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12. MAINTENANCE AND TROUBLESHOOTING (continued)
12.3 Insulation Resistance Test
WARNING
Observe the following to prevent an electrical shock.
٨
Have qualified operators or the persons familiar with this welding power source measure
insulation resistance and test withstand voltage. And install a protective wall around the
welding machine to keep away others from the welding machine. Check to make sure that
charging voltage does not exist before carrying out the maintenance before carrying out
measurement of insulation resistance and withstand voltage test.
When measuring insulation resistance and testing withstand voltage, follow the steps below. And,
refer to the schematic diagram, parts layout, and parts list for maintenance.
1. Disconnect the grounding cable (wiring number: 80) from the earth.
2. Short-circuit on AC side and commutation side of DR1.
Short-circuit between TR1 (C1) and (E1), TR2 (C2) and (E2), TR3 (C1) and (E1), TR4 (C2)
and (E2), TR5
㨯
6 (C1) and (E1), TR5
㨯
6(C2) and (E2).
3. Short-circuit between anode and cathode of DR2,DR4,DR5 and DR6.
4. Disconnect CN2,CN4,CN11,CN13 and CN18 of PCB P10535U,CN5 of PCB P10535T.
Be sure to reconnect the cables after carrying out measurement of insulation resistance and
withstand voltage test.
12.4 Replacement of Batteries
WARNING
Observe the following precautions listed below without fail, in order
to prevent fire, explosion and rupture.
٨
Do not charge, short-circuit, disassemble, heat, deform and/or solder batteries. Do
not throw batteries into a fire.
٨
Make sure the positive and negative polarity is correctly connected.
٨
Make sure battery terminals are insulated with insulation tapes when disposing
batteries. Otherwise, if batteries come in contact with other metal or batteries,
generation of heat, rupture or ignition may occur.
٨
Batteries must be replaced by an experienced repairman or engineer.
This welding power source uses lithium batteries to hold welding conditions in memory. The life of
the batteries differs depending on the environments. “E-“ and “600” shown in the displays on the
front panel blinks when the batteries gets low. Replacement of the batteries every 5 years or so
are recommended even when “E-“ and “600” do not blink. Replace the batteries following the
steps:
1. Turn off the line disconnect switch in the switch box or the no-fuse breaker, and the power
switch of the welding power source.
2. After more than three minutes, remove six screws that secure the front panel, and then pull
the front panel out. Do not pull it forcibly. With the wiring inside the equipment disconnected,
do not turn on the power switch. Failure to do so may result in damage to the welding power
source.
3. Remove the connectors on the PCB P10533R to replace the printed circuit board. Refer to
the position for “Rear side of the front panel” in Section 12.7, “ Parts Layout”.
4. Insert the disconnected connectors into the PCB P10533R.
5. Screw the front panel in position.