R,Y,B depends on the Inverter_ON_R,Y,B to decide whether it needs to turn the gate drive on or off. If the Inhibit_R,Y,B signal goes low, the microprocessor will shut down the gate immediately.
20 Keysight RP7900 Series Advanced Service Guide
Troubleshooting 1
Isolation and isolation attic board operation
– The isolation board consists of a H bridge circuitry that can step up and step
down the voltage to the required voltage level. Its main function is to provide the isolation between the primary and secondary circuits. It receives the DC voltage from the AC front end and then adjusts the voltage level to 565 V. The isolation attic board consist of a transformer and over-current protection circuitry.
– The isolation board protects itself from ‘live’ conditions, such as local over
temperature (OT) and rail over voltage (OV) or low voltage (LV). The source of a rail OV/LV will either be an issue with its input, an internal malfunction, or a regulation board malfunction.
Keysight RP7900 Series Advanced Service Guide 21
1 Troubleshooting
Bias board operation
– The bias board is made of a half-bridge LLC with two flying shielded
transformers.
– It receives the PG signal and outputs voltage (425 V or 980 V) from the AC
front end, steps down the voltage, and provides the bias voltages to the respective modules.
– It communicates using the PG signal from the front-end.
Provides ±23 V to the isolation board
Provides ±23 V to the regulation board
Provides +12 V to the chassis fan
Provides ±15 V to the control board
22 Keysight RP7900 Series Advanced Service Guide
Troubleshooting 1
Output board operation
– The output board contains an accuracy shunt resistor, a common mode choke,
filtering circuitry, and a solid state output disconnect circuit up to 40 A.
– Feedback circuitry such as V
accuracy of the voltage or current. The output board has different configuration, such as parallel or series — it depends on the unit model whether it is a high voltage or high current model. The output board will provide the second level of filtering to the output.
Keysight RP7900 Series Advanced Service Guide 23
mon
and I
will be used to fine tune the
Mon
1 Troubleshooting
MASTER/SLAVE board operation
– The master slave circuitry allows communication between the units. This
allows the user to talk with only the master when paralleling units.
24 Keysight RP7900 Series Advanced Service Guide
Troubleshooting 1
Digital personality module (DPM) operation
– The DPM modules consists of the FPGA, AUX DAC, and AUX ADC, which main
purpose is to process the signal received. The calibration files will be stored in the DPM.
P600 and constellation boards operation
– The P600 is the processor board, which will store the firmware.
– The constellation board is the interface board, which is equipped with other
communication peripherals such as the USB port, LAN port, and GPIB ports.
Keysight RP7900 Series Advanced Service Guide 25
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