Assessments - 7, GPA: 4.4
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4. Test with an AC voltmeter for proper main AC input voltage to the line side of the Input Contactor (1CR). See wiring diagram. L1 to L2. L2 to L3. L1 to L3. a. If proper voltage is not present in any or all of the three phases, check input fuses and leads. 5. Test with an AC voltmeter for proper main AC input voltage from the output side of the Input Contactor. (1CR). See wiring diagram. T1 to T2. T2 to T3. T1 to T3. a. If correct voltage is present, the Contactor is working properly. b. If the correct voltage is not present for any or all of the three phases, the contactor may be faulty. 6. Test with an AC voltmeter for approximately 60 VAC from each of the six main transformer secondary leads to the common buss connected to the negative output terminal. See Figure F.4. IDEALARC DC-1000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-18 F-18 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST FIGURE F.4 - Main Secondary Lead Test Points a. If one or more of the above voltage tests are incorrect, check for loose or faulty wiring. If the wiring is good, then the Main Transformer may be faulty. NOTE: A long wire with clip or a long probe may be required to reach the lower middle lead. 7. Test for 115 VAC between leads #31 to #32 on the terminal strip. These can be accessed through the front panel assembly door. a. If the 115 VAC is not present, check for loose or faulty wiring or blown fuse. If necessary, untape and track the continuity of leads #31 and #32 through the entire harness. b. If the wiring is good, then the Main Transformer may be faulty. 8. Remove the screws from the control box cover. It does not have to be completely removed to perform this test. 9. Test with an AC voltmeter for 75 VAC for each phase angle winding as shown. See Figure F.5. NOTE: If the main supply voltage varies, the Main Transformer voltages will vary proportionately. See Figure F.5. IDEALARC DC-1000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-19 F-19 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST Plug J5 J5 J5 From Pin 2 7 9 Lead #203 #205 #207 Plug J5 J5 J5 To Pin 4 3 8 Lead #204 #206 #208 Expected VAC 75 VAC 75 VAC 75 VAC FIGURE F.5 - Phase Angle Windings Test Points and Firing Board Pin Location IDEALARC DC-1000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-20 F-20 TROUBLESHOOTING & REPAIR FIRING BOARD TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call (216) 383-2531 or (800) 833-9353 (WELD). TEST DESCRIPTION This test determines whether or not the Firing Board is receiving the correct voltages and gate signals. The LED’s (Light Emitting Diodes) will help you determine if the Firing Board is generating gate signals to the main SCR’s. MATERIALS NEEDED Volt/Ohm Meter (Multimeter) IDEALARC DC-1000 Wiring Diagram and Firing Board Schematic Diagram (See Electrical Diagram Section of Manual). IDEALARC DC-1000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-21 F-21 TROUBLESHOOTING & REPAIR FIRING BOARD TEST FIGURE F.6 - Firing Board LED and Molex Plug Locations TEST PROCEDURE FOR NORMAL FIRING BOARD OPERATION 1. Disconnect main AC input power to the machine. 2. Remove screws, loosen and lower the front panel to access the Firing Board on the left side of Control Box facing the machine. 3. Visually inspect the Firing Board for loose or faulty connections. 4. Reconnect the input power and turn the DC-1000 on. 5. Locate LEDs 7, 8, and 9 on the Firing Board. See Figure F.6. Each LED should be ON and equally bright. Use Table F.1 to check LED operation. 6. Connect a jumper wire from terminal #2 to terminal #4 on the terminal strip. These can be accessed through the Front Panel Assembly door. See Figure F.7. WARNING JUMPERING LEADS 2 AND 4 ELECTRICALLY ENERGIZES MACHINE’S OUTPUT TERMINALS. DO NOT TOUCH ELECTRICALLY HOT COMPONENTS. 7. Locate LEDs 1 thru 6. Each LED should glow with equal brightness. NOTE: LEDs 1 through 6 indicate that the gate firing signals are be...