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Ring Tester K7205
Ring Tester K7205
WEBSITE:
E-MAIL:
www.electronicsaustralia.com.au
electaus@magna.com.au
Please read Disclaimer carefully as we
can only guarantee parts and not the
labour content you provide. K I T
Here’s the design for a low cost, easy to build and use battery operated ‘shorted turns’ tester for
line-output or ‘flyback’ transformers, and other HF wound components like deflection yoke wind-
ings and SMPS transformers. Tests have shown it capable of finding at least 80% of LOPT/FBT
faults, so it can save a lot of time and trouble. Small and rugged, it’s well worth a place in the toolk-
it of anyone involved in servicing TV receivers, video monitors and computer power supplies.
f you're reading this, then chances are tension (EHT) supply of around 25 kilo- However the failure which service
I that you're a TV and/or computer mon-
itor repair technician - who doesn't need
volts for the final anode circuit of the
cathode ray tube. It's also possible the
technicians dread is a shorted winding in
the LOPT itself. Unfortunately LOPTs
to be told that horizontal output stage HOT has failed simply from old age or tend to be specifically designed for the
faults cause more than their fair share of overheating due to unevenly- make and model of the TV or monitor
headaches! Operating at high voltages, applied/solidified heatsink compound. they are used in, which can mean a lot of
frequencies and power levels, many Another occasional culprit is an insula- hunting around for a replacement. In
components in this part of the circuit are tion breakdown in the deflection yoke's addition they are hardly ever cheap, and
highly stressed, and failures are not only horizontal winding. not always physically easy to replace.
common but their cause is often hard to In short the LOPT is not a component
identify. which is easy to test by substitution, and
The usual symptom of a major hori- a service technician needs to be as cer-
zontal output stage fault is a serious tain as possible that the LOPT really is
overload of the DC power supply feeding defective, before tracking down a
the primary winding of the line output replacement!
transformer, or `LOPT' for short (called Identifying faults
the `flyback' transformer or `FBT' in
North America). This is often accompa- Several techniques have been devel-
nied by a collector-to-emitter short cir- oped over the years for identifying faults
cuit in the horizontal output transistor or in horizontal output stages, and testing
`HOT'. LOPTs in particular for the presence of
(For consistency, we'll be referring to shorted winding turns.
the line output transformer as the `LOPT' The components in the horizontal out-
throughout this article - North American put transistor's collector circuit, includ-
readers please mentally substitute `fly- ing the LOPT's primary winding, deflec-
back' for this term!) tion yoke horizontal winding, and tuning
Any of quite a few possible compo- capacitors form a reasonably low loss
nents could be the cause of such a failure, (high Q) resonant circuit, especially at
the more common being one of the high- low voltage levels.
speed rectifier diodes fed by the LOPT's Most testing techniques, including the
secondary windings, including the diode one used in this design, are based on the
stack(s) which produce the extra-high- fact that nearly all serious faults in the
BATT
+
R6
1k R10 15
Q1 R15
R1 BC328 4.7k 4.7k
1M DATA
C6 14 16
RESET A A Vcc
R7 100pF
R3
1k 6
1M RESET B IC2
SW1 R14 1M
POWER R13 4015 C7
1k 1 0.047uF
3 CLK A
5 8
1 9 8
C1 7 IC1b CLK B DATA Vss
IC1a R8 2
+ 100uF 6 270 4 IC1 Q0A Q1A Q2A Q3A B Q0B Q1B Q2B Q3B
LM393 13 12 11 2 7 5 4 3 10
R4 2.2M
+
R11
R5 C3 C4 33k R16 R17 R18 R19 R20 R21 R22 R23 R24
6V R2 0.047uF 0.01uF 47k 1k 1k 1k 1k 1k 1k 1k 1k
(4xAAA) 1M
47k D1 C5
- 1N4148 D3 0.047uF
1N4148
R9 D2 R12
C2 150k LED1 LED2 LED3 LED4 LED5 LED6 LED7 LED8
1k 1N4148 RED RED RED YEL YEL GRN GRN GRN
0.047uF
BATT
-
EARTH HOT
(Collector)
Fig.2: The circuit is simple, but elegant. IC2 shows clearly how many rings are supported by the inductor under test.
