Lincoln Electric SVM123-A service manual PC Board Troubleshooting Procedures

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F-3

TROUBLESHOOTING & REPAIR

F-3

 

PC BOARD TROUBLESHOOTING PROCEDURES

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WARNING

ELECTRIC SHOCK can kill.

Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch elec- trically hot parts.

_______________________________

CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following pro- cedure:

1.Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2.Check for loose connections at the PC board to assure that the PC board is properly connect- ed.

3.If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

P.C. Board can be damaged by static electricity.

-Remove the P.C. Board from the static-shielding bag and place it directly into the equipment. Don’t set the P.C. Board on or near paper, plastic or cloth which could have a static charge. If the P.C. Board can’t be installed immediately, put it back in the static-shielding bag.

-If the P.C. Board uses protective shorting jumpers, don’t remove them until installation is complete.

-If you return a P.C. Board to The Lincoln Electric Company for credit, it must be in the static-shield- ing bag. This will prevent further damage and allow proper failure analysis.

4.Test the machine to determine if the failure symptom has been corrected by the replace- ment PC board.

NOTE: It is desirable to have a spare (known good) PC board available for PC board trou- bleshooting.

NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

5. Remove the replacement PC board and sub-

stitute it with the original PC board to recreate

the original problem.

a.

If the original problem does not reap-

 

pear by substituting the original board,

 

then the PC board was not the prob-

 

lem. Continue to look for bad connec-

ATTENTION

Static-Sensitive

Devices

Handle only at

Static-Safe

Workstations

Reusable

Container

Do Not Destroy

-Remove your body’s static charge before opening the static-shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equip- ment frame.

-If you don’t have a wrist strap, touch an unpainted, grounded, part of the equip- ment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.

 

tions in the control wiring harness,

 

junction blocks, and terminal strips.

b.

If the original problem is recreated by

 

the substitution of the original board,

 

then the PC board was the problem.

 

Reinstall the replacement PC board

 

and test the machine.

6. Always indicate that this procedure was fol-

lowed when warranty reports are to be submit-

ted.

 

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

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-Tools which come in contact with the P.C. Board must be either conductive, anti-static or static-dissi- pative.

IDEALARC DC-1000

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Contents Idealarc Electric and Magnetic Fields SafetyElectric Shock can kill Welding Sparks can cause fire or explosion Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Output Technical Specifications Idealarc DCStacking Electric Shock can KillSelect Proper Location Electrical Input ConnectionsGround Connection Reconnect ProcedureFuse and Wire Sizes Input Power Supply ConnectionsFigure A.3a Input Connection Diagram Figure A.3c -Input Connection Diagram Figure A.3d Input Supply Connection Diagram Output Connections Cutting Operation Connection for AIR/CARBON ARCIdealarc DC-1000 Operation Electric Shock can kill Safety InstructionsRecommended Processes and Equipment Operational Features and ControlsDesign Features Advantages General DescriptionWelding Capability Return to Section Controls and SettingsRemote Control of Machine Operation Welding Procedure RecommendationsNA-3 Automatic Wire Feeder ARC Striking with Idealarc DC-1000 and the NA-3 Start Board Remote LN-8 SEMI-AUTOMATIC Wire FeederTable of Contents AccessoriesRemote Output Control Optional OPTIONS/ACCESSORIESConnecting the NA-3 or LT-7 to Idealarc DC-1000Figure C.2 NA-5 Wire Feeder Connection to Idealarc DC-1000 Connecting the NA-5 to the Idealarc DC-1000Connecting the LN-8 to the Idealarc DC-1000 Connecting the LN-9 Wire Feeder to the Idealarc DC-1000 Connecting the LN-7 Wire Feeder to the Idealarc DC-1000 Maintenance Routine and Periodic Maintenance Safety Precautions Electric Shock Can KillFigure D.1 Major Component Locations Idealarc DC-1000 Theory of Operation TOR, and Main Transformer Input Line VOLTAGE, ContacCONTROL, and Feedback Output RectificationCircuits Contactor HOLD-IN Protection DevicesFigure E.5 SCR Operation SCR OperationIdealarc DC-1000 Troubleshooting & Repair Locate Problem Symptom HOW to USE Troubleshooting GuideBoard can be damaged by static electricity PC Board Troubleshooting ProceduresControl Transformer Test Return Return to Master TOC Return Return to Section TOC Perform SCR Output Bridge Troubleshooting & Repair Function Problems Perform Firing Board Test Perform Control Board Test SCR Output Troubleshooting & Repair Control Transformer T2 Voltage Test Test DescriptionFigure F.1 Control Transformer Lead Location Test ProcedureFigure F.2 Control Transformer X1 and X2 Test Points Main Transformer T1 Voltage Test Test Description Figure F.4 Main Secondary Lead Test Points From Expected VAC Firing Board Test Test Procedure for Normal Firing Board Operation Figure F.7 Terminal Strip Jumper Wire Connections Figure F.8 Output Pilot Relay 4CR Location Then Table F.1 LED 7, 8 and 9 Check ListControl Board Test Figure F.9 Control Board LED and Pin Locations Test Procedure for Normal Control Board OperationIf LED 1 does not light, when the start switch is on Possible Problems Pertaining to the Control BoardFigure F.11 LED 2 Open Circuit Voltage Test Points If LED 4 lights Static SCR Test Figure F.12 Test ProcedureFigure F.13 SCR Heat Sink Assembly Test Points Static SCR Test Active SCR Test Active SCR Test Figure F.16 Heat Sink Assembly Test Points Battery Test Scope Settings Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair Input Contactor 1CR Cleaning AND/OR Replacement Figure F.18 Input Contactor Cover Removal Cleaning ProcedureRemoval Contactor ReplacementInstallation SCR Output Bridge Replacement Figure F.22 Preparation For SCR Output Bridge Removal SCR Output Bridge RemovalFigure F.23 SCR Output Bridge Removal Removal of Individual SCR Heat Sink Assemblies SCR Output Bridge Installation SCR Heat Sink InstallationTOC Removal and Reassembly of Lift Bail Figure F.25 Lift Bail Removal Removal of Lift BailReassembly of Lift Bail Main Transformer Removal and Installation Figure F.26 Main Transformer Disassembly Main Transformer Disassembly and AssemblyCoil Removal Replacement Main Transformer DisassemblyTransformer Reassembly Transformer InstallationIdealarc DC-1000 Open Circuit Voltages Input Idle Amps and WattsIdealarc DC-1000 Electrical Diagrams Idealarc DC-1000 Wiring Diagram Codes 9919 Operating Schematic Control PC Board G1585 Layout Firing PC Board G1486-5 and above Layout Control PC Board G1585 Schematic Firing PC Board G1486-5 and above Schematic Output Snubber M14312 Schematic
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