Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM136-A Main Transformer Removal And Replacement, Troubleshooting & Repair

Models: SVM136-A

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MAIN TRANSFORMER REMOVAL AND REPLACEMENT

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F-46

F-46

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER 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 manu- al.

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 trou- bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in removing the main transformer for mainte- nance or replacement.

MATERIALS NEEDED

5/16” Nut driver 9/16” Socket wrench 9/16” Box end wrench 1/2” Socket wrench 1/2” Box end wrench

3/8” Nut driver or socket wrench 9/16” Deep well socket wrench

IDEALARC CV-400

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Lincoln Electric SVM136-A Main Transformer Removal And Replacement, Troubleshooting & Repair, Return to Section TOC

Contents

View Safety Info View Safety Info View Safety Info View Safety Info SVM136-ASERVICE MANUAL IDEALARC CV-400ELECTRIC AND MAGNETIC FIELDS may be dangerous SAFETYFOR ENGINE powered equipment CALIFORNIA PROPOSITION 65 WARNINGSFUMES AND GASES can be dangerous ELECTRIC SHOCK can killARC RAYS can burn SAFETYWELDING SPARKS can cause fire or explosion FOR ELECTRICALLY powered equipmentCYLINDER may explode if damaged SAFETYReturn to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉSAFETY Return to Master TOCParts Manual MASTER TABLE OF CONTENTS FOR ALL SECTIONSRETURN TO MAIN INDEX Return to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTSINSTALLATION SECTION Return to Master TOCINPUT - THREE INSTALLATIONTECHNICAL SPECIFICATIONS - IDEALARC CV-400 PHASE ONLYINSTALLATION SAFETY PRECAUTIONSLOCATION AND VENTILATION Read this entire installation section before you start installationReturn to Master TOC Return to Master TOC INSTALLATIONReturn to Section TOC Return to Section TOC FIGURE A.1 RATING PLATE LOCATIONReturn to Section TOC Section TOC INSTALLATIONFIGURE A.3 INPUT POWER SUPPLY CONNECTIONS FIGURE A.2 REAR PANELINSTALLATION RECONNECT PROCEDUREOUTPUT CONNECTIONS FIGURE A.4 INPUT CONNECTION DIAGRAM FOR 230/460 VOLTS AC, 50/60 HZReturn to Section TOC INSTALLATIONReturn to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC INSTALLATIONReturn to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC TABLE OF CONTENTS - OPERATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Section BOPERATING INSTRUCTIONS SAFETY INSTRUCTIONSOPERATION ELECTRIC SHOCK can killReturn to Section TOC Return to Section TOC Return to Section TOC GENERAL DESCRIPTIONOPERATION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC Return to Master TOC Return to Master TOC OPERATIONReturn to Section TOC Return to Section TOC Return to Section TOC Duty CycleReturn to Section TOC Return to Section TOC CONTROLS AND SETTINGSOPERATION Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC WELDING OPERATIONOPERATION Return to Master TOC Return to Master TOC Return to Master TOCOPERATION AUXILIARY POWEROVERLOAD PROTECTION 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 TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Master TOCReturn to Master TOC Return to Master TOC Return to Master TOC ACCESSORIESTABLE OF CONTENTS Return to Master TOCFIGURE C.1 REMOTE CONTROL ADAPTER CABLE K864 OPTIONS/ACCESSORIESACCESSORIES Return to Section TOC Return to Section TOCFIGURE C.2 NA-3 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400 AUTOMATIC WIRE FEEDERSACCESSORIES FEEDERTERMINALFIGURE C.3 NA-5 WIRE FEEDER CONNECTION TO THE CV-400 FEEDERTERMINALACCESSORIES Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC ACCESSORIESReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCFIGURE C.4 LN-7 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400 