Lincoln Electric SVM136-A service manual Welding Problems

Page 49

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F-9

 

 

 

 

 

 

F-9

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE

 

 

 

 

 

 

Observe Safety Guidelines

 

 

 

 

 

 

detailed in the beginning of this manual.

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

 

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

WELDING PROBLEMS

 

Poor arc characteristics.

1.

Make sure the correct weld pro-

1. Check the output capacitors and

 

 

cedures

are

being

used.

connections. A capacitor failure

 

 

(Electrode, Gas, etc.)

 

 

is indicated if the small vent plug

 

2.

Check the

welding

cables for

on top of a capacitor is raised or

 

blown out.

 

 

loose or faulty connections.

 

 

 

 

 

 

 

 

 

 

WARNING: The liquid elec-

 

 

 

 

 

 

 

trolyte in these capacitors is

 

 

 

 

 

 

 

toxic. Avoid contact with any

 

 

 

 

 

 

 

portion of your body. Clean

 

 

 

 

 

 

 

up vented electrolyte using

 

 

 

 

 

 

 

rubber gloves and a water

 

 

 

 

 

 

 

dampened cloth. Any elec-

 

 

 

 

 

 

 

trolyte which gets on skin,

 

 

 

 

 

 

 

clean with soap and water.

 

 

 

 

 

 

 

2. The control board may be faulty.

 

 

 

 

Poor arc striking with semiautomat-

1.

Make sure the correct weld pro-

1. The control board may be faulty.

ic or automatic wire feeders.

 

cedures

are

being

used.

 

 

 

(Electrode, Gas, etc.)

 

 

 

 

2.

Check the welding

cables for

 

 

 

loose or faulty connections.

 

 

 

 

The welding arc is variable and

1. Check the input voltage at the

1. Perform the SCR/Diode Recti-

sluggish.

 

CV-400, making sure the correct

fier Bridge Test.

 

 

voltage and all three phases are

2. Perform the Main Transformer

 

 

being applied to the machine.

 

 

Test.

 

 

 

 

 

 

 

 

2. Make sure the welding process

3. The control board may be faulty.

 

 

is correct for the machine set-

 

 

Replace.

 

 

tings.

 

 

 

 

 

 

 

 

 

 

 

 

3. Check the

welding

cables for

 

 

 

loose or

faulty

connections.

 

 

 

Also make sure cables are sized

 

 

 

correctly for the welding current.

 

 

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

IDEALARC CV-400

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Page 48 Page 50
Contents Idealarc CV-400 California Proposition 65 Warnings SafetyElectric Shock can kill Cylinder may explode if damaged Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Idealarc CV-400 InstallationLocation and Ventilation Safety PrecautionsLifting Input Supply Connections Ground ConnectionReturn to Input Wire and Fuse SizeConnect Electrode and Work Leads to Output Terminals Reconnect Procedure Output ConnectionsFigure A.5 Output Terminal Connections Connect Wire Feeders Table of Contents Operation Section Operation Safety InstructionsOperating Instructions Design Features Operational Features and ControlsGeneral Description Recommended ProcessesLimitations Welding CapabilityFigure B.1 Case Front Controls Controls and SettingsWelding Operation Remote ControlLocal Control Overload Protection Auxiliary PowerIdealarc CV-400 Table of Contents Accessories Factory Installed Options OPTIONS/ACCESSORIESField Installed Options Connecting the NA-3 to the Idealarc CV-400 Automatic Wire FeedersFeederterminal Connecting the NA-5 to the Idealarc CV-400Accessories Connecting the LN-7 to the Idealarc CV-400 Terminal Strip Semiautomatic Wire FeedersConnecting the LN-8 or LN-9 to the Idealarc CV-400 Idealarc CV-400 Table of Contents Maintenance Return to Return to Section TOC Safety Precautions Routine and Periodic MaintenanceFigure D.1 Idealarc CV-400 Table of Contents Theory of Operation Section Input Line VOLTAGE, Contactor and Main Transformer Theory of OperationOutput CONTROL, Rectification and Feedback Figure E.4 CV-400 Trigger and Thermal Light Circuit Protective Devices CircuitsFigure E.5 SCR Operation SCR OperationIdealarc CV-400 Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairElectric Shock can kill PC Board Troubleshooting ProceduresOutput Problems Troubleshooting GuideOutput Problems SCR/Diode Perform the SCR/Diode Bridge SCR/Diode Rectifier Bridge Test Welding Problems Description Control Transformer T2 Voltage TestMaterials Needed Control Transformer T2 Voltage Test Test ProcedureRight Side View Input Contactor Test Input Contactor Test Figure F.4 Input Contactor Test Connections Test for Contact ContinuityMain Transformer T1 Voltage Test Main Transformer T1 Voltage Test Figure F.6 Main Secondary Lead Test Points Blank Main Transformer T1 Voltage Test Static SCR/DIODE Rectifier Bridge Test Static SCR/DIODE Rectifier Bridge Test SCR Anode Remove ANY Insulating Paint Cathode SCR Active SCR Test Active SCR Test Figure F.15 Heat Sink Test Points Figure F.16 SCR Tester Circuit and SCR Connections Normal Open Circuit Voltage Waveform Maximum Output Setting no LoadTypical Output Voltage Waveform Machine Loaded Typical SCR Gate Voltage Waveform Maximum Output Setting no LoadONE Output SCR not Functioning Abnormal Output Voltage Waveform Machine LoadedDescription Input Contactor CR1 CLEANING/REPLACEMENTContactor Replacement Procedure Cleaning ProcedureFAN Motor and Blade Removal and Replacement Procedure FAN Motor and Blade Removal and ReplacementSCR/DIODE Rectifier Assembly Removal and Replacement Removal and Replacement SCR/DIODE Rectifier AssemblySCR Removal and Replacement SCR Removal and Replacement Figure F.21 1/2 Wide Leaf Spring Procedure for the 1/2 Inch Wide SpringClamping Procedure For 1/4-20 CAP Screws Clamping Procedure For 1/4-28 CAP ScrewsInch Wide Spring Procedure forAfter Replacing the SCRs Mounting of Stud Type Diodes To Aluminum Heat Sinks To Aluminum Heat Sinks Mounting of Stud Type DiodesMain Transformer Removal and Replacement Removal of Lift Bail Main Transformer Removal & ReplacementFigure F.26 Choke Removal Removal of Choke and TOP Iron AssemblyFigure F.27 Epoxy MIX Application Areas Reassembly of Transformer CoilsFigure F.28 Coil Lead Placement Figure F.30 Primary Thermostat Location Reassemble the Lift Bail Reassembling the Main Transformer Into the MachineInput Idle Amps and Watts Retest After RepairOpen Circuit Voltages Welding Output Load TestIdealarc CV-400 Section G Electrical DiagramsWiring Diagram Codes 10084, 10085 Wiring Diagram Code Control PC Board G2629-1 Layout Control PC Board G2629-1 Schematic Snubber Snubber PC Board M15370-3 Schematic Idealarc CV-400
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