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Synchronizer Tester

Synchronizer Tester

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Published by Ben Dennis

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Published by: Ben Dennis on Sep 29, 2009
Copyright:Attribution Non-commercial


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 Note: Testing is to be performed with the use of the specific test setup/fixture.The Tester consists of an EFKA (US80A4101) VARIO DC Control andMotor. Mounting the Synchronizer is made possible via an adapter shaft.Monitoring lights (LEDs) were added to a connector that plugs into B13.The B13 output jack allows for the monitoring of the synchronizer pulses.Note: The EFKA Control was setup and programmed, by Ben Dennis, justfor this application. 
1.Plug in the Synchronizer, to be tested, into the P6 socket on the front panel of the motor controller.2.Mount the Synchronizer to the motor shaft and tighten the setscrews with a 3mmmetric Allen wrench.Plug in the 220 VAC power cord of the motor controller. When the controlis on a green LED below the (-) label will be on.3.Rotate the Synchronizer slowly, by hand, in a CW direction and watch the redLED’s, plugged into the B13 socket (top right corner of the motor control panel). The512- pulses/rev. LED will flash as the Synchronizer is rotated CW.4.Very slowly push down on the attached Treadle control arm. When the CWrotation of the motor stops, note the location of the setscrew on the Synchronizer shaft. The setscrew will be aligned with a screw recess that is molded into theSynchronizer plastic body. The Synchronizer will stop at the same place every time.Both output LED’s will flash, on the B13 output plug test circuit, when the motor isrunning. The left LED is used to indicate the needle up position when on. The rightLED indicates 512-pulses/rev. when on. NOTE: The 512-pulses/rev. LED indicator appears to be “just on” and notflashing when the motor is running faster than very slow. The LED just can’tvisually display the off state of the pulse at high speed. The needle up LEDwill look like it is the only LED flashing at slow motor speed, since the pulsesare fewer and the LED can display the off state. Both LED’s will look “juston” when the motor is running at fast speed.5. Push the Treadle all the way down to run the motor at full speed. This test willcheck the Synchronizer for mechanical failure.6.
Remove the Synchronizer cover and apply heat from a heatgun to the back of the Synchronizer as the test is being performed. Watch for the failure code E1 to flash and the motor will cease to run. The red TestLED’s will not light when the E1 failure occurs.7.
After plugging in and attaching the Synchronizer tothe motor shaft. Note: The 512-pulses/rev. LED fails to flash when the Synchronizer is turned by hand. The motor drive will try to run, for a short time, before stoppingquickly and flashing an E1 Error Code.
The installation of the wrong type of Synchronizer will also cause thestartup failure as mentioned above.

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