Lincoln Electric SVM144-B service manual Output Rectification, Feedback Control

Page 33

E-3

THEORY OF OPERATION

E-3

TOC

TOC

FIGURE E.3 — OUTPUT RECTIFICATION AND FEEDBACK.

 

 

 

 

 

 

 

Section

Master

 

GAS

FAN

 

 

 

 

 

SOLENOID

MOTOR

 

WIRE

 

 

 

 

 

 

 

 

 

 

DRIVE

 

WIRE

 

 

 

MOTOR

 

to

to

 

 

 

 

 

 

SPEED

 

 

 

 

 

 

Return

Return

ARC

CONTROL

 

 

 

 

VOLTAGE

BOARD

 

 

 

 

 

 

 

 

TACH

 

 

 

 

 

 

 

 

 

 

115 VAC

 

 

 

 

GUN TRIGGER

 

 

 

 

RECTIFIER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DIODE

G

 

 

FEEDBACK

 

 

 

 

BRIDGE

 

 

 

 

 

 

A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30 VAC

 

T

 

 

 

 

 

 

 

 

E

 

 

 

 

 

 

LINE

SNUBBER

S

 

 

 

 

 

 

BOARD

 

 

 

 

 

 

SWITCH

 

I

 

 

 

 

 

 

 

 

G

 

 

 

 

 

 

 

 

N

 

 

 

 

TOC

 

 

 

A

 

 

 

 

TOC

 

 

L

 

 

 

 

 

 

 

 

 

 

 

Section

Master

 

 

POWER

C

F

OUTPUT

POSITIVE

RECONNECT

 

ENHANCEMENT

A

CHOKE

 

TERMINAL

MAIN

 

CHOKE

P

E

 

 

 

 

TRANSFORMER

 

 

A

E

 

 

 

SCR

 

C

D

 

 

to

to

 

 

B

 

 

 

RECTIFIER

 

I

 

 

 

 

 

T

A

 

 

Return

Return

 

 

 

 

 

 

 

 

O

C

 

NEGATIVE

 

 

 

R

K

 

 

 

 

 

TERMINAL

 

 

 

S

 

 

 

 

 

 

 

 

 

 

 

SHUNT

 

 

 

 

 

 

 

 

 

OUTPUT RECTIFICATION AND

the commands of the ARC Voltage Control poten-

 

 

FEEDBACK CONTROL

tiometer with the feedback signals. The appropriate

 

 

gate firing pulses are generated by the control board

 

 

 

 

 

The AC output from the main transformer secondary

and applied to the SCR rectifier assembly. The control

 

 

board controls the firing of the SCRs, thus controlling

TOC

TOC

weld winding is rectified and controlled through the

the output of the machine. See SCR Operation. The

SCR rectifier assembly. Output voltage and current are

control board also powers and commands the gas

SectiontoReturn

MastertoReturn

sensed at the shunt and output terminals and are fed

solenoid, fan motor, and the wire drive motor.

back to the control board. The control board compares

 

 

 

 

Section TOC

Master TOC

 

to

to

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

Return

Return

 

POWER MIG 255

 

 

Image 33
Contents Power MIG 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 ContentsTechnical Specifications Power MIG InstallationSafety Precautions Uncrating the Power MIGLocation Power MIG Figure A.2 Triple Voltage Machine Input Connections Shielding GAS GUN and Cable InstallationSection B Operation SectionFumes and Gases can be dangerous OPERATIONB-2Product Description OperationWelding Capability LimitationsDescription of Controls Wire Reel Loading READI-REELS, SPOOLS, or Coils Procedure for Changing Drive and Idle Roll SetsSetting RUN-IN Speed on STAN- Dard Power MIG Feeder Feeding Wire ElectrodeIdle Roll Pressure Setting To Start the WelderMaking a Weld Avoiding Wire Feeding ProblemsInput Line Voltage Protection FAN ControlSection C Accessories SectionDrive Roll Kits AccessoriesK363P READI-REEL Adapter Dual Cylinder Mounting KIT K1702-1Operating Instructions For Timer KIT Spool GUN Adapter KIT Making a Weld with the Spool GUN, Spool GUN InstalledSection D Maintenance SectionMaintenance Routine and Periodic MaintenanceGUN Tubes and Nozzles Figure D.1 Component Locations Liner Removal Replacement Contact TIP and GAS Nozzle InstallationTo open up the handle 5MAINTENANCED-5Description English Size Metric Size Table D.2Section E Theory of Operation SectionTheory of Operation Input Line VoltageMain Transformer Feedback Control Output RectificationFigure E.4 Constant Voltage Output Constant Voltage OutputFeedback Wire Drive MotorWire Feed Overload Protection Thermal and Overload ProtectionOvercurrent Protection Figure E.6 SCR Operation SCR OperationPower MIG Section F Troubleshooting & Repair SectionHOW to USE Troubleshooting Guide Troubleshooting & RepairWorkstations PC Board Troubleshooting ProceduresOutput Problems SCR Rectifier Rectifier Function Problems Wire Feeding Problems Welding Problems Welding Problems Test Description Main Transformer TestMain Transformer Test Test ProcedureFigure F.1 Troubleshooting and Repair Rectifier Diode Bridge Test Test DescriptionMaterials Needed Rectifier Diode Bridge Testing 208R 206 28 VAC 209R Power MIG Static SCR Rectifier Assembly Test Static SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Power MIG Active SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Figure F.7 Location Leads X2 Open switch SW-1 Wire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test 515B 206B 15 VDC 5J1 1J1 Test for Supply Voltage to Tachometer555 206B To 3.5 VDC 6J1 1J1 Test for Feedback Voltage to Control BoardVolts Normal Open Circuit Voltage WaveformTypical Output Voltage Waveform Machine Loaded Machine Loaded to 250 Amps AT 26 VDC Scope SettingsMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Power MIG Description Control PC Board Removal and Replacement ProcedureControl PC Board Removal and Replacement ProcedureFigure F.11 Control Board Mounting Power MIG Wire Drive Assembly Removal and Replacement Procedure 41TROUBLESHOOTING & REPAIRF-41Procedure Wire Drive Assembly Removal and ReplacementTOC Power MIG SCR Output Rectifier Removal and Replacement Procedure SCR Output Rectifier Removal and Replacement Figure F.15 Right Heat Sink Lead Disconnection Power MIG Capacitor Bank Removal and Replacement Procedure Capacitor Bank Removal and Replacement Troubleshooting & Repair Main Transformer and Output Choke Removal and ReplacementTOC Power MIG FAN Motor Assembly Removal and Replacement Procedure FAN Motor Assembly Removal and Replacement Wire Speed Range Troubleshooting and RepairRetest After Repair Open Circuit VoltagePower MIG Electrical Diagrams Section Wiring Diagram Entire Machine Code 10563 L10979 Power MIG 255 208/230VWiring Diagram Entire Machine Code 10583 L10980 Power MIG 255 230/460/575VWiring Diagram Entire Machine Code 10986 L11980 Power MIG 255 230/460/575Wiring Diagram Entire Machine Code 10990 L11979 Power MIG 255 208/230Control PC Board Schematic G3520-1D1 3521 Control PC Board Assembly G3521-1Powermig Display PC Board Schematic L10951Lincoln Electric CO Display PC Board Assembly L10952-124374 S Snubber PC Board Schematic S2437400 ~.04 Snubber PC Board Assembly M19248-1SVM Error Reporting Form