Lincoln Electric SVM136-A - Manual

Lincoln Electric SVM136-A

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Table of Contents:

  • Page 2 – SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
  • Page 3 – ii; ELECTRIC SHOCK can kill.
  • Page 4 – iii
  • Page 5 – iv; PRÉCAUTIONS DE SÛRETÉ
  • Page 6 – MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page; RETURN TO MAIN INDEX
  • Page 7 – TABLE OF CONTENTS; Section A
  • Page 8 – INSTALLATION; TECHNICAL SPECIFICATIONS - IDEALARC CV-400
  • Page 9 – SAFETY PRECAUTIONS; LOCATION AND VENTILATION; LIFTING; FALLING EQUIPMENT can cause injury.; STACKING; ELECTRICAL INPUT CONNECTIONS
  • Page 10 – GROUND CONNECTION; cations page for proper ground wire size.; INPUT SUPPLY CONNECTIONS; • Turn the input power off at the; RATING PLATE LOCATION
  • Page 11 – Also refer to; Reconnect Procedure later in this section.; INPUT WIRE AND FUSE SIZE; Technical Specifications at the begin-; ning of this section or use delay type; Technical; REAR PANEL
  • Page 12 – See; Table A.1 for recommended cable sizes for com-; bined lengths of electrode and work cables.
  • Page 13 – OUTPUT TERMINAL CONNECTIONS
  • Page 14 – CONNECT WIRE FEEDERS; Accessories section of this manual for specif-
  • Page 15 – Operation
  • Page 16 – OPERATION; OPERATING INSTRUCTIONS
  • Page 17 – GENERAL DESCRIPTION; RECOMMENDED PROCESSES
  • Page 18 – Amps
  • Page 19 – CONTROLS AND SETTINGS; FIGURE B.1 – CASE FRONT CONTROLS
  • Page 20 – WELDING OPERATION; LOCAL CONTROL; Turn on the main AC input power to the machine.; REMOTE CONTROL; section for wire feeder installation infor-
  • Page 21 – PIN
  • Page 22 – NOTES
  • Page 23 – Accessories
  • Page 24 – • CV-400 is used in conjunction with any LN-23P or; ACCESSORIES
  • Page 25 – AUTOMATIC WIRE FEEDERS; NA-3 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400; GND; TERMINAL
  • Page 26 – NOTE: The connection diagram shown in; NA-5 WIRE FEEDER CONNECTION TO THE CV-400
  • Page 28 – LN-7 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400; SEMIAUTOMATIC WIRE FEEDERS
  • Page 31 – Maintenance
  • Page 32 – MAINTENANCE
  • Page 33 – Major Component Locations
  • Page 35 – FIGURE E.1 – BLOCK LOGIC DIAGRAM
  • Page 36 – THEORY OF OPERATION; FIGURE E.2 – INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER
  • Page 37 – Output current and voltage is; See SCR Operation
  • Page 38 – FIGURE E.4 – CV-400 TRIGGER AND THERMAL LIGHT CIRCUIT; If the customer accidentally
  • Page 39 – SCR OPERATION; As long as current continues to flow from; FIGURE E.5 – SCR OPERATION
  • Page 42 – HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; CAUTION; Symptoms are grouped; PERFORM EXTERNAL TESTS.; The
  • Page 43 – PC BOARD TROUBLESHOOTING PROCEDURES
  • Page 44 – Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS; Control
  • Page 45 – If the amber thermal protection; Main Transformer
  • Page 46 – Check the remote control leads; Rectifier Bridge Test.; The control board may be
  • Page 47 – Also check associated; Check the input power switch; Input Contactor
  • Page 48 – Remove any external leads that
  • Page 49 – WELDING PROBLEMS
  • Page 50 – DESCRIPTION
  • Page 51 – FIGURE F.1 – CONTROL TRANSFORMER AND LEAD LOCATIONS; TEST PROCEDURE; Disconnect the main input supply power to
  • Page 52 – FIGURE F.2 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS; RIGHT SIDE VIEW; MACHINE FRONT
  • Page 54 – INPUT CONTACTOR TEST; FIGURE F.3 – INPUT CONTACTOR CONNECTIONS; Electric Shock can kill.
  • Page 55 – TEST FOR CONTACT CONTINUITY; Disconnect the main input supply power to the; FIGURE F.4 – INPUT CONTACTOR TEST CONNECTIONS
  • Page 57 – FIGURE F.5 – INPUT CONTACTOR, RECONNECT PANEL, AND PRIMARY LEADS
  • Page 58 – Test with an AC voltmeter for proper main; FIGURE F.6 – MAIN SECONDARY LEAD TEST POINTS
  • Page 59 – Test with an AC voltmeter for 21VAC for
