Lincoln Electric SVM189-B service manual Output CONTROL, Rectification & Voltage Feedback

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E-4

 

THEORY OF OPERATION

E-4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FIGURE E.4 — OUTPUT CIRCUITS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ARC

 

 

TRIGGER

WIRE

 

 

 

 

VOLTAGE

 

RECEPTACLE

SPEED

 

 

 

 

CONTROL

 

 

 

 

 

 

CONTROL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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CIRCUIT LINE

BREAKER SWITCH

INPUT

RECEPTACLE

FAN

MOTOR

CONTROL

GAS

BOARD

SOLENOID

 

 

WIRE

 

FEED

 

MOTOR

 

VOLTAGE FEEDBACK &

 

MOTOR POWER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MAIN

 

 

 

+

 

MAIN

 

 

 

 

TRANSFORMER

 

 

 

 

 

 

BRIDGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CHOKE

+

OUTPUT

TERMINALS

-

OUTPUT CONTROL, RECTIFICATION & VOLTAGE FEEDBACK

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The AC voltage that is applied to the main transformer primary is controlled at the control board by two SCRs (Silicon Controlled Rectifiers). The SCRs are controlled by a pulse signal developed on the control board. The control board compares the commands of the arc volt- age control with the voltage feedback signal. (The Arc Voltage Control may be either a continuous control or a selector switch, depending on the model of the machine).

The board circuitry then sends a pulse to turn on the SCRs. In this manner, the voltage applied to the pri- mary of the transformer is varied and controlled. This controlled voltage is reflected at the transformer sec- ondary winding and is applied to the rectifier diode bridge. This rectified DC voltage is filtered by the out- put capacitor and choke circuit and is applied to the machine’s output terminals.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion

COMPACT WIRE WELDERS

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Contents Safety Depends on You SVM189-BSafety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn Iii Welding CuttingFor Electrically Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical SpecificationsStacking Safety PrecautionsSelect Suitable Location TiltingIdentify and Locate Components Table of Contents Operation Section Common Welding Abbreviations OperationProduct Description Product Capabilities Wear eye, ear and body protec- tionSee Figure B.2 Controls and SettingsSee Figure B.1 See Figure B.3 Drive Roll Tension Thumbscrew TurningWire Diameter Drive Roll Drive Roll Part Inner Wire Guide Number Part NumberSetting UP and Making a FLUX-CORED Weld Items Needed for Flux Cored WeldingMachine Load Wire SpoolConnect Leads and Cables on Figure B.9 MIG Conversion Kit K2526-1 025Install Shielding GAS Shielding GAS11OPERATION Connect Leads and Cables on the Machine12OPERATION Do not Remove or Conceal Warning LabelsFigure B.20 Compact Wire Welders Table of Contents Accessories Section K2532-1 Magnum 100SG Spool Gun AccessoriesK2525-1 Spot Timer Kit K2377-1 Small Canvas CoverK520-Utility Cart K2275-1 Welding Cart Technical Specifications Magnum 100SG Spool GUN K2532-1 Unpacking the Spool GUNSafety Precautions Locating Spool GUN Components FeaturesAssembly of Items Inside the Magnum Spool GUN Figure C.3Spool GUN Safety Precautions Welding MachinesRecommended Welding Machines Open the Machine Spool GUN / Wire Drive Selector Switch InstallationDisconnect input power from the machine 11.C. Connect harness P8 6-pin to board J5 6- pin Electrical Connections11.B. Connect P5 6-pin to harness J8 6-pin If Machine does have Optional Spot Timer .A. thru 12.D 544A 543AMounting the Switch RE-ASSEMBLE Machine AS FollowsRoutine Welding Machine Preparation ACCESSORIESC-13Disconnect input power to the machine Preparing the Spool GUNLoading Aluminum Wire Figure C.5Figure C.11 Connecting the GUN to the Welding Machine Figure C.17Table of Contents Maintenance Section Routine Maintenance MaintenanceMaintenance Safety Precautions For Magnum 100L GUN GUN and Cable MaintenanceOverload Protection Liner trim length Changing LinerGUN Handle Parts Major Component Locations Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation General DescriptionFigure E.3 Input Power Circuits Input Line VOLTAGE, FAN Motor & Main TransformerOutput CONTROL, Rectification & Voltage Feedback Figure E.4 Output CircuitsTRIGGER, GAS Solenoid and Wire Drive Figure E.5 TRIGGER, GAS Solenoid & Wire DriveSCR Operation Figure E.6 SCR OperationElectronic Wire Drive Motor Protection Compact Wire Welders Table of Contents Troubleshooting & Repair Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Wiring Diagram OUTPUT/FEEDING Problems Feeding Problems Welding Problems Maintenance Section Issues Maintenance Section Cone or gas diffuser Materials Needed Case Cover Removal and Replacement ProcedureTest Description Procedure Figure F.1 Case RemovalGAS Solenoid Test GasSolenoid Leads Wire Drive Motor Test Test Procedure MOT-MOT+Main Transformer Test Secondary Test Procedure Secondary Lead Compact Wire Welders FAN Motor Test Figure F.5. Control Board Lead Locations Volts 10Volts 20ms Scope SettingsTypical Output Voltage Waveform Machine Loaded Abnormal Open Circuit Voltage Waveform Control Board Removal and Replacement Procedure See Figure F.7 Nameplate Control Knob Compact Wire Welders Power Module Removal and Replacement Procedure Viewed from Rear of Machine Center Panel PolarityPanel CenterPanelScrews OutputStuds Compact Wire Welders Misc. Hand Tools Dow Corning Fine Steel Wool See Figure F.12 Dow Corning Figure F.12 DOW Corning Application Areas Transformer Compact Wire Welders Wire Drive Motor Removal and Replacement Procedure Lincolnelectric Phillips Mounting Screws Compact Wire Welders FAN Motor Assembly Removal and Replacement Procedure Viewed from Rear of Machine Center Panel CenterPanelScrews Locking Tabs Fan Retest After Repair 140 AMP Units Troubleshooting & Repair Retest After Repair 125 AMP UnitsWire Speed Range Open Circuit VoltageTroubleshooting & Repair Retest After Repair 180 AMP Units Table of Contents Diagram Section Wiring Diagram COmpacT WirE WElDErSSpool GUN Interface Wiring Diagram Wiring Diagram M20410-3 a COmpacT WirE WElDErS Thermostat TMP FAN TS1SchEmaTic cOmplETE machiNE m21240 C12 R1Feed R24