May 2, 1996

VK-500 Rev, B Board Test

Initial Conditions:

Board connected to the power transformer.

The power is OFF.
The fuses F1 and F2 are removed from holders.
Output of the board is shorted.

TEST:

1. Connect the voltmeter between the 120V rail (bottom end of resistor R33) and
GND (right end of resistor R21).

2. Turn the power ON and monitor the voltage on 120V supply. It should ramp up
gradually.

3. After about 10 seconds the relay should click.

4. Measure voltage between top end of resistor R33 and GND. Using R9
trimpot adjust this voltage to 60V.

5. Turn the power OFF.

6. Short the external power supply leads and set its current limit to 200mA.

7. Remove the U5 from its socket.

8. Connect the external variable DC power supply to the left group of MOSFET’s.
Connect the NEGATIVE lead to the right end of R83. Connect the POSITIVE lead
to the top end of R70.

9. Make sure the supply is OFF and its voltage control is at minimum.

10. Turn the power to the board ON.

11. Turn the external supply ON.

12. While monitoring the current on external supply, slowly raise its voltage. If
current increases to over .2A and current limit LED on power supply comes ON,
turn the trimpot R73 counterclockwise to reduce the current to under .1A.
13. At maximum voltage of 70V on external supply adjust the current to .2A.

14. Using right end of R83 as COMMON, read voltages across resistors R78
through R83. The worst case differences should be under 20%. If they are greater
than 20%, then find the output transistor that is outside the 20% range and replace
it.

15. Record the voltages together with the PC board Serial Number.

16. Turn everything OFF.

17. Connect the external supply to the right group of MOSFET’s: NEG. to left end
of R84, POS. to top of R71.

18. Repeat steps 7 through 11 using R76 for adjustment.

19. Read voltages across the resistors R84 through R89 using LEFT end of R84
as common. Make sure the differences are within 20%. Replace devices if
necessary.

20. Disconnect external supply.

21. Install 10A Fast fuses in F1 and F2 position.

22. Connect voltmeters to R14 and R16.

23. Turn the power ON.

24. Wait for the relay to click and monitor the voltages across the R14 and R16.

25. Using R73 and R76, set these voltages to .075V. Turn the pots slowly, allow
the currents to stabilize, then adjust again in small increments.

26. Turn the board OFF.

VK-500 Module Test

1. Position the assembled module vertically on a bench and connect to power
transformer.

2. Connect 10 Ohm power resistor to the module’s output.

3. Make sure that U5 is removed from its socket.

4. Connect voltmeters to resistors R14 and R16.

5. Connect voltmeter to external 10 Ohm resistor.

6. Turn the power ON and monitor the voltages on voltmeters.

7. Allow the module to stabilize while adjusting the voltages across R14 and R16
to .09V. This may take about 2 hours.

8. Use R76 to adjust the voltage actoss the 10 Ohm resistor to be 0+/- 200mV.
Repeat adjustmenst several times.

9. Turn the power OFF.

10. Install U5 dual optocoupler.

11. Turn the power ON.

12. Monitor the voltages. The voltage across the 10 Ohm resistor should settle
after about two minutes to a stable value.

13. Use R95 to adjust this value as close to zero as possible.

14. Turn the power OFF and disconnect the module.

VK-500 Final Test Adjustments

I Bias Adjustment
1. Connect two DC voltmeters set to 2V scale across the R14 and R16 resistors
on left channel (polarity is unimportant).
2. Put a 10 Ohm power resistor across the left channel output terminals.

3. Turn the left channel of VK-500 ON.

4. After the relay clicks, check the voltages across R14 and R16 - they should be
under .100V. Allow unit to stabilize for about one hour.

5. Adjust the voltage across R14 to .070V using R73 trimpot.

6. Adjust the voltage across R16 to .070V using R76 trimpot.

7. Allow the unit to run for about 30 minutes.

8. Adjust the currents again.

9. Move the voltmeter from R16 to the output (across the 10 Ohm resistor).

10. Allow the unit to run for several hours while adjusting the voltages.

11. Adjust the voltage across R14 to .070V using R73.

12. Using R76 trimpot adjust the output voltage to 0 +/- 10mV. Move slowly and
allow unit to stabilize between steps.

13. Connect a voltmeter between left end of R84 and top end of R103.

14. Using R76, adjust this voltage to be between 18V and 19V.

15. Repeat these steps as nesessary.

Do the same steps on the right channel. It can be done in parallel.

II Driver Current Adjustment

1. Connect a voltmeter between the right end of R21 (negative lead) and top end
of R33 (positive lead).

2. Using R9, set this voltage to 60V.

3. Move the positive lead to the top end of R41. Voltage should be 60 +/- 1V.
III Gain Adjustment

1. Turn R52’s on both channels fully counterclockwise.

2. Measure output voltages on both channels.

3. On a channel with LOWER output voltage, adjust the R52 so the output voltage
is the same as on the other channel.