Lincoln Electric SVM188-A service manual Check all three phase input Output Control

Page 46

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F-6

 

TROUBLESHOOTING AND REPAIR

 

 

F-6

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

 

 

POSSIBLE AREAS OF

 

RECOMMENDED

 

 

(SYMPTOMS)

 

 

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

Machine input contactor

operates

1. C h e ck L E D 1 0 o n t h e F i r i n g

1. I f b o t h L E D s a r e O F F, t r y a n

but machine has no weld output with

 

Board and LED 6 on the Control

 

alternate method of triggering.

the Output terminal Switch ON. Fan

 

Board. Both Should be ON.

 

If LEDs come ON and machine

runs and pilot light glows.

 

 

 

 

 

 

 

weld output is restored check

 

 

 

 

 

 

 

 

 

the Weld Terminal Switch (S2)

 

 

 

 

 

 

 

 

 

and the associated wiring. If not,

NOTE: Alternate Trigger methods.

 

 

 

 

 

 

see the Internal Trigger Circuit

 

 

 

 

 

 

 

 

 

Test.If both LEDs are ON and

•

Operate Wire Feeder trigger.

2. Check all of the LEDs on both

 

there is still no output go to Step

•

Place a jumper across 2 & 4 on

 

2.

 

 

 

 

PC Boards for proper operation.

 

 

 

 

 

the terminal strip

T.S.2. or

 

 

 

 

 

 

 

 

 

 

 

 

2. T h e F i r i n g B o a r d o r C o n t r o l

 

across pins C & D in 14 pin con-

 

 

 

 

 

 

 

 

 

 

 

 

Board may be defective. See the

 

nector.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PC Board Troubleshooting

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Guide.

 

 

 

 

 

 

 

 

 

 

 

The machine does not have maxi-

1.

Check all three phase input

1.

Check

the

Output

Control

mum weld output.

 

 

lines

at the

DC600.

Make

 

Potentiometer (R1) and

 

 

 

 

sure

input

voltages

match

 

associated wiring for loose or

 

 

 

 

machine rating and recon-

 

faulty

connections.

See

 

 

 

 

nect panel.

 

 

 

wiring diagram.

 

 

 

 

2.

Put LOCAL/REMOTE Switch

3.

Perform

the

Control

Board

 

 

 

 

(SW3) in "LOCAL" position.

 

Test.

 

 

 

 

 

 

 

If problem is solved then

4.

Perform the Firing Board Test.

 

 

 

 

check remote control unit or

 

 

 

 

wire feeder.

 

 

5.

Perform

the

SCR

Output

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Bridge Test.

 

 

 

 

 

 

 

 

 

 

6.

Perform the Main Transformer

 

 

 

 

 

 

 

 

 

Test.

 

 

 

 

 

 

 

 

 

The weld output terminals are

1.

Remove any external

leads

1.

Check for an internal short

always electrically "hot".

 

 

hooked to #2 and #4 on the ter-

 

between leads #2 and #4. See

 

 

 

 

minal strip. If the problem dis-

 

wiring diagram.

 

 

 

 

 

appears the fault is in the control

 

 

 

 

 

 

 

 

 

cable or wire feeder.

 

3.

Perform Firing Board Test.

 

 

 

2.

If some open circuit voltage is

4.

Perform Control Board Test.

 

 

 

 

present (over 3VDC.) after per-

 

 

 

 

 

 

 

 

 

forming Step #1. then the prob-

5.

Perform

the

SCR

Output

 

 

 

 

lem is within the DC600.

 

 

Bridge Test.

 

 

 

 

 

 

 

 

 

 

6.

The SCR Snubber(s) may be

 

 

 

 

 

 

 

 

 

"leaky". Check or 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 Fumes and Gases SafetyElectric Shock can kill 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 Welding Capability Meanings of Graphical Symbols on Case FrontOFF Input Power 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 Factory or Field Installed Options AccessoriesWire Feeders and Tractors 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 Removal Procedure 42TROUBLESHOOTING and REPAIRF-42Removal and Replacement 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
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