Lincoln Electric SVM 122-A service manual Control PC Board G2588 Layout, Control DC400

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G-4

ELECTRICAL DIAGRAMS

G-4

Control PC Board (G2588) Layout

 

 

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REQ'D. PART No.IDENTIFICATION

ITEM

 

 

 

 

 

J1

 

 

 

 

 

 

 

 

 

1-G2588

 

 

 

 

 

 

 

 

 

 

 

 

 

 

J3

 

 

 

J2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROL DC400

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D75

D77

D81

DZ13

D80

R312 R313 R314 DZ14

D71

D72

D73

D19

D20

D21

D68

D70

D69

D66 D65 R9 D6

R13 R87

DZ3

R311 R34 C12

D18

D3

R3

C3

R5 R12 R86

DZ2

C2

R2

D2

D17

C11 R33 R310 R7

DZ1

R10

R1

C1

D1

D16

C10 R32 R309

IDEALARC DC-400

CONTROL P.C. BOARD ASSEMBLY

NOSHT. . G 2588-1

TOC

TOC

R151

R155

R328

R113 R154

J

R16

I

H

R15

R4

D13

R327

 

 

 

 

 

 

R326

 

D76

D78

DZ12

R152

 

R325

 

 

R324

 

 

 

 

 

 

R323

 

 

 

 

C43

 

R322

 

 

 

 

 

R321

 

 

OCI1

 

 

R320

 

 

 

 

 

 

 

 

 

 

R319

 

 

 

 

 

 

R318

 

 

R153

 

 

R317

 

 

 

 

R316

 

 

D62

 

 

 

 

 

 

 

C44

 

R116

 

 

 

 

 

 

 

 

 

 

 

DZ9

C41

 

R117

 

 

X7

 

 

 

 

 

 

 

R118

 

 

R147

 

D67

R114

C40

R112

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DZ5

 

 

 

 

 

 

N

 

 

 

 

 

R140

R93

R115

R146

C6

 

 

 

R22

R19

D9

D15

 

 

 

 

SCR3

QU3

C9

R31

R308

R25

 

R28

 

 

D12

 

 

 

 

 

 

 

 

 

R81

Q2

 

 

 

 

R8

D5

C5

R18

D8

 

QU2

C8

R30

R307

 

 

 

R27

 

 

 

C37

C38

D14

 

R21

 

R24

 

 

D11

 

 

 

 

 

 

 

 

R302

SCR2

C4

D4

R11

R17

D7

R14

R306

R23

 

 

 

 

 

 

 

 

SCR1

 

QU1

 

C7

R29

R20

 

 

 

R26

 

 

 

D10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R78

R79

X5

D74

R141

C39

C59

 

K

R126

C14

B

 

 

 

DZ4

R45

R40

R41

R42

D25

R73

D34

D35

D32

D33

Return to Section TOC

Return to Master TOC

R150

R149

DZ10

R148

C60

A

DR144

D22

 

 

 

 

 

C22

 

 

 

 

R64

 

 

 

 

 

R63

Q6

 

 

 

 

D49

 

 

 

 

 

 

 

 

 

 

R105

 

 

 

 

C26

R104

 

 

 

 

DZ8

 

 

 

 

 

R103

 

 

 

 

C25

D54

 

 

 

 

 

R36

C45

R102

R101

R35

 

R37

 

 

 

R127

 

 

 

 

 

D46

X6

 

 

G

D48

 

 

 

 

R56

R38

 

 

R55

D31

 

 

D64

 

 

C31

R57

 

 

 

 

 

 

D52

R66

 

 

 

R65

 

 

 

D51

 

D55

X3

 

 

C61

 

 

C15

 

 

 

C19

E

 

 

R58

 

 

R82

 

 

 

 

R59

 

 

 

R83

 

R139

 

 

D50

 

C56

 

 

C20

 

 

 

D23

 

 

 

R156

 

 

 

D79

 

 

 

R145

 

 

 

R142

 

 

 

R143

 

 

 

R315

 

 

 

D82

 

X4

 

R94

 

 

 

R91

 

 

 

R129

 

 

 

R90

 

 

 

R80

Q1

 

 

 

R128

 

 

 

C32

 

 

 

D56

 

 

 

D37

 

 

 

D36

 

 

 

R62

 

 

 

R60

 

 

 

R61

 

 

M

R89

R135

R134

 

R137

 

 

 

 

D63

 

 

 

C36

 

Q8

 

D29

 

R131

R120

R130

R119

C67

R121

C16

 

R46

C34

D30

 

R47

 

R48

 

R123

 

D60

 

D59

 

DZ6

 

C33

 

C24

 

C35

R88

 

 

C23

 

 

 

 

 

C

 

 

D24

 

 

 

 

R75

 

 

 

 

 

 

 

R74

 

 

 

 

 

 

 

R305

 

 

 

 

 

 

 

R72

R108

D26

 

 

X1

 

C68

 

 

 

 

R68

 

 

 

 

 

 

 

R52

 

 

 

 

 

 

 

R76

 

 

 

 

 

 

 

Q4

 

 

 

 

 

D27

R49

 

 

 

 

 

DZ7

D28

 

 

 

 

 

 

 

R50

 

 

 

 

 

R138

R51

 

 

 

 

 

 

 

R304

 

 

R132

 

 

R44

R109

 

 

 

 

 

R303

D45

 

 

 

 

 

D58

D44

 

 

 

 

 

 

 

R107

D57

 

 

Q5

C30

 

 

 

 

C51

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C58

 

 

 

 

 

 

 

D53

 