Miscellaneous
PCB, ZA1137 51 x 76mm; small (UB3)
plastic case, 130 x 68 x 41mm (DSE H-
2853); front panel; battery holder for 4 x
AAA cells; battery snap ; power switch,
push on/off; one DIP8 IC socket, one
DIP16; 4 x tapped spacers; screws,
nuts and washers (see Screw size and
allocation guide); 1 x red, 1 x black 4mm
banana sockets; test leads with 4mm Fig.3: Use this PCB overlay and the facing photo as a guide in assembling the
banana plugs; double-sided adhesive tester.
tape; wire, PCB pins, solder and instruc-
tions.
Text and illustrations courtesy of Electronics Australia Page 3
collector, or excessively high EHT result- these must be temporarily disconnected.
ing in HV shut-down. Otherwise the reading will be low, even
Because this tester uses impulses of though the winding itself is fine.
only 650mV to minimize the forward The tester can be used for checking
biasing of semiconductors, such defects high-Q transformers such as those used
will not be reflected in the ring count. in SMPS's. However, my experience has
Under these circumstances, I check for shown that it will not provide more than
measurable leakage resistance between a two or three LED indication for good
the EHT cap and the other LOPT pins. It TV horizontal drive transformers. It can
should be unmeasurable, otherwise the be used for these, however - to indicate
LOPT is defective. shorts (no LEDs lit). On the other hand
If I have gone through the above tests the ESR Meter (Dick Smith catalog num-
and have these symptoms and a normal ber K-7204) can do much the same with
ring count on the tester, the diagnosis these low resistance transformers.
can usually be confirmed only by substi- Wayne Scicluna services TVs in
tuting a known-good identical LOPT, or Sydney, and is the technician who talked
by testing with a chopper similar to the me into developing the tester in the first
one described in Sam Goldwasser's place. Here are his hints:
Electronics Repair FAQ, located on The assembled PCB, which supports If you've already checked for the more
the Internet at http://www.repairfaq.org/ virtually all of the circuitry. obvious leaky and shorted semiconduc-
sam/flytest.htm. tors and capacitors etc., and are still get-
Something else I do when testing a Overall, the LOPT tester can identify ting a low reading on the tester, there are
LOPT is to supply it with a reduced B+ about 80% of LOPT failures. When try- some other traps to avoid.
to enable scoping the HOT and measur- ing to solve a puzzle, if someone offers You need to get a good connection with
ing EHT (in situations where the monitor information that is right 80% of the time, the test leads, because contact resistance
goes into HV shutdown). To reduce the it's a lot better than having to guess can cause a low reading. The same
B+, I use two light bulbs in series, one 100% of the time, especially if the ante is applies to defective solder joints in the
end to B+ supply, centre-tap to LOPT B+ the price of a LOPT and wasted, valu- horizontal output stage, especially on the
connection, other end to ground. One able time. LOPT itself and HOT. In fact connecting
bulb is 60 watts, the other is 100, so I can Michael Caplan does general electron- the tester with clip leads, flexing the
reverse the end leads and increase or ic servicing in Ottawa, and added the fol- board and wiggling components is a
decrease the B+ value used in testing. lowing useful points in relation to TVs: good way to show up bad solder joints in
At the outset, when I have power sup- It's pretty straightforward to use, with this area.
ply cycling but have confirmed there are the usual precautions of ensuring that Body conductivity can also cause a
no shorts from HOT-C to ground, I sub- the under-test unit power is off and any lower than normal reading if you're
stitute a dummy load (60W bulb) for the caps are discharged. touching the test leads and your skin is
LOPT where the B+ enters, to see if the When testing an LOPT in circuit, it damp. Low readings can also be caused
power supply works with the LOPT out might be necessary to disconnect some of by having the test leads reversed, i.e.,
of the equation. the LOPT terminals, and/or yoke plugs connecting 'HOT Collector' to chassis,
that could load it down and upset the and by faults in an external voltage
Screw Size and Allocation readings. The tester will often not detect tripler.
