Lincoln Electric SVM188-A Input Contactor CLEANING/REPLACEMENT Procedure, Cleaning Procedure

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F-40

TROUBLESHOOTING AND REPAIR

F-40

INPUT CONTACTOR CLEANING/REPLACEMENT PROCEDURE (continued)

FIGURE F.16 – CONTACTOR

CR 1 Contactor

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Coil Terminals

Apply External

120vac Here

271

W (L3)	T3
V (L2)	T2
U (L1)	T1

L3	T3
L2	T2
L1	T1

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Cover Plate Screws

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CLEANING PROCEDURE

1.Remove the main input supply power to the machine.

2.Locate and get access to the input contactor (CR1) in the input box. See Figure F.18.

3.Remove the input contactor cover plate using a phillips head screwdriver.

WARNING

Do not apply input power to the machine with the input contactor cover plate removed.

4.Blow out any dirt or dust in or around the contacts with a low pressure air stream.

5.Inspect the contacts for signs of excessive wear, pitting, or contacts fused (stuck) together.

a.If any of these conditions are present, replace the input contactor assembly.

NOTE: Lincoln does not supply contactor parts. They may be available through the manufacturer.

6. Replace the input contactor cover plate.

CONTACTOR REPLACEMENT

PROCEDURE

1.Disconnect main input supply power to the machine.

2.Locate and get access to the input contactor (CR1) in the input box. See Figure F.18.

3.Disconnect the main input supply power leads L1, L2, and L3 to the input contactor.

Remove the control transformer primary leads H1, H2 or H3 (dependent on input voltage) from the L1 and L3 terminals on the input side of the contactor.

4.Disconnect the output leads T1, T2, and T3 from the input contactor.

5.Identify and label the leads connected to the input contactor coil. See the Wiring Diagram.

6.Disconnect the leads from the input contactor coil (leads X1, #256 and #255A). See the Wiring

Diagram.

7.Remove the three self-tapping mounting screws using a 5/16” socket wrench.

8.Remove the input contactor.

9.Insert the replacement input contactor and install it following the procedures in reverse order.

NOTE: Be sure to reconnect all leads correctly.

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-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 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 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 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 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 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