Lincoln Electric SVM188-A service manual Control Transformer Test, Procedure

Page 66

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F-26

TROUBLESHOOTING AND REPAIR

F-26

CONTROL TRANSFORMER TEST (continued)

FIGURE F.12 - CONTROL TRANSFORMER

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Secondary	Control
Thermostat	Transformer
Power
Switch

H2, H3 or H4 (see Input Diagram)

L3 T3

L2 T2

L1 T1

H1

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PROCEDURE

1.With the Input Power OFF, remove the case top, right side panel and the input access door. The Control Transformer is located on the back of the Input Box. See Figure F.12.

•The Primary Leads (black)are routed through the Input Box and two of them (depending on input voltage) are connected to L1 and L3 of the Input Contactor. Any unused leads are to be insulated and taped.

•The Secondary leads (red) are connected to the Power Switch (X1) and the Secondary Thermostat (X2).

2.Connect the Input Power and make certain that rated voltage is present at L1 and L3.

NOTE: The DC-600 does not need be to turned ON.

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically hot parts.

3.Measure the voltage from X1 to X2. It should be approximately 120VAC.

4.If this reading is incorrect check the connections on the Primary and Secondary lads. If OK, the trans- former may be defective.

NOTE: Common causes of control transformer failure are;

•Improper connection of the Primary leads.

•A defective (shorted) Input Contactor coil.

IMPORTANT

Before installing a new transformer perform the Input Contactor Test.

Carefully read and follow the Input Connection instructions located on the Input Access Door when installing the new transformer. If you do not have those instructions, call The Lincoln Electric Co. (1-888-935-3877) with the Code Number of the DC-600 and the instructions can be faxed or e- mailed to you.

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-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 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 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 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 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 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