Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM136-A service manual Operation, Operating Instructions, Safety Instructions

Models: SVM136-A

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OPERATION

OPERATING INSTRUCTIONS

Read and understand this entire section of operating instructions before operating the machine.

SAFETY INSTRUCTIONS

WARNING

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts or electrodes with your skin or wet cloth- ing.

•Insulate yourself from the work and ground.

•Always wear dry insulating gloves.

FUMES AND GASES can be

dangerous.

• Keep your head out of fumes.

•Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

•Keep flammable material away.

•Do not weld on containers that have held com- bustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional Safety Guidelines detailed in the beginning of this manual.

IDEALARC CV-400

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Lincoln Electric SVM136-A service manual Operation, Operating Instructions, Safety Instructions, ELECTRIC SHOCK can kill

Contents

SVM136-A SERVICE MANUALView Safety Info View Safety Info View Safety Info View Safety Info IDEALARC CV-400SAFETY FOR ENGINE powered equipmentELECTRIC AND MAGNETIC FIELDS may be dangerous CALIFORNIA PROPOSITION 65 WARNINGSELECTRIC SHOCK can kill ARC RAYS can burnFUMES AND GASES can be dangerous SAFETYFOR ELECTRICALLY powered equipment CYLINDER may explode if damagedWELDING SPARKS can cause fire or explosion SAFETYPRÉCAUTIONS DE SÛRETÉ SAFETYReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCRETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONSParts Manual TABLE OF CONTENTS INSTALLATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCINSTALLATION TECHNICAL SPECIFICATIONS - IDEALARC CV-400INPUT - THREE PHASE ONLYSAFETY PRECAUTIONS LOCATION AND VENTILATIONINSTALLATION Read this entire installation section before you start installationINSTALLATION Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC FIGURE A.1 RATING PLATE LOCATIONINSTALLATION FIGURE A.3 INPUT POWER SUPPLY CONNECTIONSReturn to Section TOC Section TOC FIGURE A.2 REAR PANELRECONNECT PROCEDURE OUTPUT CONNECTIONSINSTALLATION FIGURE A.4 INPUT CONNECTION DIAGRAM FOR 230/460 VOLTS AC, 50/60 HZINSTALLATION Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCINSTALLATION Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCTABLE OF CONTENTS - OPERATION SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC Section BSAFETY INSTRUCTIONS OPERATIONOPERATING INSTRUCTIONS ELECTRIC SHOCK can killGENERAL DESCRIPTION OPERATIONReturn to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCOPERATION Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Duty CycleCONTROLS AND SETTINGS OPERATIONReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCWELDING OPERATION OPERATIONReturn to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCAUXILIARY POWER OVERLOAD PROTECTIONOPERATION Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCACCESSORIES TABLE OF CONTENTSReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCOPTIONS/ACCESSORIES ACCESSORIESFIGURE C.1 REMOTE CONTROL ADAPTER CABLE K864 Return to Section TOC Return to Section TOCAUTOMATIC WIRE FEEDERS ACCESSORIESFIGURE C.2 NA-3 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400 FEEDERTERMINALFEEDERTERMINAL ACCESSORIESFIGURE C.3 NA-5 WIRE FEEDER CONNECTION TO THE CV-400 Return to Section TOC Return to Section TOCACCESSORIES Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Section TOCSEMIAUTOMATIC WIRE FEEDERS ACCESSORIESFIGURE C.4 LN-7 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400 FEEDERTERMINALACCESSORIES FIGURE C.5 LN-8 OR LN-9 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCTABLE OF CONTENTS MAINTENANCE Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC Section DMAINTENANCE MAINTENANCEROUTINE AND PERIODIC SAFETY PRECAUTIONSMAINTENANCE 11. CASE BACK WITH FAN MOTOR ASSEMBLYReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCTHEORY OF OPERATION SECTION TABLE OF CONTENTSGENERAL DESCRIPTION to MasterTHEORY OF OPERATION INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMERSection TOC Master TOCOUTPUT CONTROL, RECTIFICATION AND FEEDBACK THEORY OF OPERATIONSection TOC Master TOCPROTECTIVE DEVICES AND CIRCUITSTHEORY OF OPERATION FIGURE E.4 - CV-400 TRIGGER AND THERMAL LIGHT CIRCUITSCR OPERATION THEORY OF OPERATIONto Section TOC Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS TROUBLESHOOTING & REPAIR SECTIONReturn to Master TOC TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDEReturn to Section TOC Return to Master TOCTROUBLESHOOTING & REPAIR Section TOCMaster TOC Return toTROUBLESHOOTING & REPAIR OUTPUT PROBLEMSObserve Safety Guidelines Return to Section TOC Return to Section TOC Return to Section TOCOUTPUT PROBLEMS TROUBLESHOOTING & REPAIRObserve Safety Guidelines Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR OUTPUT PROBLEMSObserve Safety Guidelines Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR OUTPUT PROBLEMSObserve Safety Guidelines Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR OUTPUT PROBLEMSObserve Safety Guidelines Return to Section TOC Return to Section TOC Return to Section TOCWELDING PROBLEMS TROUBLESHOOTING & REPAIRObserve Safety Guidelines Return to Section TOC Return to Section TOC Return to Section TOCCONTROL TRANSFORMER T2 VOLTAGE TEST TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCCONTROL TRANSFORMER T2 VOLTAGE TEST continued TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCRIGHT SIDE