Lincoln Electric IDEALARC DC 1000 SVM123-A - Manual (Page 41)

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IDEALARC DC-1000
F-1 TROUBLESHOOTING & REPAIR F-1
TABLE OF CONTENTS
-TROUBLESHOOTING AND REPAIR SECTION-
TROUBLESHOOTING AND REPAIR SECTION ...............................................................Section F
How to Use Troubleshooting Guide.......................................................................................F-2
Safety Precautions.................................................................................................................F-3
PC Board Troubleshooting Procedures .................................................................................F-3
Troubleshooting Guide ..........................................................................................................F-4
Output Problems .............................................................................................................F-4
Function Problems ..........................................................................................................F-9
Welding Problems .........................................................................................................F-11
Test Procedures
Control Transformer (T2) Voltage Test .........................................................................F-13
Main Transformer (T1) Voltage Test .............................................................................F-16
Firing Board Test...........................................................................................................F-20
Control Board Test ........................................................................................................F-25
Static SCR Test.............................................................................................................F-30
Active SCR Test ............................................................................................................F-34
Oscilloscope Waveforms
Normal Open Circuit Voltage Waveform Constant Current Mode ..................................F-38
No Load
Normal Open Circuit Voltage Waveform Constant Voltage ............................................F-39
Innershield - Maximum Output Setting - No Load
Normal Open Circuit Voltage Waveform Constant Voltage ............................................F-40
Innershield - Minimum Output Setting - No Load
Typical Output Voltage Waveform - Machine Loaded Constant Voltage........................F-41
Innershield Mode
Typical Output Voltage Waveform - Machine Loaded ....................................................F-42
500 Amp Output Terminal Constant Voltage Innershield Mode
Typical SCR Gate Voltage Waveform Constant Voltage................................................F-43
Innershield Maximum Output Setting - No Load
Abnormal Open Circuit Voltage Waveform Constant Voltage ........................................F-44
Innershield One Output SCR Not Functioning Maximum Output Setting
Replacement Procedures
Input Contactor Cleaning and or Replacement .............................................................F-45
SCR Output Bridge Replacement .................................................................................F-49
SCR Output Bridge Removal..................................................................................F-50
Removal of Individual SCR Heat Sink Assemblies.................................................F-52
SCR Heat Sink Installation .....................................................................................F-53
SCR Output Bridge Installation...............................................................................F-53
Removal and Reassembly of Lift Bail ...........................................................................F-55
Removal of Lift Bail.................................................................................................F-56
Reassembly of Lift Bail ...........................................................................................F-57
Main Transformer Removal and Installation .................................................................F-58
Main Transformer Disassembly and Assembly ......................................................F-59
Main Transformer Disassembly ..............................................................................F-60
Coil Removal and Replacement .............................................................................F-60
Transformer Reassembly .......................................................................................F-61
Retest After Repair ..............................................................................................................F-63