SCR Removal and Replacement | Lincoln Electric SVM 122-A manual

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F-46

F-46

TROUBLESHOOTING & REPAIR

SCR 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 SCRs from the output rectifier heat sink for maintenance or replacement.

MATERIALS NEEDED

NO.000 Fine Steel Wool

Penetrox A-13 (Lincoln E2529) or Penetrox A 7/16” Open end wrench

Allen head type wrenches

IDEALARC DC-400

LINCOLN ®

ELECTRIC

Image 90

Lincoln Electric SVM 122-A service manual SCR Removal and Replacement

Contents

Safety Depends on You Idealarc TMDC-400 Safety California Proposition 65 Warnings Electric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Idealarc DC-400 Lifting Safety PrecautionsSelect Suitable Location Tilting Input Supply Connections Input ConnectionsGround Connection Electric Shock can kill Input Wire and Fuse Size Figure A.3 Input Power Supply Connections Reconnect Procedure Input Supply Connection Diagram Output Connections Figure A.6 Output Terminal Connections Wire Feeder Connections Cycle 500 Amp 50% DutyCycle Operation Section Safety Instructions OPERATIONB-2Operating Instructions Operation General Description Controls and Settings Figure B.1 Case Front Controls Operation Welding Operation Remote ControlWelding Procedure Recommendations Operating Steps NA-3 Automatic Wire Feeder ARC Striking with the NA-3 Start Board NA-5 Automative Wire Feeder LN-8 Semiautomatic Wire Feeder Auxiliary Power Overload Protection Table of Contents Accessories Field Installed Options OPTIONS/ACCESSORIESFactory Installed Option Diode Option Multiprocess Switch Operation Connections Remote Output Control K857 with K864 Adapter Plug or K775 Remote Control Adapter Cable K864K843 Amptrol Adapter Installation Instructions Amptrol Adapter Cable K843 K843 Amptrol Adapter Installation Instructions Amptrol and Hi-Freq. Kit The Amptrol will start Capacitor Discharge Circuit K828-1 Automatic Wire FeedersConnecting the NA-3 to the Idealarc DC-400 Terminal Strip HI-FREQ KIT K799 for Codes 8634 and Above only Connecting the NA-5 to the Idealarc DC-400 Terminal Strip Cable Plug K597-XX Input Cable Assembly Idealarc DC-400 To NA-3 or NA-5 Input Semiautomatic Wire Feeders Connecting the LN-7 to the Idealarc DC-400 14-PIN Amphenol Connecting the LN-7 to the Idealarc DC-400 Terminal Strip Accessories Accessories Figure C.11 Idealarc DC-400/LN-742 Connection Diagram Table of Contents Maintenance Routine and Periodic Maintenance Figure D.1 General Component Locations Table of Contents Theory of Operation Section Contactor and Main Theory of OperationInput Line Voltage Transformer Output Mode and CONTROL, Rectification and Feedback Protective Devices and Circuits SCR Operation Figure E.4 SCR Operation Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures PC Board can be damaged by static electricity Troubleshooting Guide Output Problems Perform the Main Transformer Rectifier Bridge Test Tifier Bridge Test Output Problems Test Perform the SCR/Diode Rec Tifier Bridge Test Function Problems Form the SCR/Diode Rectifier Welding Problems Portion of your body. Clean Trolyte in these capacitors isToxic. Avoid contact with any Make sure welding process is Input Contactor Test DescriptionMaterials Needed Test Procedure Input Contactor Test Test for Contact Continuity Figure F.2 Input Contactor Test Connections Control Transformer T2 Voltage Test Control Transformer T2 Voltage Test Figure F.3 Control Transformer and Lead Locations Troubleshooting & Repair Main Transformer T1 Voltage Test Main Transformer T1 Voltage Test Figure F.6 Main Secondary Lead Test Points Troubleshooting & Repair Plug P1 Phase Angle Winding Voltages Figure F.8 Control Board Plug P1 Location Static SCR/DIODE Rectifier Bridge Test Static SCR/DIODE Rectifier Bridge Test Figure F.9 Control Board and Snubber Board Plug Locations SCR Test Active SCR Test Active SCR Test P1 and P3 Locations Plug P5 Location Figure F.15 Heat Sink Test Points Figure F.16 SCR Tester Circuit and SCR Connections Scope Settings CH1 Maximum Output Setting no Load Troubleshooting & Repair Troubleshooting & Repair Troubleshooting & Repair 2V/Div Troubleshooting & Repair Input Contactor CR1 CLEANING/REPLACEMENT Input Contactor CR1 CLEANING/REPLACEMENT Cleaning ProcedureContactor Replacement Procedure FAN Motor and Blade Removal and Replacement FAN Motor and Blade Removal and Replacement Procedure SCR/DIODE Rectifier Assembly Removal and Replacement SCR/DIODE Rectificer Assembly Removal and Replacement SCR Removal and Replacement SCR Removal and Replacement Special Instructions Procedure for the 1/2 Inch Wide Spring Figure F.21 1/2 Wide Leaf Spring Clamping Procedure For 1/4-28 CAP Screws Clamping Procedure For 1/4-20 CAP Screws Procedure for Inch Wide Spring After Replacing the SCRs Mounting of Stud Type Diodes to Aluminum Heat Sinks Mounting of Stud Type Diodes to Aluminum Heat SinksDiode Stud Foot Inch Size Pounds Main Transformer Removal and Replacement Main Transformer Removal & Replacement Removal of Lift Bail Removal of Choke and TOP Iron Assembly Figure F.26 Choke Removal Reassembly of Transformer Coils Figure F.27 Epoxy MIX Application Areas Figure F.28 Coil Lead Placement Figure F.30 Primary Thermostat Location Reassembling the Main Transformer Into the Machine Reassemble the Lift Bail Retest After Repair Input volts/Phase/Hertz Maximum Idle Amps Maximum Idle KWMode Input Hertz Open Circuit Volts Input Idle Amps and Watts Maximum Acceptable Output Voltage AT Minimum Ouput Settings Mode Control Settings LoadRetest After Repair Table of Contents Electrical Diagrams Section Idealarc DC400 Wiring Diagram Codes 9847 LOW Voltage Wiring Diagram Code Only. It may not be accurate for all Control PC Board G2588 Layout Control DC400 Starting PC Board M14520 Layout TP2 Snubber PC Board M15370 Layout Control PC Board G2588 Schematic 2586 Starting PC Board M14520 Schematic General Information Snubber PC Board M15370 Schematic General Information