Lincoln Electric SVM188-A service manual Weld

Page 88

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F-48

TROUBLESHOOTING AND REPAIR

F-48

MAIN TRANSFORMER AND CHOKE

REMOVAL AND REPLACEMENT (continued)

FIGURE F.21 – CHOKE TIG WELD

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REPLACEMENT PROCEDURE

1.Place the flat washers and the choke on top of the transformer and the lift bale assembly over both.

2.Install the four thread cutting bolts that mount the lift bale to the transformer and then replace the choke mounting hardware that was removed in Step 20 of the removal procedure. See Figure F.20.

NOTE: Cover the transformer assembly with ‘damp’ shop cloths before performing Step 3 to prevent weld spatter from damaging the transformer.

3.Thouroughly clean the choke lead and the sec- ondary lead and TIG weld along the two edges. The welds must be at least as long as the widths of the two pieces See Figure F.21.

4.Mount the SCR Bridge assembly using the hard- ware and insulators removed in Step 18 of the removal procedure. See Figure F.18.

5.Connect the transformer secondary and snubber leads to the SCR assembly. See Figure F.19 for proper assembly. Torque all bolts per the following:

1/4”	bolts	6 ft/lbs.
5/16” bolts		11 ft/lbs.
3/8”	bolts	19	ft/lbs.
1/2”	bolts	45	ft/lbs.

6.Using the hoist, place the transformer/lift bale assembly over the mounting bolts in the base and replace the hardware removed in Step 21 of the removal procedure.

7.Carefully back track through the removal procedure, re-routing and re-connecting the leads that were cut, removed or separated using proper electrical techniques and insulating where required.

8.Replace the baffles and any sleeving, cable ties or sealants that were removed during the disassembly procedure.

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-600Electric Shock can Kill Safety PrecautionsSelect Proper Location Electrical Input Connections Fuse and Wire SizesGround 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 ELECTRODE, Work and #21 Lead Output ConnectionsConnections Terminal Strip 1 T.S.1 Auxiliary Power Control ConnectionsTerminal Strip 2 T.S.2 DC-600 Table of Contents Operation Section Safety Precautions OperationGeneral Description Design Features AdvantagesRecommended 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 ProtectionWelding Procedure Recommendations Remote Control of Machine OperationOperating 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 Safety Precautions Electric Shock can Kill MaintenanceRoutine and Periodic Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Input Circuit and Main TRANS- FormerRectification Firing CIRCUIT, Control CIR- Cuit and 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 Test Description PC Board Troubleshooting GuideMaterials 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 Cleaning Procedure Input Contactor CLEANING/REPLACEMENT 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