Lincoln Electric SVM169-A service manual Output Rectification Feedback Control

Page 33

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E-3

 

THEORY OF OPERATION

E-3

 

FIGURE E.3 Control Board and Output Feedback Control.

 

 

 

 

 

 

 

BY-PASS

 

 

 

 

 

 

 

BOARD

 

 

 

 

POLARITY

 

 

WORK

 

 

 

 

 

 

 

 

 

SWITCH

 

 

ELECTRODE

 

 

 

 

 

 

 

 

 

MAIN

 

 

 

HI-FREQUENCY

 

 

 

TRANSFORMER

 

 

 

TRANSFORMER

 

 

INPUT

 

 

 

 

 

 

 

POWER

 

 

 

 

 

 

 

SWITCH BYPASS

 

 

 

C

 

 

ASBLY

 

 

 

 

 

 

 

 

 

 

H

 

 

 

H1

AC

DC+

 

O

 

 

 

X1

 

 

 

 

 

K

 

 

 

 

SCR

 

 

 

 

 

 

E

 

 

 

 

BRIDGE

 

 

 

 

H2

 

 

SHUNT

HIGH VOLTAGE

 

 

 

X2

 

 

 

 

 

AC

DC-

TRANSFORMER

 

 

 

H3

 

 

 

 

 

 

F

CIRCUIT

 

 

 

 

 

 

 

 

 

 

 

 

 

E

 

 

 

 

 

 

 

E

 

 

 

 

 

 

 

D

 

 

 

 

 

 

 

B

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

C

 

 

 

 

 

 

 

K

 

 

 

 

18VAC

 

 

 

115VAC

 

 

 

18VAC

 

CONTROL

POWER

 

 

 

 

 

 

 

 

 

FAN

115VAC

 

BOARD

"ON"

 

 

 

DIGITAL

 

 

 

 

 

 

 

DISPLAY

 

 

 

 

 

 

 

MODE

 

 

 

 

 

 

 

SWITCH

 

 

 

REMOTE

 

 

THERMO-

 

 

 

 

RECEPTACLE

THERMAL

GAS

OUTPUT

 

 

 

 

STATS

 

 

 

 

LIGHT

VALVE

CONTROL

 

 

 

 

 

 

AUTO

PULSE TIG

STICK

AC

PULSE POSTFLOW

BALANCE FREQ. LED

LED

BALANCE

CONTROL CONTROL

LED

LED

 

CONTROL

 

 

 

 

 

 

OUTPUT RECTIFICATION AND

FEEDBACK CONTROL

The AC output from the main transformer secondary is rectified and controlled through the SCR bridge. Output current is sensed at the shunt as a low voltage signal and fed back to the control board. The control board compares the commands of the mode switch, output control, AC balance control, pulse control, post- flow control, or remote control with the feedback infor- mation. The appropriate SCR gate firing signals are created by the control board and sent to the SCR bridge. The control board controls the firing of the SCRs, which control the output of the machine. See SCR Operation. The control board monitors the ther- mostats, and also controls the gas solenoid valve, ther- mal light, auto balance LED, pulse frequency LED, TIG LED, stick LED, and the digital display.

NOTE: Unshaded areas of block logic diagrams are the subject of discussion.

PRECISION TIG 185

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Contents Precision TIG Safety Electric Shock can kill Welding Sparks can cause fire or explosion SafetySûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Section Table of ContentsInput Single Phase only InstallationK2345-2 Input at Rated Output Model Height Width Depth WeightSelect Suitable Location Safety PrecautionsInput Connections Output Connections Input Reconnect ProcedureConnections for TIG Gtaw Welding TIG Torch ConnectionRemote Control Connection Work Cable ConnectionShielding GAS Connection Precision TIG Section B Operation SectionOperation Recommended Processes and Equipment Product DescriptionControl Functionality Controls and SettingsWelding in TIG Mode Operating StepsPulse TIG Control Benefits of the Precision TIG 185 Design Remote Control OperationRecommended Electrode Amperage Ranges Precision TIG Welding in Stick ModePrecision TIG Accessories Section Accessories Factory Installed OptionsTable C.1 K2348-1 Under-Storage Cart Field Installed OptionsPrecision TIG Section D Maintenance SectionMaintenance Routine and Periodic MaintenanceSpark GAP Adjustment Figure D.2 Location of Maintenance Components Return to Section TOC Section E Theory of Operation SectionInput Power Circuit Theory of OperationGeneral Description Figure E.3 Control Board and Output Feedback Control Output Rectification Feedback ControlFigure E.4 High Voltage/High Frequency Circuit High Voltage / High Frequency CircuitFigure E.5 DC Welding Current Generation DC Welding OutputFigure E.6 AC Square Wave Welding Current Generation AC Welding OutputFigure E.7 SCR Operation SCR OperationProtective Circuits Thermal ProtectionOverload Protection Section F Troubleshooting & Repair SectionHigh Voltage / High Frequency can damage test equipment Troubleshooting & RepairWorkstations PC Board Troubleshooting ProceduresCourse of Action Problems Possible Areas Recommended SymptomsPossible Areas Recommended Symptoms Problems Possible Areas Check the welding cables and or TIG Mode Problems Troubleshooting & Repair TIG Welding Problems Problems Possible Areas Electric Shock can Problems Possible Areas Recommended Symptoms Stick Welding Problems Test Description High Frequency Circuit Disable ProcedureFigure F.1 Spark GAP Assembly ProcedureT1 Transformer Test T1 Transformer Test Test ProcedurePrimary Windings Primary Voltages Return to Section Section TOCPrecision TIG Static SCR Test Static SCR Test Assembly Removal and Replacement Precision TIG Active SCR Test Active SCR Test Figure F.6 SCR Gate Locations Precision TIG AC TIG Mode Scope SettingsNormal Open Circuit Voltage Waveform DC TIG Mode AC Stick Mode DC Stick Mode Machine Loaded to 180 Amps AT 16VDC Typical Output Voltage Waveform Machine LoadedDC TIG Mode Machine Loaded to 180 Amps AT 26VDC DC Stick Mode 50 V/Div Precision TIG SCR Bridge Assembly Removal and Replacement Procedure Troubleshooting and RepairProcedure SCR Bridge AssemblyFront Panel Mounting Screws Figure F.9 Plug J2 on Control Board 42TROUBLESHOOTING & REPAIRF-42Replacement Procedure 43TROUBLESHOOTING & REPAIRF-43Precision TIG Polarity Switch Removal and Replacement Procedure Removal Procedure Polarity SwitchReplacement Procedure Precision TIG High Voltage Transformer Removal and Replacement Procedure Transformer Secondary Leads Precision TIG High Voltage TransformerFigure F.12 High Voltage Transformer Mounting Insulators Precision TIG Nutdriver Wrench Wire cutters Perform the SCR Bridge Assembly Removal Procedure Assembly Replacement Procedure Precision TIG Retest After Repair Troubleshooting and RepairInput Idle Amps Recommended Meters for Machine Output TestsPrecision TIG Electrical Diagrams Section Precision TIG Wiring Diagram Entire Machine G4549G4588 Schematic Entire Machine G4588Schematic Control PC Board G4550-1B4-1 Schematic Control P.C. Board G4550-1B4-2 Schematic Control P.C. Board G4550-1B4-3 G4551 PC Board Assembly Control G4551-1SVM Error Reporting Form