Lincoln Electric SVM155-A service manual General Description, Recommended EQUIPMENT/PROCESSES

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OPERATION

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GENERAL DESCRIPTION

The Multi-Source is designed to supply power to the Multi-Weld welders. It has a wide range three phase AC input and can be operated on 50 or 60 Hz. The Multi-Source output peak voltage regulates against wide changes in output loading and input line voltage variations to supply a consistently stable voltage high enough to allow the Multi-Welds to provide good man- ual electrode capability.

Primary input voltage taps are selected by a single movable link on the reconnect panel. Main transformer auxiliary windings power the firing circuit and fan motor. The control auxiliary transformer has a single, wide range primary and is not reconnectable.

The Fan As Needed feature is activated by an output current of 20 amps DC or a thermostat on the main transformer iron.

An independent safety circuit on the Control board monitors the voltage peaks and opens the input con- tactor if the limit is exceeded. The green Safe Output light indicates when the machine output voltage is with- in the safe operating range.

Other indicator lights include the amber Thermal light that signals when the long term output current limit has been exceeded. This limit is determined by a thermo- stat sensing the temperature of the negative output lead from the secondary coils. The white Power light indicates when the Control board is energized. The three lights are high intensity LEDs for improved visi- bility in daylight.

The Output Power display uses high intensity LEDs to indicate the percentage of full rated output the machine is supplying.

Two additional thermostats protect the machine in the case of fan failure or blocked air flow. The SCR heat sink thermostat responds first to loss of air flow at nor- mal output loads. This thermostat will disable the machine output. The transformer iron rear thermostat senses that the lamination (and thus the coil insulation) is over heating (which can happen even if the output is disabled). This thermostat will interrupt power to the Control board causing the input contactor to open until the iron cools.

The only user controls are an on-off toggle Power switch that energizes the machine and a 10 A cir- cuit breaker protecting the fan auxiliary against short circuits.

RECOMMENDED

EQUIPMENT/PROCESSES

The only recommended use for the Multi-Source is to power the Multi-Weld welders. It is conceivable that the machine could be used as a constant voltage DC power supply up to its rating of 40,000 watts (36,000 watts on 50Hz) output. Its output is stable with a wide range of inductive, resistive and capacitive loads but each application would have to be tested. The output is peak voltage regulated and at light resistive loads (maximum ripple) the average voltage deviates from peak voltage the most.

The Multi-Weld 350 K1752-1 is the recommended means by which to control the Multi-Source power sup- ply. Connections between Multi-Source and Multi- Weld may be easily made using Twist-Mate male and female connectors and the K1736-1 distribution box. The Multi-Weld 350 has multi-process capability and may be used with manual and semi-automatic processes. When a wire feeder is required, an LN-25 (K449) is recommended. The Multi-Source 40kW (36kW on 50Hz) 80VDC buss power source (K1752-1)

is recommended for use in the Multi-Weld system.

DESIGN FEATURES AND ADVAN- TAGES

•80 volt peak OCV.

•40,000 watts of output (36,000 watts on 50Hz) at

100% Duty Cycle.

•75 volts at 533 amps (75.8 volts at 475 amps on 50 Hz) over 900 amps for 5 seconds without harming the machine.

•The machine has copper windings and a varnish dipped transformer for added environmental protec- tion.

•Sealed external controls.

•Voltage ratings have been upgraded and used with higher voltage MOVs.

•Input lines are protected by the most rugged surge protection we’ve ever used.

•Indicator lights and digital display are extra bright to enhance visibility outdoors.

•HP_Cooling fan can operate on a wider range of voltage.

