Lincoln Electric SVM188-A service manual For Electrically, Powered equipment

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iii

 

 

 

 

 

SAFETY

iii

 

WELDING and CUTTING

CYLINDER may explode

 

SPARKS can

 

 

 

if damaged.

 

 

cause fire or explosion.

7.a. Use only compressed gas

cylinders

 

6.a. Remove fire hazards from the welding area.

containing the correct shielding gas for the

 

 

If this is not possible, cover them to prevent

process used and properly operating

 

 

the welding sparks from starting a fire.

regulators designed for the gas and

 

Remember

that

welding

sparks

and

hot

pressure used. All hoses, fittings, etc. should be suitable for

 

materials from welding can easily go through small cracks

the application and maintained in good condition.

 

 

and openings to adjacent areas. Avoid welding near

 

 

 

hydraulic lines. Have a

fire extinguisher readily available.

7.b. Always keep cylinders in an upright position securely

6.b. Where compressed gases are to be used at the job site,

chained to an undercarriage or fixed support.

 

 

 

 

special precautions should be used to prevent hazardous

7.c. Cylinders should be located:

 

 

situations. Refer to “Safety in Welding and Cutting” (ANSI

• Away from areas where they may be struck or subjected to

 

Standard Z49.1) and the operating information for the

physical damage.

 

 

equipment being used.

 

 

 

 

 

 

6.c. When not welding, make certain no part of the electrode

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

 

 

circuit is touching the work or ground. Accidental contact can

 

 

 

cause overheating and create a fire hazard.

 

 

7.d. Never allow the electrode, electrode holder or any other

6.d. Do not heat, cut or weld tanks, drums or containers until the

electrically “hot” parts to touch a cylinder.

 

 

 

 

proper steps have been taken to insure that such procedures

7.e. Keep your head and face away from the cylinder valve outlet

 

will not cause flammable or toxic vapors from substances

when opening the cylinder valve.

 

 

inside. They can cause an explosion even though they have

 

 

 

been “cleaned”. For information, purchase “Recommended

7.f. Valve protection caps should always be in place and hand

 

Safe Practices for the Preparation for Welding and Cutting of

tight except when the cylinder is in use or connected for

 

Containers and Piping That Have Held Hazardous

use.

 

 

Substances”, AWS F4.1 from the American Welding Society

 

 

 

(see address above).

 

 

 

 

7.g. Read and follow the instructions on compressed gas

6.e. Vent hollow castings or containers before heating, cutting or

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

 

welding. They may explode.

 

 

 

Cylinders,” available from the Compressed Gas Association

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil

1235 Jefferson Davis Highway, Arlington, VA 22202.

 

 

 

free protective garments such as leather gloves, heavy shirt,

FOR ELECTRICALLY

 

cuffless trousers, high shoes and a cap over your hair. Wear

 

ear plugs when welding out of position or in confined places.

 

powered equipment.

 

Always wear safety glasses with side shields when in a

 

welding area.

 

 

 

 

 

 

 

6.g. Connect the work cable to the work as close to the welding

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

 

area as practical. Work cables connected to the building

the equipment.

 

 

framework or other locations away from the welding area

 

 

 

increase the possibility of the welding current passing

8.b. Install equipment in accordance with the U.S. National

 

through lifting chains, crane cables or other alternate circuits.

Electrical Code, all local codes and the manufacturer’s

 

This can create fire hazards or overheat lifting chains or

recommendations.

 

 

cables until they fail.

 

 

 

 

8.c. Ground the equipment in accordance with the U.S. National

 

 

 

 

 

 

 

6.h. Also see item 1.c.

 

 

 

 

Electrical Code and the manufacturer’s recommendations.

6.I.

Read and follow NFPA 51B “ Standard for Fire Prevention

 

 

 

During Welding, Cutting and Other Hot Work”, available from

 

 

 

NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma

 

 

 

022690-9101.

 

 

 

 

 

 

 

6.j.

Do not use a welding power source for pipe thawing.

 

 

 

Jan ‘07

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Contents DC-600 ISAFETYi Safety Electric Shock can killFumes and Gases Can be dangerousPowered equipment For ElectricallyPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcElectromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications DC-600Electric Shock can Kill Safety PrecautionsSelect Proper Location Electrical Input Connections Fuse and Wire SizesGround Connection Reconnect Procedure Connection for Highest Rating Plate VOLTAGE, 50 or 60 HZConnection 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 Safety Precautions OperationGeneral Description Design Features AdvantagesRecommended Processes and Equipment Meanings of Graphical Symbols on Case Front OFF Input PowerWelding Capability Output Control Output Voltage CurrentMeaning of Graphical Symbol for Ground CON- Nection Controls and SettingsAuxiliary Power in MS-RECEPTACLE OVERLOAD, OVERCURRENT, and Fault ProtectionWelding Procedure Recommendations Remote Control of Machine OperationOperating Steps NA-3 Automatic Wire Feeder RemoteLN-8 or LN-9 SEMI-AUTOMATIC Wire Feeder LN-7 and Other Constant Wire FeedersDC-600 Table of Contents Accessories Section Accessories Wire Feeders and TractorsFactory 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 Theory of Operation Input Circuit and Main TRANS- FormerRectification Firing CIRCUIT, Control CIR- Cuit and RectificationFiring Board Thermal Protection SCR Operation DC-600 1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting GuideTroubleshooting and Repair PC Board Troubleshooting ProceduresControl 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 Control Board Figure F.2 Control Board LEDsDC-600 Internal Trigger Circuit Test Procedure Internal Trigger Circuit TestInternal Trigger Circuit Test 75 76DC-600 Firing Board Test Firing Board Test Control Board Test Control Board Test Figure F.7 Control BoardMain Transformer Voltage Test Main Transformer Voltage Test Figure F.8 Input Contactor and Reconnect PanelFigure F.9 Transformer Secondaries Main Transformer Voltage Test Control Transformer Test Procedure Control Transformer TestInput Contactor Test Input Contactor Test Voltage TestSCR Bridge Test Anode Cathode Remove Insulating Paint SCR Bridge TestActive 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 42TROUBLESHOOTING and REPAIRF-42 Removal and Replacement ProcedureRemoval Procedure SCR Rectifier BridgeReplacement Procedure Insulator Lock Washer Plain Washer Output Snubber LeadDC-600 Main Transformer and Choke Removal and Replacement Removal and Replacement Main Transformer and ChokeRemoval Procedure Weld Input Idle Amps and Watts Maximum Open Circuit VoltagesDC-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