 

 

 

 

 

 

R110

 

 

D47

D61

R85

R124

R125

R100

 

 

 

 

 

 

 

X2

 

 

D40

R99

R98

R95

 

R122

 

 

 

 

 

 

 

 

 

 

C57

C18

C17

R77

R67

 

 

R54

Q3

R69

 

 

R53

 

R71

 

R301

 

R70

 

R97

 

D42

 

R300

 

R96

D43

F

R111

R106

D41

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not

available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result IDEALARC DC400 in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

Image 111
Contents Idealarc TMDC-400 Safety Depends on YouCalifornia Proposition 65 Warnings SafetyElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Idealarc DC-400 InstallationTilting Safety PrecautionsSelect Suitable Location LiftingElectric Shock can kill Input ConnectionsGround Connection Input Supply ConnectionsFigure A.3 Input Power Supply Connections Input Wire and Fuse SizeInput Supply Connection Diagram Reconnect ProcedureFigure A.6 Output Terminal Connections Output ConnectionsWire Feeder Connections Cycle 500 Amp 50% DutyCycle Operation Section Safety Instructions OPERATIONB-2Operating Instructions General Description OperationFigure B.1 Case Front Controls Controls and SettingsOperation Operating Steps Remote ControlWelding Procedure Recommendations Welding OperationARC Striking with the NA-3 Start Board NA-3 Automatic Wire FeederLN-8 Semiautomatic Wire Feeder NA-5 Automative Wire FeederOverload Protection Auxiliary PowerTable of Contents Accessories Diode Option OPTIONS/ACCESSORIESFactory Installed Option Field Installed OptionsConnections Multiprocess Switch OperationAmptrol Adapter Cable K843 Remote Control Adapter Cable K864K843 Amptrol Adapter Installation Instructions Remote Output Control K857 with K864 Adapter Plug or K775Amptrol and Hi-Freq. Kit The Amptrol will start K843 Amptrol Adapter Installation InstructionsHI-FREQ KIT K799 for Codes 8634 and Above only Automatic Wire FeedersConnecting the NA-3 to the Idealarc DC-400 Terminal Strip Capacitor Discharge Circuit K828-1Connecting the NA-5 to the Idealarc DC-400 Terminal Strip To NA-3 or NA-5 Input Cable Plug K597-XX Input Cable Assembly Idealarc DC-400Connecting the LN-7 to the Idealarc DC-400 14-PIN Amphenol Semiautomatic Wire FeedersConnecting the LN-7 to the Idealarc DC-400 Terminal Strip Accessories Accessories Figure C.11 Idealarc DC-400/LN-742 Connection Diagram Table of Contents Maintenance Routine and Periodic Maintenance Figure D.1 General Component Locations Table of Contents Theory of Operation Section Transformer Theory of OperationInput Line Voltage Contactor and MainOutput Mode and CONTROL, Rectification and Feedback Protective Devices and Circuits Figure E.4 SCR Operation SCR OperationTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board can be damaged by static electricity PC Board Troubleshooting ProceduresOutput Problems Troubleshooting GuidePerform the Main Transformer Rectifier Bridge Test Tifier Bridge Test Output Problems Test Perform the SCR/Diode Rec Tifier Bridge Test Function Problems Form the SCR/Diode Rectifier Welding Problems Portion of your body. Clean Trolyte in these capacitors isToxic. Avoid contact with any Make sure welding process is Input Contactor Test DescriptionMaterials Needed Input Contactor Test Test ProcedureFigure F.2 Input Contactor Test Connections Test for Contact ContinuityControl Transformer T2 Voltage Test Figure F.3 Control Transformer and Lead Locations Control Transformer T2 Voltage TestTroubleshooting & Repair Main Transformer T1 Voltage Test Main Transformer T1 Voltage Test Figure F.6 Main Secondary Lead Test Points Troubleshooting & Repair Figure F.8 Control Board Plug P1 Location Plug P1 Phase Angle Winding VoltagesStatic SCR/DIODE Rectifier Bridge Test Figure F.9 Control Board and Snubber Board Plug Locations Static SCR/DIODE Rectifier Bridge TestSCR Test Active SCR Test P1 and P3 Locations Plug P5 Location Active SCR TestFigure F.15 Heat Sink Test Points Figure F.16 SCR Tester Circuit and SCR Connections CH1 Scope SettingsMaximum Output Setting no Load Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair 2V/Div Troubleshooting & Repair Input Contactor CR1 CLEANING/REPLACEMENT Input Contactor CR1 CLEANING/REPLACEMENT Cleaning ProcedureContactor Replacement Procedure FAN 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 Rectificer AssemblySCR Removal and Replacement Special Instructions SCR Removal and ReplacementFigure 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 Mounting of Stud Type Diodes to Aluminum Heat SinksDiode Stud Foot Inch Size Pounds Main 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 Input volts/Phase/Hertz Maximum Idle Amps Maximum Idle KWMode Input Hertz Open Circuit Volts Retest After RepairMaximum Acceptable Output Voltage AT Minimum Ouput Settings Mode Control Settings LoadRetest After Repair Table of Contents Electrical Diagrams Section Idealarc DC400 LOW Voltage Wiring Diagram Codes 9847Only. It may not be accurate for all Wiring Diagram CodeControl DC400 Control PC Board G2588 LayoutTP2 Starting PC Board M14520 LayoutSnubber PC Board M15370 Layout 2586 Control PC Board G2588 SchematicGeneral Information Starting PC Board M14520 SchematicGeneral Information Snubber PC Board M15370 Schematic