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TEST PROCEDURE WITH IT01
1. Turn off the welding system.
2. Hold the IT01 with one hand and touch the unit under test with the other hand to obtain a
discharge (This is a precaution to protect the unit from electrostatic discharges).
3. Disconnect the Molex drive lead from connector X11 (i) on A1 and connect it to the tester.
Switch position 1: Both generator LEDs (k, l) must blink, otherwise the upper primary switch
A5, A12 is defective.
4. Disconnect the Molex drive lead from the tester and bend it aside so that no undesirable
electrical connections can occur to the disconnected Molex sockets.
5. Disconnect the Molex drive lead from X12 on A1 and connect it to the tester. Switch position
1: Both generator LEDs (k, l) must blink, otherwise the upper primary switch A4, A11 is
defective.
6. Disconnect the Molex drive lead from the tester and bend it aside so that no undesirable
electrical connections can occur to the disconnected Molex sockets.
7. Testing the upper drive on A1:
Connect the Molex cable (b) from the tester to X11 on A1. Set the mode selector switch on
A2 to "2-Cycle Lift Arc". Turn on the welding unit: The primary switch red LED (l) must come
on (no drive).
8. Set mode selector switch on A2 to "DC-Electrode": The green LED (d) and the red LED (c)
must come on (drive).
9. Turn off the welding unit.
10. Testing the lower drive on A1:
Connect the Molex cable from the tester to X12 on A1. Set the mode selector switch on A2
to "2-Cycle Lift Arc". Turn on the welding unit: The primary switch red LED (l) must come on
(no drive).
11. Set mode selector switch on A2 to "DC-Electrode": The green LED (d) and the red LED (c)
must come on (drive).
12. Turn off the welding unit. Disconnect the tester.
13. Disconnect inverter drive leads (ribbon cable) from connectors X6 and X7 on A8 (If possible,
mark the leads before the test so they cannot be mixed up afterwards).
14. Connect the drive lead from X6 (j) to the tester.
Switch position 1: Generator LEDs (k, l) must blink, otherwise the upper inverter switch of
A9, A13 is defective.
Switch position 2: Generator LEDs (k, l) must blink, otherwise the lower inverter switch of
A9, A13 is defective.
15. Connect the drive lead from X7 to the tester.
Switch position 1: Generator LEDs (k, l) must blink, otherwise the upper inverter switch of
A10, A14 is defective.
Switch position 1: Generator LEDs (k, l) must blink, otherwise the lower inverter switch of
A10, A14 is defective.
16. Testing the AC-converter drives on module A8 X6:
Connect the ribbon cable from IT01 to X6 on A8.
Select the DC-Electrode mode: Two green LEDs (e, g) must come on.
Select the AC1-Electrode mode: Two red LEDs (f, h) must come on.
17. Testing the AC-converter drives on module A8 X7:
Connect the ribbon cable (a) from IT01 to X7 on A8.
Select the DC-Electrode mode: Two red LEDs (f, h) must come on.
Select the AC1-Electrode mode: Two green LEDs (e, g) must come on.
18. Turn off the welding unit. Disconnect the tester.
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