Guide bad HV diodes in integrated split-diode How to build it
LOPT units, nor shorts/arcing that is
Printed Circuit Board to Spacers voltage dependent - but then no other Before soldering anything to the print-
4 x Screw M3 x 6mm (zinc plated) passive tester does either. ed circuit board, hold it up to a bright
Front Panel to Spacers
I have found it useful for checking TV light and examine the copper side care-
4 x Screw Countersunk M3 x 6mm (Blk) deflection yokes, both horizontal and fully for fine track breaks and especially
vertical. A good yoke lights at least five whiskers or bridges - particularly where
Front Panel To Case and typically the full eight LEDs. tracks pass close to component solder
4 x Screw Countersunk No4 x 6mm (Blk) However, many yokes have built-in par- pads.
allel or series damping resistors, and Referring to the board overlay in Fig.3,
begin installing the components, starting
Resistor Colour Codes with the resistors and diodes and work-
ing your way up to the tall ones including
Value 4 Band (1%) 5 Band (1%) the four PCB pins for `GND', `HOT' and
`+6V' terminal connections- but leaving
270R Red-Vio-Brn-Brn Red-Vio-Blk-Blk-Brn
1K Brn-Blk-Red-Brn Brn-Blk-Blk-Brn-Brn Capacitor Codes
4.7K Yel-Vio-Red-Brn Yel-Vio-Blk-Brn-Brn
10K Brn-Blk-Org-Brn Brn-Blk-Blk-Red-Brn
33K Org-Org-Org-Brn Org-Org-Blk-Red-Brn Value IEC Code EIA Code
47K Yel-Vio-Org-Brn Yel-Vio-Blk-Red-Brn
150K Brn-Grn-Yel-Brn Brn-Grn-Blk-Org-Brn 100pF 100p 101K
1M Brn-Blk-Grn-Brn Brn-Blk-Blk-Yel-Brn 0.01uF 10n 103K
2.2M Red-Red-Grn-Brn Red-Red-Blk-Yel-Brn 0.047uF 47n 473K
PCB
M3 x 6mm
Pan head
screw
Battery holder
Double-sided
tape
Fig.5: Shows how the PCB with LEDs is mounted to the front
panel using 19mm hex tapped spacers. The battery holder is
fixed to the bottom of the case by two pieces of double-sized
tape.
adhesive tape to stick the battery holder done now is to screw the front panel into Sabo, Michael Caplan and Wayne
into the bottom of the case, with the cells place and try out your tester on some Scicluna for their assistance in complet-
aligned in a `north-south' direction for LOPTs and their associated circuitry. ing this project. We couldn't have done it
easiest access. All that remains to be Finally, our sincere thanks to Larry without you!
Parts Supplied
1 x Balun core (R 5440)
1 x Enamel copper wire (30B&S or 0.25mm dia x 2 metres)
Assembly Notes
Text and illustrations courtesy of Electronics Australia Dick Smith Electronics © ZA8738-3
16
1
8
9
NTE4015B
.1”
.7”
Clock B 1 16 VDD
Q4 B 2 15 Data B
Q3 A 3 14 Reset B
Q2 A 4 13 Q1 B
Q1 A 5 12 Q2 B
Reset A 6 11 Q3 B
Data A 7 10 Q4 A
VSS 8 9 Clock A
16
1
8
9
NTE4015B
.1”
.7”
Clock B 1 16 VDD
Q4 B 2 15 Data B
Q3 A 3 14 Reset B
Q2 A 4 13 Q1 B
Q1 A 5 12 Q2 B
Reset A 6 11 Q3 B
Data A 7 10 Q4 A
VSS 8 9 Clock A