MULTI-SOURCE

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Contents MULTI-SOURCE TM California Proposition 65 Warnings SafetyElectric Shock can kill Welding Sparks can cause fire or explosion Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Multi-Source K1752-1 InstallationTilting Safety PrecautionsSelect Proper Location StackingInput and Grounding Connections Fuse and Wire SizesParalleling Output ConnectionsMULTI-SOURCE Table of Contents Operation Section Operation Safety InstructionsDesign Features and ADVAN- Tages General DescriptionRecommended EQUIPMENT/PROCESSES Recommended EQUIPMENT/CONNECTIONS Controls and SettingsTable of Contents Accessories Field Installed Options / Accessories Factory Installed Options / AccessoriesTable of Contents Maintenance Routine and Periodic MAINTE- Nance Safety PrecautionsFigure D.1 Major Component Location MULTI-SOURCE Table of Contents Theory of Operation Input VOLTAGE, FILTER, Contac TOR and Control Trans Former General DescriptionReturn to Section Section TOC Troubleshooting & RepairOperation Protection Devices and CIR Cuits Figure E.5 SCR Operation SCR OperationTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Electric Shock can kill PC Board Troubleshooting Procedures and ReplacementTroubleshooting Guide T1 Test Calibration ProcedurePerform the Firing Board Test Perform the Main TransformerCircuit external to the Multi Main Transformer Test Technical SpecificationsInput Contactor Test Functions ProblemsControl Transformer T2 Voltage Test Test DescriptionFigure F.1. Control Transformer Location & Leads Test Procedure575 VAC 43.0 VAC 460 VAC 34.50 VAC 380 VAC 28.50 VAC Secondary Thermostat Input Contactor Test 241COIL Input Contactor TestTest for Contact Continuity Removal and Replacement ProcedureMULTI-SOURCE Main Transformer T1 Voltage Test Contactor Test Main Transformer T1 Voltage TestFigure F.6. Main Secondary Lead Test Points MULTI-SOURCE Static SCR Test Static SCR Test Leads Remove Red Paint Active SCR Test Active SCR Test Active SCR Test Remove Red Paint SW1 MULTI-SOURCE Control Board Test See Figure F.15 Control Board Test#341 #230 #215 #231 #263 #201 J1 MULTI-SOURCE Firing Board Test Static and Active SCR Tests Figure F.17Then Table F.2. LED 7, 8 and 9 Check List#231 #215 #340 J8 #287 MULTI-SOURCE Meter Accuracy Check Control Board Normal Open Circuit Voltage Waveform no Load Volts Typical SCR Gate Voltage Waveform no Load MULTI-SOURCE Description Input Contactor Cleaning AND/OR ReplacementRemoval Procedure Coil 240MULTI-SOURCE Control Board Replacement Procedure Control Board Firing Board Replacement Procedure Firing Board SCR Bridge / Heat Sink Assembly Replacement Procedure Bridge Assembly Mount #251 Mounting Bolt Removal of Individual SCR Heat Sink Assemblies Figure F.27 See Figure F.26No Load Readings FAN OFF Maximum Open Circuit VoltagePerform Meter Accuracy Test MULTI-SOURCE Table of Contents Electrical Diagrams Section Electrical DiagramsMULTI-SOURCE Wiring DiagramSchematic Control PC Board Return to Section PC Board ASSEMBLY-CONTROLSchematic Firing Printed Circuit Board TP1 PC Board ASSEMBLY-FIRINGM14312 PC Board Assembly SnubberSVM Error Reporting Form

SVM155-A specifications

The Lincoln Electric SVM155-A is a state-of-the-art welding machine that excels in versatility and performance, making it ideal for both professional welders and hobbyists. This multi-process welder supports MIG, TIG, and stick welding processes, allowing users to tackle a wide range of applications with a single device. Its user-friendly design and advanced technology make it an exceptional choice for those looking to enhance their welding capabilities.

One of the main features of the SVM155-A is its robust power output, which can handle welding materials ranging from thin sheets to heavier stock. The welder offers a high duty cycle, ensuring that users can work efficiently without the need for prolonged breaks. This is especially important in industrial settings where productivity is key. Additionally, the SVM155-A is equipped with a digital display that allows for easy monitoring and precise control of the welding parameters, ensuring consistency in weld quality.

The European-designed INVERTER technology embedded in the SVM155-A significantly contributes to its lightweight and compact design. Weighing in at only 19.4 lbs, this welder is portable and ideal for fieldwork or workshops where space is limited. The inverter technology not only reduces the size and weight but also improves energy efficiency, leading to lower operational costs over time.

The SVM155-A also features advanced safety mechanisms, including over-current protection to safeguard the machine from potential damage during excessive use. It also includes a thermal overload shut-off, which prevents overheating, ensuring a longer lifespan for the welder.

Another standout characteristic of the SVM155-A is its exceptional arc stability and ease of use. The machine is designed to provide a smooth and consistent arc, reducing spatter and ensuring clean welds. Moreover, the welder is compatible with a wide range of materials, including stainless steel, aluminum, and carbon steel, further enhancing its versatility.

In conclusion, the Lincoln Electric SVM155-A is a powerful, durable, and multifunctional welding machine that incorporates advanced technologies to meet the needs of modern welding applications. Its portability, safety features, and ability to deliver high-quality welds make it an excellent investment for anyone looking to improve their welding skills or expand their capabilities in various welding projects.
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