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DC-400
IMA 474
GROUND TEST PROCEDURE
NOTE:
This procedure is for ‘machines as built’ many
modifications could have taken place over the life of a
particular machine, so details of this procedure may need
to be ‘adjusted’ to suit these modifications.
For prompt service contact your local authorised Lincoln
field service shop.
The insulation resistance values listed below are from
Australian Standard AS1966.1.
1.
Disconnect input power mains supply. (Be sure power
is off before disconnection).
2.
Remove welding leads (electrode cables, control
cables and work leads) from the machine before any
tests are carried out.
3.
Install a receptacle with all pins shorted together into
PCB harness plug P3.
4.
Install a receptacle with all pins shorted into P2. Install
a receptacle with all pins shorted together except pin
9 into P5. Install a receptacle with pin 1 through 6
shorted into P1. Connect together all of the pins
indicated in this step - this is the
output group
.
5.
Install a receptacle with all pins shorted together into
PCB harness plug P6 - this is the
115V auxiliary
group
.
6.
Install a receptacle with Pins 7, 8, 9 and 10 shorted
together into PCB harness plug P1 - this is the
42V
auxiliary group
.
7.
Jumper all input and output lead connections on the
input contactor (1CR).
[
Harness wiring or shorting receptacles must not
touch any part of the PCBs]
8.
Set the -
Arc Control Switch to position ‘2’.
Mode Switch to ‘FCAW GMAW - CV’.
Output Control Switch to ‘Remote’.
9.
Input Circuit Test:
Connect one lead of the ‘MEGA’
tester to the frame of the machine and the other to the
input contactor jumper. Apply the test. (Min resistance
1M
Ω
)
10.
Input Circuit to Welding Circuit Tests:
Connect one
lead of the ‘MEGA’ tester to the input contactor jumper
and the other lead to the positive output stud. Apply
the test. (Min resistance 10M
Ω
)
11.
Input Circuit to Auxiliary Circuit Tests:
Connect one
lead of the ‘MEGA’ tester to the input contactor jumper
and the other lead to:
a) lead No. 32A
b) lead No. 233A
c) lead No. 42A.
Apply the tests. (Min resistance 1M
Ω
)
12.
Welding Circuit to Auxiliary Circuit Tests:
Connect
one lead of the ‘MEGA’ tester to the positive output
stud and the other lead to:
a) lead No. 32A
b) lead No. 233A
Apply the tests. (Min resistance 1M
Ω
)
13.
Between Auxiliary Circuit Tests:
i)
Connect one lead of the ‘MEGA’ tester to lead No.
42A and the other to:
a) lead No. 32A
b) lead No. 233A.
Apply the tests.
ii) Connect one lead of the ‘MEGA’ tester to lead No.
32A and the other to:
a) lead No. 233A.
Apply the test. (Min resistance 1M
Ω
)
14. Connect the
output group, 115V group
and
42V
auxiliary group
together.
15.
Welding and Auxiliary Circuit Test:
Connect one
lead of the ‘MEGA’ tester to the frame of the machine
and the other to the positive output stud. Apply the
tests. (Min resistance 1M
Ω
).
16.
Auxiliary Circuit Test:
Connect one lead of the
‘MEGA’ tester to the frame of the machine and the
other lead to No. 233. Apply the test. (Min resistance
1M
Ω
).
17. Remove all shorting plugs and jumpers and reconnect
all plugs and leads.
This procedure is only suitable for applications using
DC mega testers up to 500V.
WARNING
ELECTRIC SHOCK can kill
ARC WELDING SUPPLIES - 07 847 7870
