Lincoln Electric SVM188-A service manual PC Board Troubleshooting Guide

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F-10

TROUBLESHOOTING AND REPAIR

F-10

PC BOARD TROUBLESHOOTING GUIDE (continued)

 

 

FIGURE F.1 – FIRING BOARD LEDs

 

 

 

 

 

J5

 

 

LED8

LED9 LED7

(205) 8

16 (204)

 

 

 

(206) 7

15 (203)

 

 

 

(207) 6

14

 

 

 

(208) 5

13 (231)

 

 

 

4

12 (215)

 

 

 

3

11

 

 

 

2

10

 

 

 

1

 

 

 

9

 

 

 

 

LED5

LED3

LED1

 

J6

 

 

 

 

LED10

J7

LED6 LED4 LED2

J8

J4

 

 

G3742-[ ]

 

 

FIRING BOARD

FIRING BOARD

 

 

1. With DC-600 set for the Test Conditions all ten

 

4. LEDs 1 thru 6 indicate that gate signals are being

LEDs on the Firing Board should be lit.

 

 

sent to the SCRs in the Main Rectifier. These

 

 

 

 

 

2. LEDs 7, 8 & 9 indicate that the three 34vac sup-

 

LEDs will vary in brightness as the Output Control

plies from the Main Transformer are present on the

 

is changed.

Firing Board. They should all be ON whenever the

 

• It is important that all six LEDs are the same bril-

Power Switch is ON.

 

liance as each other.

• If any are not ON check the voltages at P5

 

If none are lit, check the voltage at lead 231

 

(P5 - Pin13). See the Control Board Test. If

 

 

 

 

 

LED that

Check AC voltage between pins specified,

 

OK, Replace the Firing Board.

was off

it should be approximately 34VAC .

 

If LEDs are not the same brilliance, see the

7

P5 pins 15 & 16 (wires 203,204)

 

SCR Bridge Test and check the connections

8

P5 pins 7 & 8 (wires 205,206)

 

 

to J-4. If OK, replace the Firing Board.

9P5 pins 5 & 6 (wires 207,208)

If voltage is present and the LED is OFF, replace the Firing Board

3.LED 10 indicates that the machine is “triggered” (Output Terminal Switch ON).

Alternate Trigger Methods:

Operate Wire Feeder trigger.

Place a jumper across 2 & 4 on T.S.2.

Jumper between pins C & D of 14 pin connector.

If LED 10 does not come ON, check wiring. Perform the Internal Trigger Circuit Test.

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-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 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 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 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 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 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