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Lincoln Electric SVM133-B SCR/DIODE Rectifier Bridge Removal and Replacement, Description

Models: SVM133-B

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F-89

F-89

TROUBLESHOOTING & REPAIR

SCR/DIODE RECTIFIER BRIDGE

REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot- ing assistance before you proceed. Call 1-800-833-9353 (WELD).

DESCRIPTION

This procedure will aid the technician in the removal and replacement of the SCR/Diode rectifier bridge assembly.

MATERIALS NEEDED

5/16" Nut driver 3/8" Wrench 1/2" Wrench 3/4" Wrench 11/32" Wrench

This procedure takes approximately 80 minutes to perform.

COMMANDER 400

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Lincoln Electric SVM133-B service manual SCR/DIODE Rectifier Bridge Removal and Replacement, Description

Contents

Commander TM Commander SafetyFumes and Gases can be dangerous Electric Shock can killARC Rays can burn Iii Welding Sparks can cause fire or explosionCylinder may explode if damaged Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Duty Cycle Welding Output Volts at Rated Amps Welding Range Open Circuit Voltage Auxiliary Power1HEIGHT2 Width Depth Weight Bore x StrokeStacking Safety PrecautionsLocation and Ventilation StoringTowing PRE-OPERATION Engine ServiceLifting High Altitude OperationFuel CAP Battery Connections FuelBattery Acid can Burn Eyes and Skin Muffler Outlet PipeWelding Cable Connections Cable Installation and Cable SizesElectrical Output Connections Machine Grounding Auxiliary Power ReceptaclesPower Table of Contents Operation Section General Description Safety InstructionsOperating Instructions Recommended Applications Design FeaturesWelding Capability Additional Design FeaturesFor Wire Welding Engine Controls Controls and SettingsIdler Operational Exceptions Tor is closed and the welding terminals are Hot Table B.1 Output Range Switch and OUTWhen the triggering device is pressed the contac PUT Control FunctionsStarting the Engine Auxiliary Power ControlsWire Feeder Mode Controls Engine OperationTable B.2 Deutz F3L 912 Engine Fuel Consumption Stopping the Engine Typical Fuel ConsumptionBREAK-IN Period Pipe Welding Welder OperationStick Welding TIG WeldingTable B.3 Typical Current RANGES1 for Tungsten ELECTRODES2 Commander 400 Settings When Using the K799 HI-FREQ UnitCommander 400 Settings When Using the K930-1 TIG Module Simultaneous Welding and AUXIL- Iary Power Loads Wire Feed Constant Voltage WeldingAuxiliary Power Table of Contents Accessories High Frequency Generators for TIG Applications OPTIONS/ACCESSORIESSemiautomatic Welding Accessories Electric Shock can kill Connection of Lincoln Electric Wire FeedersING Terminals Remotely Controlled PIN Amphenol Adjust wire feed speed and voltage at the LN-8 Electrode Cable To Work ING Terminals Always on Adjust wire feed speed at the SG Control Module Commander Table of Contents Maintenance Engine Maintenance Routine and Periodic MaintenanceFigure D.1 OIL Drain and Refill Fuel Filters Figure D.2 Fuel PRE-FILTER/WATER Separator AssemblyFigure D.3 Secondary Fuel Filter AIR Filter Maintenance Every Daily or BeforeStarting Engine 1First 50 HoursEngine Maintenance Parts Manufacturer Part Number Battery Maintenance WELDER/GENERATOR Maintenance Figure D.5 Major Component Locations Table of Contents Theory of Operation Section Theory of Operation Itors Operation SCR Operation CommanderInduction Generators Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board can be damaged by static electricity PC Board Troubleshooting ProceduresDetailed in the beginning of this manual Troubleshooting GuideObserve Safety Guidelines Control Board Power Supply TestOscilloscope Oscilloscope Waveforms Section Resistance Test Engine Problems Tight Check solenoid Waveforms as Illustrated Shutdown Function Problems Local/Remote switch Welding Problems Range Switch Control Board Wave forms SectionTroubleshooting & Repair Definition / Symptom Corrective Action Commander 400 with G2713-1 Control BoardECL SCR/Diode Rectifier Bridge ECP CAL Error Codes During Definition / Symptom Corrective ActionEHC While Running Error Codes Definition / Symptom Corrective ActionLFL COP time-out error Frequency intrusion from another Running Commander 400 with G2713-2 or -3 Control BoardMaterials Needed Case Cover Removal and Replacement ProcedureDescription Procedure Case Cover Removal and Replacement ProcedureTroubleshooting & Repair Figure F.4 Left Side Engine Cover Removal Figure F.5 Front Control Panel Removal Front Shroud Removal