TDCG2-0.5D Brush Realign Procedure

TDCG2-0.5D Variac Brush Realign Procedure (Note: This procedure is similar on all of our Variacs)

Symptom: The unit does not provide a maximum output of 120 VAC.

Solution: Realign the TDCG-0.5D brush to get maximum contact.

Caution: You are about to work on ac AC power supply unit. Please make sure the unit is unplugged and has been unplugged for at least an hour.

Step 1: Remove the knob by unscrewing the 2 screws on the side of the knob.

Step 2: Remove the 2 front panel screws.

Step 3: Remove the 3 screws around the unit casing. This will allow you to take the casing out.

Step4: Make sure the damping tap (circled in red) is all the way down.

Step 5: Loosen the 2 screws that hold on to the staff (circled in red).

Step 6: Make sure the brush makes full contact with the coil all-around before tightening down the screws. The damping system should also help with pushing the brush toward the coil.

Please notice that the brush will make contact with the coil and design to wear out over time, therefore the brush will get smoother over time.

Reassemble process

Step 1: Put the unit casing back on, making sure the ground wire is attached to the casing.

Step 2: Reinstall the front panel. As you see, the knob is crooked and not the staff.

Step 3: Make sure the knob is flat before tightening the 2 screws.

Step 4: If the knob is still slightly leaning, you can push the knob against the case for better results.