Lincoln Electric SVM 122-A service manual Active SCR Test, P1 and P3 Locations Plug P5 Location

Page 74

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F-30

F-30

TROUBLESHOOTING & REPAIR

ACTIVE SCR TEST (continued)

FIGURE F.12 – CONTROL BOARD PLUG	FIGURE F.13 – SNUBBER BOARD
P1 AND P3 LOCATIONS	PLUG P5 LOCATION

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Plug P1

DC-400 CONTROL

G2588-X

Plug P5

M15370-X SNUBBER

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Plug P3

FIGURE F.14 – RESISTOR R2 LOCATION

TEST PROCEDURE

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1.Disconnect the main input supply power to the machine.

2.With the 5/16” nut driver, remove the case top and sides. Remove the screws holding the front panel and lower the panel.

3.Disconnect the welding cables from the welding output terminals.

4.Locate and remove molex plugs P1 and P3 from the control board. See Figure F.12.

5.Locate and remove molex plug P5 from the snubber board. See Figure F.13.

6.Rotate the mode switch (S4) to the constant current (CC) position.

7.Locate and remove lead #204 from resistor R2 (40 ohms, 50 Watts). See Figure F.14.

IDEALARC DC-400

LINCOLN ®

ELECTRIC

Image 74

Contents Safety Depends on You Idealarc TMDC-400Safety California Proposition 65 WarningsElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Idealarc DC-400Lifting Safety PrecautionsSelect Suitable Location TiltingInput Supply Connections Input ConnectionsGround Connection Electric Shock can killInput Wire and Fuse Size Figure A.3 Input Power Supply ConnectionsReconnect Procedure Input Supply Connection DiagramOutput Connections Figure A.6 Output Terminal ConnectionsCycle Wire Feeder ConnectionsCycle 500 Amp 50% Duty Operation Section Operating Instructions Safety InstructionsOPERATIONB-2 Operation General DescriptionControls and Settings Figure B.1 Case Front ControlsOperation Welding Operation Remote ControlWelding Procedure Recommendations Operating StepsNA-3 Automatic Wire Feeder ARC Striking with the NA-3 Start BoardNA-5 Automative Wire Feeder LN-8 Semiautomatic Wire FeederAuxiliary Power Overload ProtectionTable of Contents Accessories Field Installed Options OPTIONS/ACCESSORIESFactory Installed Option Diode OptionMultiprocess Switch Operation ConnectionsRemote Output Control K857 with K864 Adapter Plug or K775 Remote Control Adapter Cable K864K843 Amptrol Adapter Installation Instructions Amptrol Adapter Cable K843K843 Amptrol Adapter Installation Instructions Amptrol and Hi-Freq. Kit The Amptrol will startCapacitor Discharge Circuit K828-1 Automatic Wire FeedersConnecting the NA-3 to the Idealarc DC-400 Terminal Strip HI-FREQ KIT K799 for Codes 8634 and Above onlyConnecting the NA-5 to the Idealarc DC-400 Terminal Strip Cable Plug K597-XX Input Cable Assembly Idealarc DC-400 To NA-3 or NA-5 InputSemiautomatic Wire Feeders Connecting the LN-7 to the Idealarc DC-400 14-PIN AmphenolConnecting 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 Contactor and Main Theory of OperationInput Line Voltage TransformerOutput Mode and CONTROL, Rectification and Feedback Protective Devices and Circuits SCR Operation Figure E.4 SCR OperationTable of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures PC Board can be damaged by static electricityTroubleshooting Guide Output ProblemsPerform 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 Toxic. Avoid contact with any Portion of your body. CleanTrolyte in these capacitors is Make sure welding process is Materials Needed Input Contactor TestDescription Test Procedure Input Contactor TestTest for Contact Continuity Figure F.2 Input Contactor Test ConnectionsControl Transformer T2 Voltage Test Control Transformer T2 Voltage Test Figure F.3 Control Transformer and Lead LocationsTroubleshooting & Repair Main Transformer T1 Voltage Test Main Transformer T1 Voltage Test Figure F.6 Main Secondary Lead Test Points Troubleshooting & Repair Plug P1 Phase Angle Winding Voltages Figure F.8 Control Board Plug P1 LocationStatic SCR/DIODE Rectifier Bridge Test Static SCR/DIODE Rectifier Bridge Test Figure F.9 Control Board and Snubber Board Plug LocationsSCR Test Active SCR Test Active SCR Test P1 and P3 Locations Plug P5 LocationFigure F.15 Heat Sink Test Points Figure F.16 SCR Tester Circuit and SCR Connections Scope Settings CH1Maximum Output Setting no Load Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair 2V/Div Troubleshooting & Repair Input Contactor CR1 CLEANING/REPLACEMENT Contactor Replacement Procedure Input Contactor CR1 CLEANING/REPLACEMENTCleaning Procedure FAN Motor and Blade Removal and Replacement FAN Motor and Blade Removal and Replacement ProcedureSCR/DIODE Rectifier Assembly Removal and Replacement SCR/DIODE Rectificer Assembly Removal and ReplacementSCR Removal and Replacement SCR Removal and Replacement Special InstructionsProcedure 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 Diode Stud Foot Inch Size Pounds Mounting of Stud Type Diodes to AluminumHeat Sinks Main 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 volts/Phase/Hertz Maximum Idle Amps Maximum Idle KWMode Input Hertz Open Circuit Volts Input Idle Amps and WattsRetest After Repair Maximum Acceptable Output Voltage AT Minimum Ouput SettingsMode Control Settings Load Table of Contents Electrical Diagrams Section Idealarc DC400 Wiring Diagram Codes 9847 LOW VoltageWiring Diagram Code Only. It may not be accurate for allControl PC Board G2588 Layout Control DC400Starting PC Board M14520 Layout TP2Snubber PC Board M15370 Layout Control PC Board G2588 Schematic 2586Starting PC Board M14520 Schematic General InformationSnubber PC Board M15370 Schematic General Information