Lincoln Electric SVM188-A service manual Wiring Diagram

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F-8	TROUBLESHOOTING AND REPAIR							F-8
Observe Safety Guidelines detailed in the beginning of this manual.

	PROBLEMS		POSSIBLE AREAS OF		RECOMMENDED
	(SYMPTOMS)		MISADJUSTMENT(S)		COURSE OF ACTION

			OUTPUT PROBLEMS
Poor arc starting when the DC600 is		1.	Make sure the proper welding	1.	Check the connections from the
in the CV Sub-Arc or CV Innershield			procedures are being used.		shunt to the Control Board
Modes.			(wire feed speed, arc voltage		(leads 210 and 215). When weld
			and wire size)		current is present there should
		2. Check weld cables for loose or			be a millivolt signal at the board
		2. Check weld cables for loose or			(6.25mv/100 amps).
			faulty connections.
				2. Perform the Firing Board Test.
				3.	Perform	the	SCR	Output
					Bridge Test.
				4. The Control			Board	may be
					faulty.

Poor arc characteristics in all		1.	Check for the correct input volt-	1.	Check the Mode Switch (SW4)
processes.			ages on the three phase input		and the associated wiring for
			lines at the DC600.		loose or faulty connections. See
					the Wiring Diagram .
		2. Make sure the proper welding
			procedures are being used (wire	2.	Check the voltage at the shunt
			feed speed, arc voltage and wire		(leads 210 and 215). When weld
			size).		current is present there should
					be a millivolt signal at the board
		3.	Check the welding cables for		(6.25mv/100 amps). If not cor-
			loose or faulty connections.		rect, the shunt may be defective
				3. Perform the Firing Board Test.
				4.	Perform	the	SCR	Output
					Bridge test .
				5. The Control			Board	may be
					faulty.

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-600Safety Precautions Electric Shock can KillSelect Proper Location Fuse and Wire Sizes Electrical Input ConnectionsGround 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 Output Connections ELECTRODE, Work and #21 LeadConnections Auxiliary Power Control Connections Terminal Strip 1 T.S.1Terminal Strip 2 T.S.2 DC-600 Table of Contents Operation Section Safety Precautions OperationDesign Features Advantages General DescriptionRecommended 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 ProtectionRemote Control of Machine Operation Welding Procedure RecommendationsOperating 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 Maintenance Safety Precautions Electric Shock can KillRoutine and Periodic Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Input Circuit and Main TRANS- FormerFiring CIRCUIT, Control CIR- Cuit and Rectification 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 PC Board Troubleshooting Guide Test DescriptionMaterials 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 Input Contactor CLEANING/REPLACEMENT Procedure Cleaning 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