Trouble shooting guide for Dual Frequency system.

LRC board.
Do not disconnect any of the plugs to perform the following tests unless and until
specified.
1. Heart beat signal (J9): Connect a DC voltmeter on the screwed terminals of J9
plug on the board. This is 13 VDC square wave signal. If this signal is absent then
the DF transformer will operate in the default condition, where it would ignore the
control signal from the LRC board. If this is the case, the LRC board should be
replaced.
2. Go to the meter ranges screen and verify the following values. Make changes to
the screen if necessary.
Positive Sec. Voltage = 40000KV
Negative Sec. Voltage = 40000KV
Bus Voltage (J13) = 800V
Bus Current (J12) = 240 Amps
Base Freq. = 1600Hz.

3. Checking the input signals to the board: Disconnect J12, J13, J14, and J15 plugs
from the LRC board. These are the input signals from the DF transformer to the
board. Input 20ma current signal from a 4-20ma current source to each one of the
jack (one at a time). Use the following chart as a reference and check the
performance screen on the display to confirm the read outs.

Positive Sec Voltage (J12) = 40000KV (+ 200V)

Negative Sec. Voltage (J13) = 40000KV (+ 200V)
Bus Voltage (J14) = 800V (+ 20V)
Bus Current (J15) = 240 Amps (+ 10 A)

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 If either one the signal does not match then it confirms that the LRC board it out
of calibration. Replace the board.
4. Checking the control signal (J19): Set the minimum and maximum voltage on the
DF settings screen equal to 17000V. Measure the current (using a 4-20ma
ammeter) by connecting the probes on the screwed terminals on J19. It should
read 12ma ( + 0.02ma). Replace the LRC board if the readings do not match.
5. Checking the base frequency (J18): Set the base frequency to 1600Hz on the DF
settings screen and measure the current by connecting the probes of a 4-20ma
meter. If the current is equal to 20ma ( + 0.05ma) then the board is good.

DF transformer:

1. Checking the Diodes in the Transformer: With the transformer running, measure
the voltage and current at 3 phase power lines coming out of the Step-Start panel
from T1, T2 and T3 lines. If any one of the current values is lower than the other
two values then it means that one the diodes in the transformer have gone bad.
2. Audio inspection (quick test): With the same DF parameters as that of D4-B
transformer. The tone (humming) of the transformer should be the same. Though
this a very superficial test but it surely confirms if there is an apparent damage the
DF transformer. Shut down the Df transformer and open the chopper section.
3. Visual Inspection of the DF Transformer: Switch off the DF transformer by
disconnecting the main circuit breaker at the Step start panel. Open the
Transformer chopper section. Look in to the chopper section for discoloration of
transformer oil or contamination of transformer oil with carbon. Contamination
of transformer oil corresponds to damage to the chopper section. Replace the
chopper module and the transformer oil.
4. Checking interface board: The interface board mounted above the chopper section
in the transformer. The interface board is mounted at the corner of the chopper
section. Physically disconnect the 3 phase power supply lines coming out of the
step start( T1, T2 and T3). Apply 120 VAC to the step start panel. Press HV on
button. This should put 120VAC on the DF transformer which enables the

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 electronics. Visually confirm if the interface board has a flashing green light. This
is where the heartbeat signals from the LRC board lands on the interface board.
Refer interface board layout drawing. If this signal is missing replace the interface
board.

NATCO Page 3 of 3 Oct 29, 2007