Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM136-A service manual MAIN TRANSFORMER REMOVAL & REPLACEMENT continued

Models: SVM136-A

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MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)

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F-47

F-47

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)

FIGURE F.25 – LIFT BAIL REMOVAL

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REMOVAL OF LIFT BAIL

1.Remove the main input supply power to the machine.

2.With the 5/16” nut driver, remove the case top and sides.

3.Remove the two fiber baffles from the left and right sides of the lift bail adjacent to the main transformer. See Figure F.25.

4.Remove the two leads (#220 and #204) from resistor R2 (7.5 ohms, 100 watts).

5.Remove the positive capacitor strap from the output shunt.

6.Remove the negative capacitor strap from the negative rectifier plate.

7.Remove the sheet metal screw that holds the capacitor bank assembly to the case back. (This should enable the capacitor bank to be removed with the lift bail assem- bly.)

8.Using the 9/16” socket wrench, remove the four bolts (left and right) mounting the lift bail to the transformer top and bottom irons.

9.Using the 9/16” socket wrench, remove the four bolts, flat washers, and lock washers mounting the lift bail assembly to the base of the machine.

WARNING

The transformer and choke assembly is now loose and free to slide or “tip” on the base of the machine.

10.Remove the lift bail by lifting straight up and clear from the machine.

IDEALARC CV-400

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Lincoln Electric SVM136-A service manual MAIN TRANSFORMER REMOVAL & REPLACEMENT continued, Troubleshooting & Repair

