Lincoln Electric SVM136-A service manual Reassembling the Main Transformer Into the Machine

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F-52

F-52

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)

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REASSEMBLING THE MAIN TRANSFORMER INTO THE MACHINE

NOTE: The following procedure assumes you have completely reassembled the transformer coils as described in the procedure above. The lower iron has remained in place in the machine. See Figures F.25 and F.26.

1.Attach the bottom choke lead to the negative out- put terminal.

2.Attach the top choke lead to the negative rectifier plate.

REASSEMBLE THE LIFT BAIL

1.Carefully position the lift bail onto the machine base. Using the 9/16” socket wrench, attach the lift bail to the base of the machine with four bolts, flat washers, and lock washers.

2.Using the 9/16” socket wrench, attach the lift bail to the transformer top and bottom irons with four bolts.

3.Attach the sheet metal screw that holds the capac- itor bank assembly to the case back.

4.Connect leads #220 and #204 to resistor R2.

5.Connect the negative capacitor strap to the nega- tive rectifier plate.

6.Connect the positive capacitor strap to the output shunt and positive rectifier plate.

7.Attach the fiber baffle on the bottom choke lead.

8.Attach the two fiber baffles to the left and right sides of the lift bail, adjacent to the main trans- former.

9.Install the machine case top and sides.

NOTE: When aluminum leads are reconnected, apply a thin layer of Dow Corning 340 Heat Sink Compound (Lincoln E1868) to the mating surfaces.

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IDEALARC CV-400

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Contents Idealarc CV-400 Safety California Proposition 65 WarningsElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Idealarc CV-400Lifting Safety PrecautionsLocation and Ventilation Ground Connection Input Supply ConnectionsInput Wire and Fuse Size Return toReconnect Procedure Output Connections Connect Electrode and Work Leads to Output TerminalsFigure A.5 Output Terminal Connections Connect Wire Feeders Table of Contents Operation Section Operating Instructions Safety InstructionsOperation Operational Features and Controls Design FeaturesGeneral Description Recommended ProcessesWelding Capability LimitationsControls and Settings Figure B.1 Case Front ControlsLocal Control Remote ControlWelding Operation Auxiliary Power Overload ProtectionIdealarc CV-400 Table of Contents Accessories Field Installed Options OPTIONS/ACCESSORIESFactory Installed Options Automatic Wire Feeders Connecting the NA-3 to the Idealarc CV-400Connecting the NA-5 to the Idealarc CV-400 FeederterminalAccessories Semiautomatic Wire Feeders Connecting the LN-7 to the Idealarc CV-400 Terminal StripConnecting the LN-8 or LN-9 to the Idealarc CV-400 Idealarc CV-400 Table of Contents Maintenance Safety Precautions Routine and Periodic Maintenance Return to Return to Section TOCFigure D.1 Idealarc CV-400 Table of Contents Theory of Operation Section Theory of Operation Input Line VOLTAGE, Contactor and Main TransformerOutput CONTROL, Rectification and Feedback Protective Devices Circuits Figure E.4 CV-400 Trigger and Thermal Light CircuitSCR Operation Figure E.5 SCR OperationIdealarc CV-400 Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Electric Shock can killTroubleshooting Guide Output ProblemsOutput Problems SCR/Diode Perform the SCR/Diode Bridge SCR/Diode Rectifier Bridge Test Welding Problems Materials Needed Control Transformer T2 Voltage TestDescription Test Procedure Control Transformer T2 Voltage TestRight Side View Input Contactor Test Input Contactor Test Test for Contact Continuity Figure F.4 Input Contactor Test ConnectionsMain 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 Maximum Output Setting no Load Normal Open Circuit Voltage WaveformTypical Output Voltage Waveform Machine Loaded Maximum Output Setting no Load Typical SCR Gate Voltage WaveformAbnormal Output Voltage Waveform Machine Loaded ONE Output SCR not FunctioningInput Contactor CR1 CLEANING/REPLACEMENT DescriptionCleaning Procedure Contactor Replacement ProcedureFAN Motor and Blade Removal and Replacement FAN Motor and Blade Removal and Replacement ProcedureSCR/DIODE Rectifier Assembly Removal and Replacement SCR/DIODE Rectifier Assembly Removal and ReplacementSCR Removal and Replacement SCR Removal and Replacement Procedure for the 1/2 Inch Wide Spring Figure F.21 1/2 Wide Leaf SpringClamping Procedure For 1/4-28 CAP Screws Clamping Procedure For 1/4-20 CAP ScrewsProcedure for Inch Wide SpringAfter Replacing the SCRs Mounting of Stud Type Diodes To Aluminum Heat Sinks Mounting of Stud Type Diodes To Aluminum Heat SinksMain Transformer Removal and Replacement Main Transformer Removal & Replacement Removal of Lift BailRemoval of Choke and TOP Iron Assembly Figure F.26 Choke RemovalReassembly of Transformer Coils Figure F.27 Epoxy MIX Application AreasFigure F.28 Coil Lead Placement Figure F.30 Primary Thermostat Location Reassembling the Main Transformer Into the Machine Reassemble the Lift BailRetest After Repair Input Idle Amps and WattsOpen Circuit Voltages Welding Output Load TestIdealarc CV-400 Electrical Diagrams Section GWiring 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