Lincoln Electric SVM188-A service manual J1,Pin2. See Wiring Diagram

Page 47

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F-7

TROUBLESHOOTING AND REPAIR

 

 

 

 

F-7

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

 

 

POSSIBLE AREAS OF

 

RECOMMENDED

 

(SYMPTOMS)

 

 

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

 

Machine has maximum weld output

1.

If remote control is being used

1.

Check

the

LOCAL/REMOTE

and no control.

 

 

set LOCALl/REMOTE SWITCH

 

Switch (SW3)

and

associated

 

 

 

(SW3) to ‘LOCAL’ position and

 

wiring.

 

 

 

 

 

 

 

 

try to control weld output using

 

 

 

 

 

 

 

 

 

 

the Output Control

2.

Check

feedback leads #222

 

 

 

Potentiometer (R1) at the

 

(negative

output

terminal),

 

 

 

DC600. If the problem is solved

 

#215, and

#210 (output shunt)

 

 

 

check the remote control unit

 

for loose or faulty connections.

 

 

 

(or wire feeder) and associated

 

See Wiring Diagram.

 

 

 

 

control cable.

 

 

 

 

 

 

 

 

 

 

 

3. Check the #75 lead for continu-

 

 

 

 

 

ity (zero ohms) from the Output

 

 

 

 

 

Control

Potentiometer

(R1) to

 

 

 

 

 

the control board

connector

 

 

 

 

 

J1,Pin2. See Wiring Diagram.

 

 

 

 

4.

Possible

defective

 

Control

 

 

 

 

 

Board or Firing Board. See the

 

 

 

 

 

PC Board

Troubleshooting

 

 

 

 

 

Guide.

 

 

 

 

 

 

 

 

 

5.

Perform

the

SCR

Output

 

 

 

 

 

Bridge Test.

 

 

 

 

 

 

 

 

 

 

 

Machine has minimum output and

1.

If a remote control unit is NOT

1.

Check

the

Output

Control

no control.

 

 

connected to the DC-600, the

 

Potentiometer (R1) and associ-

 

 

 

LOCAL/REMOTE Switch must

 

ated wiring.

 

 

 

 

 

 

 

be in the "LOCAL" position.

 

 

 

 

 

 

 

 

 

 

 

2.

Check

the

LOCAL/REMOTE

 

 

2. If a remote control cable is con-

 

Switch (SW3), the Weld Mode

 

 

 

nected, the control leads may

 

Switch (SW4)

and

associated

 

 

 

be "shorted" to the positive weld

 

wiring.

 

 

 

 

 

 

 

 

output.

 

 

 

 

 

 

 

 

 

 

 

3.

Perform

the

Control

Board

 

 

3.

Make certain the three phase

 

Test.

 

 

 

 

 

 

 

 

input voltage is correct and

 

 

 

 

 

 

 

 

 

 

matches the machine rating and

4.

Perform the Firing Board Test.

 

 

 

the reconnect panel.

 

 

 

 

 

 

 

 

 

 

 

5.

Perform

the

SCR

Output

 

 

 

 

 

Bridge Test.

 

 

 

 

 

 

 

6. Perform the Main Transformer

 

 

 

 

 

Test.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 Can be dangerous SafetyElectric Shock can kill Fumes and GasesFor 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 InstallationSelect Proper Location Safety PrecautionsElectric Shock can Kill Ground Connection Fuse and Wire SizesElectrical Input Connections 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 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 Operation Safety PrecautionsRecommended Processes and Equipment Design Features AdvantagesGeneral Description Output Control Output Voltage Current Meanings of Graphical Symbols on Case FrontOFF Input Power Welding CapabilityControls and Settings Meaning of Graphical Symbol for Ground CON- NectionOVERLOAD, OVERCURRENT, and Fault Protection Auxiliary Power in MS-RECEPTACLEOperating Steps Remote Control of Machine OperationWelding Procedure Recommendations 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 Field Installed Options AccessoriesWire Feeders and Tractors Factory or 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 Input Circuit and Main TRANS- Former Theory of OperationFiring Board Firing CIRCUIT, Control CIR- Cuit and RectificationRectification 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 Materials Needed PC Board Troubleshooting GuideTest Description 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 Contactor Replacement Procedure Input Contactor CLEANING/REPLACEMENT ProcedureCleaning Procedure SCR Rectifier Bridge Removal and Replacement Procedure SCR Rectifier Bridge 42TROUBLESHOOTING and REPAIRF-42Removal and Replacement Procedure Removal ProcedureInsulator 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
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