Contents

IDEALARC CV-400 SVM136-ASERVICE MANUAL View Safety Info View Safety Info View Safety Info View Safety InfoCALIFORNIA PROPOSITION 65 WARNINGS SAFETYFOR ENGINE powered equipment ELECTRIC AND MAGNETIC FIELDS may be dangerousSAFETY ELECTRIC SHOCK can killARC RAYS can burn FUMES AND GASES can be dangerousSAFETY FOR ELECTRICALLY powered equipmentCYLINDER may explode if damaged WELDING SPARKS can cause fire or explosionReturn to Master TOC PRÉCAUTIONS DE SÛRETÉSAFETY Return to Master TOC Return to Master TOC Return to Master TOCMASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEXParts Manual Return to Master TOC TABLE OF CONTENTSINSTALLATION SECTION Return to Master TOC Return to Master TOC Return to Master TOCPHASE ONLY INSTALLATIONTECHNICAL SPECIFICATIONS - IDEALARC CV-400 INPUT - THREERead this entire installation section before you start installation SAFETY PRECAUTIONSLOCATION AND VENTILATION INSTALLATIONFIGURE A.1 RATING PLATE LOCATION INSTALLATIONReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCFIGURE A.2 REAR PANEL INSTALLATIONFIGURE A.3 INPUT POWER SUPPLY CONNECTIONS Return to Section TOC Section TOCFIGURE A.4 INPUT CONNECTION DIAGRAM FOR 230/460 VOLTS AC, 50/60 HZ RECONNECT PROCEDUREOUTPUT CONNECTIONS INSTALLATIONReturn to Master TOC Return to Master TOC Return to Master TOC INSTALLATIONReturn 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 INSTALLATIONReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCSection B TABLE OF CONTENTS - OPERATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCELECTRIC SHOCK can kill SAFETY INSTRUCTIONSOPERATION OPERATING INSTRUCTIONSReturn to Master TOC Return to Master TOC Return to Master TOC GENERAL DESCRIPTIONOPERATION Return to Section TOC Return to Section TOC Return to Section TOCDuty Cycle OPERATIONReturn 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 Return to Master TOC CONTROLS AND SETTINGSOPERATION Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC WELDING OPERATIONOPERATION Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC AUXILIARY POWEROVERLOAD PROTECTION OPERATIONReturn to Master TOC 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 TOCReturn to Master TOC ACCESSORIESTABLE OF CONTENTS Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC OPTIONS/ACCESSORIESACCESSORIES FIGURE C.1 REMOTE CONTROL ADAPTER CABLE K864FEEDERTERMINAL AUTOMATIC WIRE FEEDERSACCESSORIES FIGURE C.2 NA-3 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400Return to Section TOC Return to Section TOC FEEDERTERMINALACCESSORIES FIGURE C.3 NA-5 WIRE FEEDER CONNECTION TO THE CV-400Return to Section TOC ACCESSORIESReturn to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCFEEDERTERMINAL SEMIAUTOMATIC WIRE FEEDERSACCESSORIES FIGURE C.4 LN-7 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400Return 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 Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCSection D TABLE OF CONTENTS MAINTENANCEReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSAFETY PRECAUTIONS MAINTENANCEMAINTENANCE ROUTINE AND PERIODICReturn to Section TOC MAINTENANCE11. CASE BACK WITH FAN MOTOR ASSEMBLY Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC 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 TOCto Master THEORY OF OPERATION SECTIONTABLE OF CONTENTS GENERAL DESCRIPTIONMaster TOC THEORY OF OPERATIONINPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER Section TOCMaster TOC OUTPUT CONTROL, RECTIFICATION AND FEEDBACKTHEORY OF OPERATION Section TOCFIGURE E.4 - CV-400 TRIGGER AND THERMAL LIGHT CIRCUIT PROTECTIVE DEVICES ANDCIRCUITS THEORY OF OPERATIONReturn to Master TOC SCR OPERATIONTHEORY OF OPERATION to Section TOCReturn to Master TOC 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 TROUBLESHOOTING & REPAIR SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIRHOW TO USE TROUBLESHOOTING GUIDE Return to Section TOCReturn to TROUBLESHOOTING & REPAIRSection TOC Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIROUTPUT PROBLEMS Observe Safety GuidelinesReturn to Section TOC Return to Section TOC Return to Section TOC OUTPUT PROBLEMSTROUBLESHOOTING & REPAIR Observe Safety GuidelinesReturn to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIROUTPUT PROBLEMS Observe Safety GuidelinesReturn to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIROUTPUT PROBLEMS Observe Safety GuidelinesReturn to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIROUTPUT PROBLEMS Observe Safety GuidelinesReturn to Section TOC Return to Section TOC Return to Section TOC WELDING PROBLEMSTROUBLESHOOTING & REPAIR Observe Safety GuidelinesReturn to Section TOC CONTROL TRANSFORMER T2 VOLTAGE TESTTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC CONTROL TRANSFORMER T2 VOLTAGE TEST continuedTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC RIGHT SIDE VIEWTROUBLESHOOTING & REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST continuedReturn to Section TOC INPUT CONTACTOR TESTTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOC#233 INPUT CONTACTOR TEST continuedX1, #232 TROUBLESHOOTING & REPAIRReturn to Master TOC TROUBLESHOOTING & REPAIRINPUT CONTACTOR TEST continued Return to Section