  • Page 60 – Plug P1 PHASE ANGLE WINDING VOLTAGES; Expected VAC; FIGURE F.8 – CONTROL BOARD PLUG P1 LOCATION; Plug P1
  • Page 61 – STATIC SCR/DIODE RECTIFIER BRIDGE TEST
  • Page 62 – FIGURE F.9 – CONTROL BOARD AND SNUBBER BOARD PLUG LOCATIONS
  • Page 63 – Remove any red insulating paint from the; FIGURE F.11 – HEAT SINK AND SCR TEST POINTS
  • Page 64 – ACTIVE SCR TEST
  • Page 65 – FIGURE F.12 – CONTROL BOARD PLUG
  • Page 66 – FIGURE F.15 – HEAT SINK TEST POINTS
  • Page 67 – Test the voltage level of the battery. Short; FIGURE F.16 – SCR TESTER CIRCUIT AND SCR CONNECTIONS
  • Page 68 – SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM; MAXIMUM OUTPUT SETTING – NO LOAD; volts
  • Page 69 – TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED
  • Page 70 – TYPICAL SCR GATE VOLTAGE WAVEFORM
  • Page 71 – ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED; ONE OUTPUT SCR NOT FUNCTIONING
  • Page 73 – FIGURE F.17 – INPUT CONTACTOR CLEANING AND REMOVAL; CLEANING PROCEDURE; NOTE: Be sure to reconnect all leads correctly.
  • Page 74 – FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT
  • Page 75 – FIGURE F.18 – FAN MOTOR MOUNTING DETAILS; PROCEDURE
  • Page 77 – SCR/DIODE RECTIFIER ASSEMBLY
  • Page 78 – SCR REMOVAL AND REPLACEMENT
  • Page 79 – FIGURE F.20 – SCR DETAILS; SPECIAL INSTRUCTIONS
  • Page 80 – FIGURE F.22 – CLAMP ASSEMBLY; Go to the procedure below that matches your
  • Page 81 – Do not turn the nuts. While holding the nuts
  • Page 82 – FIGURE F.23 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING
  • Page 83 – AFTER REPLACING THE SCRs
  • Page 85 – Install the case top and sides.; DIODE STUD; MOUNTING OF STUD TYPE DIODES
  • Page 86 – MAIN TRANSFORMER REMOVAL AND REPLACEMENT
  • Page 87 – REMOVAL OF LIFT BAIL; MAIN TRANSFORMER REMOVAL & REPLACEMENT; FIGURE F.25 – LIFT BAIL REMOVAL
  • Page 88 – FIGURE F.26 – CHOKE REMOVAL; Remove the top choke lead from the negative; NOTE: The coils may be “stuck” to the top iron; The leads from the coils that are to be
  • Page 89 – FIGURE F.27 – EPOXY MIX APPLICATION AREAS; The following procedure describes a
  • Page 90 – FIGURE F.28 – COIL LEAD PLACEMENT
  • Page 91 – Mount the primary thermostat to the lead; FIGURE F.30 – PRIMARY THERMOSTAT LOCATION
  • Page 92 – NOTE: The following procedure assumes you have; REASSEMBLE THE LIFT BAIL
  • Page 93 – RETEST AFTER REPAIR; INPUT IDLE AMPS AND WATTS
  • Page 95 – ELECTRICAL DIAGRAMS
  • Page 100 – S N U B B E R
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SVM136-A

November 1997

Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built
with safety in mind. However,

your overall safety can be in-
creased by proper installation . . .
and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think

before you act and be careful.

SERVICE MANUAL

World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

Sales and Service through subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100

For Machines with Code Numbers 10084 thru 10087

IDEALARC

®

CV-400

Retur

n to Master TOC

Retur

n to Master TOC

Retur

n to Master TOC

Retur

n to Master TOC

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iew Safety Info

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iew Safety Info

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iew Safety Info

RETURN TO MAIN INDEX

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Summary

Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

SAFETY i i IDEALARC CV-400 FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the eng...

Page 3 - ii; ELECTRIC SHOCK can kill.

SAFETY ii ii IDEALARC CV-400 ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing m...

Page 4 - iii

IDEALARC CV-400 FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the...

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