SEMIAUTOMATIC WIRE FEEDERSACCESSORIES FEEDERTERMINALReturn to Section TOC Return to Section TOC ACCESSORIESFIGURE C.5 LN-8 OR LN-9 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400 Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Master TOCReturn to Master TOC TABLE OF CONTENTS MAINTENANCEReturn to Master TOC Return to Master TOC Return to Master TOC Section DROUTINE AND PERIODIC MAINTENANCEMAINTENANCE SAFETY PRECAUTIONSReturn to Section TOC Return to Section TOC Return to Section TOC MAINTENANCE11. CASE BACK WITH FAN MOTOR ASSEMBLY Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Master TOCGENERAL DESCRIPTION THEORY OF OPERATION SECTIONTABLE OF CONTENTS to MasterSection TOC THEORY OF OPERATIONINPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER Master TOCSection TOC OUTPUT CONTROL, RECTIFICATION AND FEEDBACKTHEORY OF OPERATION Master TOCTHEORY OF OPERATION PROTECTIVE DEVICES ANDCIRCUITS FIGURE E.4 - CV-400 TRIGGER AND THERMAL LIGHT CIRCUITto Section TOC SCR OPERATIONTHEORY OF OPERATION Return to Master TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Master TOCReturn to Master TOC TABLE OF CONTENTS TROUBLESHOOTING & REPAIR SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIRHOW TO USE TROUBLESHOOTING GUIDE Return to Master TOCMaster TOC TROUBLESHOOTING & REPAIRSection TOC Return toObserve Safety Guidelines TROUBLESHOOTING & REPAIROUTPUT PROBLEMS Return to Section TOC Return to Section TOC Return to Section TOCObserve Safety Guidelines OUTPUT PROBLEMSTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCObserve Safety Guidelines TROUBLESHOOTING & REPAIROUTPUT PROBLEMS Return to Section TOC Return to Section TOC Return to Section TOCObserve Safety Guidelines TROUBLESHOOTING & REPAIROUTPUT PROBLEMS Return to Section TOC Return to Section TOC Return to Section TOCObserve Safety Guidelines TROUBLESHOOTING & REPAIROUTPUT PROBLEMS Return to Section TOC Return to Section TOC Return to Section TOCObserve Safety Guidelines WELDING PROBLEMSTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC CONTROL TRANSFORMER T2 VOLTAGE TESTTROUBLESHOOTING & REPAIR Return to Section TOCReturn to Section TOC Return to Section TOC CONTROL TRANSFORMER T2 VOLTAGE TEST continuedTROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOCCONTROL TRANSFORMER T2 VOLTAGE TEST continued RIGHT SIDE VIEWTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC INPUT CONTACTOR TESTTROUBLESHOOTING & REPAIR Return to Section TOCTROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST continuedX1, #232 #233Return to Section TOC TROUBLESHOOTING & REPAIRINPUT CONTACTOR TEST continued Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC MAIN TRANSFORMER T1 VOLTAGE TESTTROUBLESHOOTING & REPAIR Return to Section TOCReturn to Section TOC Return to Section TOC MAIN TRANSFORMER T1 VOLTAGE TEST continuedTROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER T1 VOLTAGE TEST continued Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER T1 VOLTAGE TEST continued Return to Master TOC Return to Master TOCMAIN TRANSFORMER T1 VOLTAGE TEST continued TROUBLESHOOTING & REPAIRPlug P1 PHASE ANGLE WINDING VOLTAGES FIGURE F.8 - CONTROL BOARD PLUG P1 LOCATIONReturn to Section TOC Return to Section TOC Return to Section TOC STATIC SCR/DIODE RECTIFIER BRIDGE TESTTROUBLESHOOTING & REPAIR Return to Section TOCto Section TOC STATIC SCR/DIODE RECTIFIER BRIDGE TEST continuedTROUBLESHOOTING & REPAIR to Master TOCSTATIC SCR/DIODE RECTIFIER BRIDGE TEST continued SCR ANODE REMOVE ANY INSULATING PAINT CATHODE SCRTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC ACTIVE SCR TESTTROUBLESHOOTING & REPAIR Return to Section TOCReturn to Section TOC ACTIVE SCR TEST continuedTROUBLESHOOTING & REPAIR Return to Master TOCSCR ANODE REMOVE ANY INSULATING PAINT CATHODE SCR TROUBLESHOOTING & REPAIRACTIVE SCR TEST