TOCReturn to Section TOC MAIN TRANSFORMER T1 VOLTAGE TESTTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC MAIN TRANSFORMER T1 VOLTAGE TEST continuedTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER T1 VOLTAGE TEST continued Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER T1 VOLTAGE TEST continued Return to Section TOC Return to Section TOCFIGURE F.8 - CONTROL BOARD PLUG P1 LOCATION TROUBLESHOOTING & REPAIRPlug P1 PHASE ANGLE WINDING VOLTAGES MAIN TRANSFORMER T1 VOLTAGE TEST continuedReturn to Section TOC STATIC SCR/DIODE RECTIFIER BRIDGE TESTTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCto Master TOC STATIC SCR/DIODE RECTIFIER BRIDGE TEST continuedTROUBLESHOOTING & REPAIR to Section TOCReturn to Section TOC Return to Section TOC SCR ANODE REMOVE ANY INSULATING PAINT CATHODE SCRTROUBLESHOOTING & REPAIR STATIC SCR/DIODE RECTIFIER BRIDGE TEST continuedReturn to Section TOC ACTIVE SCR TESTTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC ACTIVE SCR TEST continuedTROUBLESHOOTING & REPAIR Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIRACTIVE SCR TEST continued SCR ANODE REMOVE ANY INSULATING PAINT CATHODE SCRReturn to Master TOC TROUBLESHOOTING & REPAIRACTIVE SCR TEST continued Return to Section TOCTROUBLESHOOTING & REPAIR MAXIMUM OUTPUT SETTING - NO LOADSCOPE SETTINGS NORMAL OPEN CIRCUIT VOLTAGE WAVEFORMReturn to Section TOC Return to Section TOC Return to Section TOC TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADEDTROUBLESHOOTING & REPAIR SCOPE SETTINGSReturn to Section TOC Return to Section TOC Return to Section TOC TYPICAL SCR GATE VOLTAGE WAVEFORMTROUBLESHOOTING & REPAIR SCOPE SETTINGSReturn to Section TOC Return to Section TOC Return to Section TOC ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADEDTROUBLESHOOTING & REPAIR SCOPE SETTINGSTROUBLESHOOTING & REPAIR INPUT CONTACTOR CR1 CLEANING/REPLACEMENTDESCRIPTION MATERIALS NEEDEDReturn to Section TOC to Section TOC TROUBLESHOOTING & REPAIRINPUT CONTACTOR CR1 CLEANING/REPLACEMENT continued FIGURE F.17 - INPUT CONTACTOR CLEANING AND REMOVALReturn to Section TOC FAN MOTOR AND BLADE REMOVAL AND REPLACEMENTTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOCReturn to Section TOC SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENTTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC to Section TOC SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING & REPAIR FIGURE F.19 - SCR/DIODE ASSEMBLY DETAILSMATERIALS NEEDED SCR REMOVAL AND REPLACEMENTTROUBLESHOOTING & REPAIR DESCRIPTIONTROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT continuedPROCEDURE SPECIAL INSTRUCTIONSReturn to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIRSCR REMOVAL AND REPLACEMENT continued FIGURE F.22 - CLAMP ASSEMBLYReturn to Master Return to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIRSCR REMOVAL AND REPLACEMENT continued Return to Section Return to Section TOC Return to Section TOCHOUSING TROUBLESHOOTING & REPAIRSCR REMOVAL AND REPLACEMENT continued FIGURE F.23 - HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRINGReturn to Section Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIRSCR REMOVAL AND REPLACEMENT continued Removal and Replacement procedure toReturn to Section TOC MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKSTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCMaster TOC MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS continuedTROUBLESHOOTING & REPAIR Section TOCReturn to Section TOC MAIN TRANSFORMER REMOVAL AND REPLACEMENTTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC MAIN TRANSFORMER REMOVAL & REPLACEMENT continuedTROUBLESHOOTING & REPAIR Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER REMOVAL & REPLACEMENT continued Return to Section TOC Return to Section TOCReturn to Section TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER REMOVAL & REPLACEMENT continued Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER REMOVAL & REPLACEMENT continued FIGURE F.28 - COIL LEAD PLACEMENTReturn to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER REMOVAL & REPLACEMENT continued Return to Section TOC Return to Section TOCReturn to Master Return to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIRMAIN TRANSFORMER REMOVAL & REPLACEMENT continued Return to Section Return to Section TOC Return to Section TOCOutput Control Setting RETEST AFTER REPAIRTROUBLESHOOTING & REPAIR Input Volts/Phase/HertzReturn to Master TOC 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 TOCReturn to Master TOC ELECTRICAL DIAGRAMSElectrical Diagrams Section Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master Wiring Diagram Codes 10084, 10085ELECTRICAL DIAGRAMS Return to SectionMaster TOC Wiring Diagram CodeELECTRICAL DIAGRAMS Section TOCReturn to Section TOC Control PC Board G2629-1 LayoutELECTRICAL DIAGRAMS Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Control PC Board G2629-1 SchematicELECTRICAL DIAGRAMS to Section TOCSNUBBER Snubber PC Board M15370-3 LayoutELECTRICAL DIAGRAMS M15370-3Snubber PC Board M15370-3 Schematic ELECTRICAL DIAGRAMS38J GENERAL INFORMATION Return to Master TOC 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 TOC