Lincoln Electric SVM136-A service manual Cleaning Procedure, Contactor Replacement Procedure

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F-33

F-33

TROUBLESHOOTING & REPAIR

INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued)

FIGURE F.17 – INPUT CONTACTOR CLEANING AND REMOVAL

1.INPUT SUPPLY LINE

2.INPUT CONTACTOR CR1

3.RECONNECT PANEL

Return

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CLEANING PROCEDURE

1.Remove the main input supply power to the machine and remove the input access panel.

2.Locate and get access to the input contac- tor (CR1) in the input box. See Figure F.17.

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

CONTACTOR REPLACEMENT PROCEDURE

1.Disconnect main input supply power to the machine.

2.Locate and get access to the input contac- tor (CR1) in the input box. See Figure F.17.

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

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WARNING

 

Remove the control transformer primary

Do not apply input power to

leads H1, H2 or H3 (dependent on input volt-

age) from L1 and L3 terminals on the input

the machine with the input

side of the contactor.

contactor cover plate re-

4.

Using the 7/16” socket wrench, disconnect

moved.

 

the output leads T1, T2, and T3 from the

 

 

 

 

input contactor. (Label the leads.)

 

5.

Identify and label the leads connected to the

4. Blow out any dirt or dust in or around the

 

input contactor coil.

See the Wiring

 

Diagram.

 

contacts with a low pressure air stream.

 

 

 

 

 

5. Inspect the contacts for signs of excessive

6.

Disconnect the leads from the input contac-

 

tor coil (leads X1, #232 and #233). See the

wear, pitting, or contacts fused (stuck)

 

 

Wiring Diagram.

 

together.

 

 

 

 

 

a. If any of these conditions are present,

7.

Remove the three self-tapping mounting

 

screws using a 5/16” socket wrench. See

replace the input contactor assembly.

 

 

Figure F.17.

 

6. Replace the input contactor cover plate.

 

 

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.

IDEALARC CV-400

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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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