Lincoln Electric SVM188-A service manual Control

Page 44

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F-4

TROUBLESHOOTING AND REPAIR

F-4

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

OUTPUT PROBLEMS

The Machine is dead - The Input

1.

Check

for blown

or missing

1.

The ON/OFF Switch

(S1) may

contactor does not operate.

fuses in input lines.

be faulty

2. Check the three phase input line

2.

The

Control Transformer

(T2)

voltage

at the

machine. The

may

be faulty.

Perform

the

input voltage must match the

Control Transformer Test.

rating

plate

and

reconnect

panel.

3.

The primary or secondary ther-

mostats may be open. Check or

replace. Also check the associ-

ated wiring. See the Wiring

Diagram.

4.

The pilot relay (CR2) may be

faulty. Check or replace.

5.

The input contactor coil may be

open.

6.

The Control Board may be

faulty. Perform

the

Control

Board Test .

Input contactor (CR1) chatters.

1.

The input line voltage may be

1.

The pilot relay (CR2) may have

low. Check all three phases.

bad contacts. Check or replace

relay.

2. Make sure input line voltage

2.

Check for loose or faulty wiring

matches machine rating and the

reconnect panel is

connected

between pilot relay (CR2) and

correctly for the line voltage

input contactor (CR1) coil con-

nections.See Wiring Diagram.

3.

The input contactor (CR1) may

be faulty.-Replace.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

DC-600

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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-600Select Proper Location Safety PrecautionsElectric Shock can Kill Ground Connection Fuse and Wire SizesElectrical Input Connections 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 Connections Output ConnectionsELECTRODE, Work and #21 Lead Terminal Strip 2 T.S.2 Auxiliary Power Control ConnectionsTerminal Strip 1 T.S.1 DC-600 Table of Contents Operation Section Safety Precautions OperationRecommended Processes and Equipment Design Features AdvantagesGeneral Description 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 ProtectionOperating Steps Remote Control of Machine OperationWelding Procedure Recommendations 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 Routine and Periodic Maintenance MaintenanceSafety Precautions Electric Shock can Kill 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Input Circuit and Main TRANS- FormerFiring Board Firing CIRCUIT, Control CIR- Cuit and RectificationRectification 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 Materials Needed PC Board Troubleshooting GuideTest Description 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 Contactor Replacement Procedure Input Contactor CLEANING/REPLACEMENT ProcedureCleaning 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