ProcedureRemoval Case Front Knobs Removal and Replacement ProcedureTest Description Idler Solenoid TestIdler Solenoid Test Test ProcedureShutdown Solenoid Test Figure F.9 Shutdown Solenoid Lead Terminals Shutdown Solenoid TestEngine Throttle Adjustment Test Strobe Tach Method Engine Throttle Adjustment TestOscilloscope Method Frequency Counter MethodFigure F.11 High Idle Adjustment Locking NUT CommanderStatic SCR/DIODE Rectifier Bridge Test Plug J6 Static SCR/DIODE Rectifier Bridge TestFigure F.15 Resistor R1 Location Figure F.14 Snubber Board Plug J30 LocationTest Active SCR Test Active SCR Test Test ProcedureFigure F.19 Resistor R1 Location Figure F.21 SCR Tester Circuit and SCR Connections Charging Circuit Test #239 #285#281 #238 Charging Circuit TestStator Voltage Test Stator Voltage Test Test Procedure Auxiliary Power Windings TestW2/W5 W1/W4 W3/W6 Plug J2 CommanderTest Procedure Exciter Winding Voltage Test Troubleshooting & Repair Troubleshooting and Repair Range Switch Test Range Switch Test Plug J7 Commander Shunt Calibration Test Shunt Calibration Test Exciter Voltage Feedback Test Exciter Voltage Feedback Test Exciter Capacitor Bank Test Exciter Capacitor Bank Test Control Board Power Supply Test C112 Stator Resistance Test Stator Resistance Test Table F.3 High Idle no Load Output Current Control AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115VAC Supply MAX TAP MAX Control POT High Idle no Load Normal Open Circuit Voltage Waveform StickMachine Loaded to 400AMPS AT 40 Volts Normal Weld Voltage Waveform Stick CCNormal Weld Voltage Waveform Wire CV MAX Control POT High Idle no Load Normal Open Circuit Voltage Waveform Wire CV TAPNormal Solenoid Pull & Hold Coil Waveforms 200 MV Abnormal Solenoid Pull & Hold Coil WaveformsTypical Exciter Voltage Feedback Waveforms Abnormal Exciter Voltage Feedback Waveforms Control PC Board REMOVAL, Replacement Calibration CV Board Molex Plug Control Board Molex Plugs Control PC Board Removal and ReplacementB2/262 B3/232 ReassemblyB1/227 Stick and Wire Model Only Calibration ProcedureShutdown Solenoid Removal and Replacement Figure F.35 Shutdown Solenoid Lead Connections Shutdown Solenoid Removal and ReplacementFigure F.36 Shutdown Solenoid Linkage ARM Assembly Commander SCR/DIODE Rectifier Bridge Removal and Replacement Heat Sink Plate Lower Removal and ReplacementSCR/DIODE Rectifier Bridge Shunt Remove Bolt AT PositiveOutput Terminal #207 from StickFigure F.40 Resistor R1 Location Figure F.42 SCR/DIODE Rectifier Bridge Assembly Removal Commander SCR Removal and Replacement Special Instructions SCR Removal and ReplacementProcedure Figure F.45 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 Screws100 Procedure for5/8 Inch Wide Spring 101 After Replacing the SCRs102 103 Mounting of Stud Type Diodes to Aluminum Heat SinksDiode Stud Foot Inch Size Pounds Mounting of Stud Type Diodes to AluminumHeat Sinks 104105 ENGINE, STATOR/ROTOR Removal and Replacement106 ENGINE, STATOR/ROTOR Removal and ReplacementPreparation and Lead Removal Procedure 107 Figure F.50 Rear Panel Assembly Removal DetailsFigure F.52 Shutdown Solenoid Lead Removal 108Figure F.54 OIL Pressure Sensor Lead Removal 109Figure F.56 Engine Grounding Lead Lead Attachment Point 110Cover ExciterBoard Exciter Brass BoardFigure F.58 Control Board Plug J2 Location 112Figure F.60 Vertical Baffle /ENGINE Mount Removal 113114 Stator Removal Procedure115 Rotor Removal ProcedureReassembly Notes Rotor will be free to fall when the bolts are removed116 Lead Reconnection ChecklistEngine Output Welder CV Wire OutputAuxiliary Power Output Retest After Repair118 Electrical Diagrams Section Wiring Diagram Stick Model Code Electrical DiagramsSource Wiring Diagram Stick & Wire Model CodePOS CC NEG To Mother Control PCB Schematic Amphenol Bypass PC BoardXxxxx PC Board Assembly Amphenol Bypass PC BoardSchematic Auxiliary Protection PC Board REQ’D Part no Description PC Board Assembly Auxiliary Protection PC BoardSchematic Bypass PC Board ~.04 PC Board Assembly Bypass PC BoardSchematic Control PC Board Part Electrical Diagrams PC Board Assembly Control PC Board +15 Cvscr Schematic CV Control PC BoardXXX PC Board Assembly CV Control PC BoardOIL Temp Switch F.B Schematic Engine Protection PC BoardL9596-1 PC Board Assembly Engine Protection PC BoardCommon Schematic Meter PC BoardREQ’D Part no Identification PC Board Assembly Meter PC BoardAmphenol Schematic Remote Protection PC BoardPC Board Assembly Remote Protection PC Board Schematic Snubber PC Board XXX Xxxxxxx PC Board Assembly Snubber PC BoardSVM Error Reporting Form