Lincoln Electric SVM188-A service manual Control Board Test, Figure F.7 Control Board

Page 60

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F-20

TROUBLESHOOTING AND REPAIR

F-20

CONTROL BOARD TEST (continued)

FIGURE F.7 CONTROL BOARD

	1
(291) 8	2 (256)
(291) 8	J2
	J2
(290) 7
(255) 6	5 (231)
(255) 6
	J3	LED1 LED3
	1 (210)	LED1 LED3
	1 (210)

(222)12	1	LED4	LED5

LED2

J1

LED6

DC600 CONTROL G3409-1

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PROCEDURE

WARNING

ELECTRIC SHOCK can kill.

•Do not touch electrically hot parts.

1.Turn the POWER Switch ON. LEDs 1 and 3 should turn ON.

2.If LED 1 does not come ON, but the Power Light is ON, check for 120vac at J2 (pin 6 and pin 2). See the Wiring Diagram.

•If the Power Light is not ON, perform the Control Transformer Voltage Test and check the Power Switch and associated wiring.

3.If LED 3 does not come ON but LED4 is ON, the DC-600 has shut down due to over-current or a fault in the control leads (75,76 & 77).

•Disconnect any control cables, welding leads or jumpers from the terminal strips (TS1& TS2).

4.If the machine stays ON and all LEDs are correct, the problem is external to the machine. If LED4 still comes ON:

•Check the Output Studs and associated wiring for a ‘shorted’ or ‘grounded’ condition.

•Check for grounds in the control circuit (Output Control, Local/Remote Switch & TS1).

•Control Board may be defective.

NOTE: LED 4 should be OFF except in a “shutdown“ condition. If ON and machine is still function- ing, replace the Control Board.

5.LED 5 indicates a signal to the Firing Board and should vary in brilliance as the Output Control is adjusted. If LED 5 is not ON or does not change:

•Make certain that LED 6 is ON. The Output Terminal Switch the Local/Remote Switch must be in “LOCAL” position and the Mode Switch in CV. If switches are set properly and functional, the Control Board may be defective.

6.LED 6 indicates a signal from the Firing Board that the DC-600 is “triggered”. If not ON, perform the Internal Trigger Test.

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