Lincoln Electric SVM153-A guide

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F-71		F-71
		TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE DIODE REMOVAL AND

REMOVAL AND REPLACEMENT (CONTINUED)

FIGURE F.32 – POWER MODULE/OUTPUT RECTIFIER BRIDGE ASSEMBLY DETAILS

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DIODE

DIODE

PIGTAIL

LEADS

PROCEDURE

Refer to Figure F.32.

1.Turn the engine off.

2.Perform the Output Panel Removal as described in the Case Cover Removal pro- cedure.

3.Perform the Power Module Capacitor Discharge procedure.

4.Using the 7/16" wrench, remove the appro- priate stator leads and diode pigtail lead from the stud on the output rectifier bridge glastic insulator bracket. The bottom diodes require a 1/2" wrench to remove the double heavy leads.

HEATSINKS

Label the leads for reassembly if more than one is removed.

5.Using the 1" wrench, loosen the appropriate diode and remove the diode that is to be replaced.

6.Clean the area on the heat sink around the diode mounting surface using a putty knife or similar tool. DO NOT SCRATCH THE DIODE MOUNTING SURFACE.

7.Polish the heat sink's mounting surface using an abrasive disc, E2827-2 or fine steel wool to provide a bright, clean surface where the diode seats on the heat sink. Wipe the surface clean with a lint-free cloth or paper towel.

COMMANDER 500

Image 124

Lincoln Electric SVM153-A service manual Refer to Figure F.32 Turn the engine off