VIEW TROUBLESHOOTING & REPAIRCONTROL TRANSFORMER T2 VOLTAGE TEST continued Return to Section TOC Return to Section TOCINPUT CONTACTOR TEST TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCINPUT CONTACTOR TEST continued X1, #232TROUBLESHOOTING & REPAIR #233TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST continuedReturn to Section TOC Return to Master TOCMAIN TRANSFORMER T1 VOLTAGE TEST TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCMAIN TRANSFORMER T1 VOLTAGE TEST continued TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCTROUBLESHOOTING & REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continuedReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCTROUBLESHOOTING & REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continuedReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCTROUBLESHOOTING & REPAIR Plug P1 PHASE ANGLE WINDING VOLTAGESMAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F.8 - CONTROL BOARD PLUG P1 LOCATIONSTATIC SCR/DIODE RECTIFIER BRIDGE TEST TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCSTATIC SCR/DIODE RECTIFIER BRIDGE TEST continued TROUBLESHOOTING & REPAIRto Section TOC to Master TOCSCR ANODE REMOVE ANY INSULATING PAINT CATHODE SCR TROUBLESHOOTING & REPAIRSTATIC SCR/DIODE RECTIFIER BRIDGE TEST continued Return to Section TOC Return to Section TOCACTIVE SCR TEST TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCACTIVE SCR TEST continued TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Master TOCTROUBLESHOOTING & REPAIR ACTIVE SCR TEST continuedSCR ANODE REMOVE ANY INSULATING PAINT CATHODE SCR Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR ACTIVE SCR TEST continuedReturn to Section TOC Return to Master TOCMAXIMUM OUTPUT SETTING - NO LOAD SCOPE SETTINGSNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM TROUBLESHOOTING & REPAIRTYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED TROUBLESHOOTING & REPAIRSCOPE SETTINGS Return to Section TOC Return to Section TOC Return to Section TOCTYPICAL SCR GATE VOLTAGE WAVEFORM TROUBLESHOOTING & REPAIRSCOPE SETTINGS Return to Section TOC Return to Section TOC Return to Section TOCABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED TROUBLESHOOTING & REPAIRSCOPE SETTINGS Return to Section TOC Return to Section TOC Return to Section TOCINPUT CONTACTOR CR1 CLEANING/REPLACEMENT DESCRIPTIONMATERIALS NEEDED TROUBLESHOOTING & REPAIRTROUBLESHOOTING & REPAIR INPUT CONTACTOR CR1 CLEANING/REPLACEMENT continuedFIGURE F.17 - INPUT CONTACTOR CLEANING AND REMOVAL Return to Section TOC to Section TOCFAN MOTOR AND BLADE REMOVAL AND REPLACEMENT TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCFAN MOTOR AND BLADE REMOVAL AND REPLACEMENT continued TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCSCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCSCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT continued TROUBLESHOOTING & REPAIRFIGURE F.19 - SCR/DIODE ASSEMBLY DETAILS Return to Section TOC to Section TOCSCR REMOVAL AND REPLACEMENT TROUBLESHOOTING & REPAIRDESCRIPTION MATERIALS NEEDEDSCR REMOVAL AND REPLACEMENT continued PROCEDURESPECIAL INSTRUCTIONS TROUBLESHOOTING & REPAIRTROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT continuedFIGURE F.22 - CLAMP ASSEMBLY Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT continuedReturn to Section Return to Section TOC Return to Section TOC Return to Master Return to Master TOC Return to Master TOCTROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT continuedFIGURE F.23 - HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING HOUSINGTROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT continuedRemoval and Replacement procedure to Return to Section Return to Section TOC Return to Section TOCMOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCMOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS continued TROUBLESHOOTING & REPAIRSection TOC Master TOCMAIN TRANSFORMER REMOVAL AND REPLACEMENT TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCMAIN TRANSFORMER REMOVAL & REPLACEMENT continued TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCTROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT continuedReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCTROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT continuedReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT continuedFIGURE F.28 - COIL LEAD PLACEMENT Return to Section TOCTROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT continuedReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCTROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT continuedReturn to Section Return to Section TOC Return to Section TOC Return to Master Return to Master TOC Return to Master TOCRETEST AFTER REPAIR TROUBLESHOOTING & REPAIRInput Volts/Phase/Hertz Output Control SettingReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCELECTRICAL DIAGRAMS Electrical Diagrams SectionReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCWiring Diagram Codes 10084, 10085 ELECTRICAL DIAGRAMSReturn to Section Return to MasterWiring Diagram Code ELECTRICAL DIAGRAMSSection TOC Master TOCControl PC Board G2629-1 Layout ELECTRICAL DIAGRAMSReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCControl PC Board G2629-1 Schematic ELECTRICAL DIAGRAMSto Section TOC Return to Master TOCSnubber PC Board M15370-3 Layout ELECTRICAL DIAGRAMSM15370-3 SNUBBERELECTRICAL DIAGRAMS Snubber PC Board M15370-3 Schematic38J GENERAL INFORMATION Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC