Lincoln Electric SVM188-A service manual Reconnect Procedure

Page 13

A-5

INSTALLATION

A-5

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RECONNECT PROCEDURE

Multiple voltage machines are shipped connected to the highest input voltage listed on the machine’s rating plate. Before installing the machine, check that the Reconnect Panel in the Input Box Assembly is con- nected for the proper voltage.

To reconnect a multiple voltage machine to a different voltage, remove input power and change the position of the reconnect board on the Reconnect Panel. Follow The Input Connection Diagram located on the inside of Case Back Input Access Door. These connection diagrams for the following codes are listed below.

1.For Dual Voltage except 380/500-460/575, see Figure A.4. (M15009)

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CAUTION

Failure to follow these instructions can cause immediate failure of components within the machine.

When powering welder from a generator be sure to turn off welder first, before generator is shut down, in order to prevent damage to the welder

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2.For 220/380/460, see Figure A.5. (M15010)

3.For 380/500-460/575, see Figure A.6. (M15011)

4.For 460 and 440 Single Voltage, see Figure A.7. (S17894)

5.For 230/460/575, see Figure A.8. (M15666)

6.For Voltages not listed, see the Input Connection Diagram pasted on the inside of the Case Back Input Access Door.

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CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

LINK

L3

W CRI

 

1.

TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX

LINES

 

2.

DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT

L2

V

 

LEAST 600 VOLT INSULATION.

 

 

CONTACTOR

 

3.

CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF

INPUT L1

U

 

THE CRI CONTACTOR AS SHOWN.

 

GND

H1

 

4.

CONNECT TERMINAL MARKED

TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.

H2

5.

MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS,

 

 

H3

DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE

 

 

PILOT

 

 

 

 

REMAINING HEX NUTS IN PLACE.

 

 

 

TRANSF.

 

 

LINK

 

CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

L3

W CRI

 

1.

TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX

 

 

LINES

L2

V

 

2.

DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT

 

LEAST 600 VOLT INSULATION.

 

INPUT L1

U

 

3.

CONNECT L1, L2 & L3 INPUT SUPPLY LINES H1 AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF

 

 

CTOR

 

 

 

 

 

 

 

 

THE CRI CONTACTOR AS SHOWN.

 

GND

 

H1

 

 

4.

CONNECT TERMINAL MARKED

 

 

TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.

H2

 

 

H3

 

 

 

 

 

 

 

 

 

 

 

 

 

5.

MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.

 

 

 

 

 

 

 

 

 

PILOT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TRANSF.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIGURE A.4-Reconnect Panel Board Positions for Dual Voltage Machines

DC-600

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Contents DC-600 ISAFETYi Electric Shock can kill SafetyFumes and Gases Can be dangerousFor Electrically Powered equipmentSûreté Pour Soudage a L’Arc Précautions DE SûretéElectromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications DC-600 InstallationElectric Shock can Kill Safety PrecautionsSelect Proper Location Electrical Input Connections Fuse and Wire SizesGround Connection Connection for Highest Rating Plate VOLTAGE, 50 or 60 HZ Reconnect ProcedureConnection for 440 Volts 50 or 60 HZ V 60HZ See Machine Rating Plate for Required Input Supply Voltage ELECTRODE, Work and #21 Lead Output ConnectionsConnections Terminal Strip 1 T.S.1 Auxiliary Power Control ConnectionsTerminal Strip 2 T.S.2 DC-600 Table of Contents Operation Section Operation Safety PrecautionsGeneral Description Design Features AdvantagesRecommended Processes and Equipment OFF Input Power Meanings of Graphical Symbols on Case FrontWelding Capability Output Control Output Voltage CurrentControls and Settings Meaning of Graphical Symbol for Ground CON- NectionOVERLOAD, OVERCURRENT, and Fault Protection Auxiliary Power in MS-RECEPTACLEWelding Procedure Recommendations Remote Control of Machine OperationOperating Steps Remote NA-3 Automatic Wire FeederLN-7 and Other Constant Wire Feeders LN-8 or LN-9 SEMI-AUTOMATIC Wire FeederDC-600 Table of Contents Accessories Section Wire Feeders and Tractors AccessoriesFactory or Field Installed Options Field Installed OptionsFigure C.2 MULTI-PROCESS Switch Cable Connections Accessories Table of Contents Maintenance Section Safety Precautions Electric Shock can Kill MaintenanceRoutine and Periodic Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 Input Circuit and Main TRANS- Former Theory of OperationRectification Firing CIRCUIT, Control CIR- Cuit and RectificationFiring Board Thermal Protection SCR Operation DC-600 1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Troubleshooting and RepairControl Feeder. See Protective Devices Check all three phase input Output Control J1,Pin2. See Wiring Diagram Wiring Diagram Test Description PC Board Troubleshooting GuideMaterials Needed PC Board Troubleshooting Guide Figure F.2 Control Board LEDs Control BoardDC-600 Internal Trigger Circuit Test Internal Trigger Circuit Test Procedure75 76 Internal Trigger Circuit TestDC-600 Firing Board Test Firing Board Test Control Board Test Figure F.7 Control Board Control Board TestMain Transformer Voltage Test Figure F.8 Input Contactor and Reconnect Panel Main Transformer Voltage TestFigure F.9 Transformer Secondaries Main Transformer Voltage Test Control Transformer Test Control Transformer Test ProcedureInput Contactor Test Voltage Test Input Contactor TestSCR Bridge Test SCR Bridge Test Anode Cathode Remove Insulating PaintActive Test Scope Settings Maximum Output Setting no Load Minimum Output Setting no Load 35TROUBLESHOOTING and REPAIRF-35 2V/Div Volts DC-600 Input Contactor CR1 CLEANING/REPLACEMENT Cleaning Procedure Input Contactor CLEANING/REPLACEMENT ProcedureContactor Replacement Procedure SCR Rectifier Bridge Removal and Replacement Procedure Removal and Replacement Procedure 42TROUBLESHOOTING and REPAIRF-42Removal Procedure SCR Rectifier BridgeInsulator Lock Washer Plain Washer Output Snubber Lead Replacement ProcedureDC-600 Main Transformer and Choke Removal and Replacement Main Transformer and Choke Removal and ReplacementRemoval Procedure Weld Maximum Open Circuit Voltages Input Idle Amps and WattsDC-600 Table of Contents Diagram Section Electrical Diagrams Wiring Diagram 230/460/575 Volt Machines G3506-1 Schematic Complete Machine G3575 Schematic Control PC Board G3408-1 Control PC Board Assembly G3409-1 Schematic Firing PC Board G3741-1