Lincoln Electric SVM123-A service manual Perform SCR Output Bridge

Page 47

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F-7

TROUBLESHOOTING & REPAIR

F-7

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

 

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

 

Machine has maximum weld out-

1. If remote control is being

1.

Check output control switch

put and no control.

 

used, put output control switch

 

(SW3) and associated wiring.

 

 

(SW3) in “OUTPUT CON-

 

 

 

 

 

TROL AT DC-1000” position

2.

Check feedback leads #222

 

 

and control weld output with

 

(negative output terminal) and

 

 

the output control (R1) at DC-

 

#215, #210(output shunt) for

 

 

1000. If the problem is solved,

 

loose or faulty connections.

 

 

check the remote control unit

 

See wiring diagram.

 

 

 

(or wire feeder) and associat-

 

 

 

 

 

ed control cable.

3.

Check the #75 lead for conti-

 

 

 

 

nuity (zero ohms) from the

 

 

 

 

output control potentiometer

 

 

 

 

(R1) to the control board plug

 

 

 

 

10J1. See wiring diagram.

 

 

 

4. Perform Firing Board Test.

 

 

 

5. Perform Control Board Test.

 

 

 

6. Perform SCR Output Bridge

 

 

 

 

Test.

 

 

 

 

 

 

Machine has minimum output

1. If a remote control unit is NOT

1.

Check the output

control

and no control.

 

connected to the terminal strip

 

potentiometer (R1) and asso-

 

 

#73, #74,#75, #76, and/or #77

 

ciated wiring.

 

 

 

terminals, the output control

 

 

 

 

 

switch must be in the “OUT-

2.

Check the output

control

 

 

PUT CONTROL AT DC-1000”

 

switch (SW3) the welding

 

 

position.

 

mode switch (SW4) and asso-

 

 

 

 

ciated wiring.

 

 

 

2. If a remote control cable is

 

 

 

 

 

connected to terminals #73,

3.

Perform the Control Board

 

 

#74, #75, #76, and/or #77, the

 

Test.

 

 

 

leads may be shorted to the

 

 

 

 

 

positive weld output.

4.

Perform the Firing Board

 

 

 

 

Test.

 

 

 

3. Make certain the three phase

 

 

 

 

 

input voltage is correct and

5.

Perform the SCR Output

 

 

matches the machine rating

 

Bridge Test..

 

 

 

and the reconnect panel.

 

 

 

 

 

 

6.

Perform Main Transformer

 

 

 

 

Test.

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

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 SettingsNA-3 Automatic Wire Feeder Welding Procedure RecommendationsRemote Control of Machine Operation 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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