continued Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC TROUBLESHOOTING & REPAIRACTIVE SCR TEST continued Return to Master TOCNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING - NO LOADSCOPE SETTINGS TROUBLESHOOTING & REPAIRSCOPE SETTINGS TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADEDTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCSCOPE SETTINGS TYPICAL SCR GATE VOLTAGE WAVEFORMTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCSCOPE SETTINGS ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADEDTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCMATERIALS NEEDED INPUT CONTACTOR CR1 CLEANING/REPLACEMENTDESCRIPTION TROUBLESHOOTING & REPAIRFIGURE F.17 - INPUT CONTACTOR CLEANING AND REMOVAL TROUBLESHOOTING & REPAIRINPUT CONTACTOR CR1 CLEANING/REPLACEMENT continued Return to Section TOC to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC FAN MOTOR AND BLADE REMOVAL AND REPLACEMENTTROUBLESHOOTING & REPAIR Return to Section TOCReturn to Section TOC Return to Section TOC FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENTTROUBLESHOOTING & REPAIR Return to Section TOCFIGURE F.19 - SCR/DIODE ASSEMBLY DETAILS SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING & REPAIR Return to Section TOC to Section TOCDESCRIPTION SCR REMOVAL AND REPLACEMENTTROUBLESHOOTING & REPAIR MATERIALS NEEDEDSPECIAL INSTRUCTIONS SCR REMOVAL AND REPLACEMENT continuedPROCEDURE TROUBLESHOOTING & REPAIRFIGURE F.22 - CLAMP ASSEMBLY TROUBLESHOOTING & REPAIRSCR REMOVAL AND REPLACEMENT continued Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIRSCR REMOVAL AND REPLACEMENT continued Return to Master Return to Master TOC Return to Master TOCFIGURE F.23 - HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING TROUBLESHOOTING & REPAIRSCR REMOVAL AND REPLACEMENT continued HOUSINGRemoval and Replacement procedure to TROUBLESHOOTING & REPAIRSCR REMOVAL AND REPLACEMENT continued Return to Section Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKSTROUBLESHOOTING & REPAIR Return to Section TOCSection TOC MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS continuedTROUBLESHOOTING & REPAIR Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC MAIN TRANSFORMER REMOVAL AND REPLACEMENTTROUBLESHOOTING & REPAIR Return to Section TOCReturn to Section TOC Return to Section TOC MAIN TRANSFORMER REMOVAL & REPLACEMENT continuedTROUBLESHOOTING & REPAIR Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER REMOVAL & REPLACEMENT continued Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER REMOVAL & REPLACEMENT continued Return to Section TOCFIGURE F.28 - COIL LEAD PLACEMENT TROUBLESHOOTING & REPAIRMAIN TRANSFORMER REMOVAL & REPLACEMENT continued Return to Section TOCReturn to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER REMOVAL & REPLACEMENT continued Return to Master TOC Return to Master TOCReturn to Section Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER REMOVAL & REPLACEMENT continued Return to Master Return to Master TOC Return to Master TOCInput Volts/Phase/Hertz RETEST AFTER REPAIRTROUBLESHOOTING & REPAIR Output Control SettingReturn to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Master TOCReturn to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMSElectrical Diagrams Section Return to Master TOCReturn to Section Wiring Diagram Codes 10084, 10085ELECTRICAL DIAGRAMS Return to MasterSection TOC Wiring Diagram CodeELECTRICAL DIAGRAMS Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC Control PC Board G2629-1 LayoutELECTRICAL DIAGRAMS Return to Section TOCto Section TOC Control PC Board G2629-1 SchematicELECTRICAL DIAGRAMS Return to Master TOCM15370-3 Snubber PC Board M15370-3 LayoutELECTRICAL DIAGRAMS SNUBBER38J GENERAL INFORMATION Snubber PC Board M15370-3 SchematicELECTRICAL DIAGRAMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Master TOC