Contents

CommanderTM Safety California Proposition 65 Warnings Electric Shock can kill Welding Sparks can cause fire or explosion Iii Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Commander 500 K1639-1 Safety Precautions Location / VentilationStoring Stacking High Temperature Operation LiftingTowing High Altitude Operation PRE-OPERATION Engine Service Muffler Outlet Pipe Spark Arrester Auxiliary Power Receptacles Standby Power ConnectionsWelding Output Cables Machine Grounding Company Table of Contents Operation Section Safety Instructions OperationOperating Instructions General Description Design Features and Advantages Recommended Applications K1639-1 Commander 500 Standard Model Controls and SettingsWelding Capability RUN/STOP Switch Idler SwitchStart Pushbutton Fuel Level Gauge and Light Weld Mode Output Control Welding Terminals SwitchTable B.1 Weld Mode and Output Control Functions Hour Meter Auxiliary Power Controls Engine Operation Starting the EngineBREAK-IN Period Typical Fuel Consumption Welder Operation Stick WeldingConstant Current CC Welding TIG Welding Commander 500 Settings When Using the K799 HI-FREQ Unit Commander 500 Settings When Using the K930-1 TIG ModuleTable B.3 Typical Current RANGES1 for Tungsten ELECTRODES2 TIG Torch Auxiliary Power Operation Wire Feed Constant Voltage WeldingSimultaneous Welding and Auxiliary Power Loads ARC Gouging Extension Cord Recommendations Permissible Permissible Auxiliary Table of Contents Accessories Section Accessories OPTIONS/ACCESSORIESField Installed Options Stick Welding Accessories Semiautomatic Welding Accessories Connection of Lincoln Electric Wire FeedersOther Wire Feeders for the Commander High Frequency Generators for TIG Applications To Work Electrode Cable To Wire Feed Unit ING CV ING CV ING CV Figure C.5 Commander 500/LN-23P Connection Diagram ING Terminals Always on Table of Contents Maintenance Section Maintenance Routine and Periodic MaintenanceEngine Maintenance Daily Figure D.1 OIL Drain and Refill Figure D.2 Fuel PRE-FILTER/WATER Separator Assembly Fuel Filters Figure D.3 Secondary Fuel Filter AIR Filter Maintenance Frequency Maintenance Required Table D.2 Engine Maintenance Parts Manufacturer Part Number Battery Maintenance Connecting a Battery Charger WELDER/GENERATOR Maintenance Figure D.5 Major Component Locations Commander Table of Contents Theory of Operation Section Commander Theory of Operation Weld WINDINGS, RECTIFIER, Power Modules and Feedback Analog Control Power Supply Board and Weld Control Board Insulated Gate Bipolar Transistor Igbt Operation Pulse Width Modulation 6E-6Minimum Output Maximum Output Chopper Technology Fundamentals External DC Solid State Inductor ARC Source Switch Diode70-80VDC Troubleshooting & Repair Section Table of ContentsSection F-1 Troubleshooting & Repair HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures PC Board can be damaged by static electricity Observe Safety Guidelines Troubleshooting GuideDetailed in the beginning of this manual Perform the Rotor Resistance Justment Test Function Problems Charging Circuit Test Engine Problems Shutdown Perform the Idler Solenoid Problems Possible Areas Symptoms Misadjustments Course of Action Engine Starting Diagnostic Chart START-UP and OCV Diagnostic Chart Return Description Case Cover Removal and Replacement ProcedureMaterials Needed Case Cover Removal Replacement Procedure Procedure Figure F.1 Case Front Knobs Removal and Replacement Procedure Removal Power Module Capacitor Discharge Procedure Procedure Idler Solenoid Test Test Description Test Procedure Figure F.5 Idler Solenoid Leads Shutdown Solenoid Test Figure F.6 Shutdown Solenoid Lead Terminals Engine Throttle Adjustment Test Figure F.7 Strobe Mark Location Mark Blower Paddle Here Strobe-tach Method Locking NUT Frequency Counter Method 28F-28Oscilloscope Method Rotor Resistance Test Test Procedure Flashing and Rotor Voltage Test 10 11 12 13 14 15 Lead # 201A Troubleshooting & Repair Stator Voltage Test Figure F.13 Front Control Panel Removal Screws Troubleshooting & Repair Auxiliary Leads #5B, #5E, #8, #9, #11, #12 Auxiliary Power and Weld Windings TestBehind Panel W6W1 Weld Winding Lead Connections Analog Power Supply PC Board Voltage Test 40F-40 Control Circuit Input PowerJ41 Analog Control Power Supply PC Board Test Test Points Component Tested Voltage Reading Output Rectifier Bridge Test Perform the Power Module Capacitor Discharge Procedure Troubleshooting & Repair Figure F.20 Diode Lead Removal Power Module Test Power Module PC Board Diode Lead D4 Positive + Strap Temperature SwitchW10 Check Igbt For Shorts When all tests are complete Check Diode Module Charging Circuit Test Figure F.24 Engine Alternator Location #239 #281 #238 Scope Settings Normal Open Circuit Voltage Waveform 115VAC SupplyHigh Idle no Load 15.8 ms Volts 50V5ms MAX TAP MAX Control POT High Idle no Load Normal Open Circuit Voltage Waveform StickVolts 50V5ms Machine Loaded to 500 Amps AT 40 Volts Normal Weld Voltage Waveform Stick CCVolts 20V0.1ms Normal Weld Voltage Waveform Wire CV Loaded to 200A 16 Volts Normal TIG Mode Voltage WaveformVolts 10V50ms Normal Open Circuit Voltage Waveform Wire CV TAP MAX Control POT High Idle no Load Shutdown Solenoid Removal and Replacement Figure F Shutdown Solenoid Lead Connections Reassembly Figure F Shutdown Solenoid Linkage ARM Assembly Description Control Panel Removal Screws Front Green Ground Lead Figure F Power Module Capacitor Lead Removal Troubleshooting & Repair Replacement Procedure Description Power Module PC Board Removal Figure F.30 Power Module PC Board Power Module PC Board Replacement Diode Module Replacement Diode Module Removal Output Rectifier Bridge Diode Removal and Replacement Refer to Figure F.32 Turn the engine off Return Section TOC Diode Stud Size Foot Pounds Inch Pounds STATOR/ROTOR Removal and Replacement Leads #229 #242D Preparation and Lead Removal ProcedurePlug Fuel Lines Bolts #200D #5P #201 #201A Filter Field Diode Capacitor Figure F.35 Brush Holder and Lead Removal #232M Figure F.37 Alternator Shroud Removal Screws Acoustical Foam Figure F.38 Lift Frame and Associated Component Removal Stator Removal Procedure Figure F.39 Stator Removal Rotor Removal Procedure Reassembly Notes Engine Lead Reconnection ChecklistOutput Panel and Control BOX Welder CV Wire Output Retest After RepairEngine RPM Welder DC Stick Output Touch Start TIG Mode Output Auxiliary Power Output Electrical Diagrams Table of Contents Electrical Diagrams Section Electrical Diagrams Schematic Complete Machine Commander G3834 Schematic Battery PC Board PC Board Assembly Battery PC Board Return to Section Schematic Chopper PC Board PWM Input PC Board Assembly Chopper PC Board Return to Section Return to Section TOC Schematic Peripheral PC Board PC Board Assembly Peripheral PC Board Return to Section Schematic Power Supply Analog PC Board PC Board Assembly Power Supply Analog PC Board PC Board Reference QTY Designators Description Schematic PULL-COIL PC Board PC Board Assembly PULL-COIL PC Board MOSFET/HEATSINK ASBLY,T12704-82&S1810 Schematic Weld Control PC Board Sheet Electrical Diagrams Electrical Diagrams Electrical Diagrams Electrical Diagrams PC Board Assembly Weld Control PC Board RESISTOR,SMD,METAL FILM,1/10W,150OHMS SVM Error Reporting Form