Lincoln Electric SVM101-B service manual Theory of Operation Section, Section E-1

Page 23

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Section E-1

TABLE OF CONTENTS

Section E-1

 

- THEORY OF OPERATION SECTION -

 

 

 

 

Theory of Operation

Section E

Power Supply Operation

E-2

Pre Charge and Protection Circuitry

E-3

Switch Board and Main Transformer

E-4

Control and Output Circuitry

E-5

Field Effect Transistor (FET) Operation

E-6

Pulse Width Modulation

E-7

Protective Circuits

E-8

FIGURE E.1 – V300-I BLOCK LOGIC DIAGRAM

 

 

 

 

 

POWER SWITCH

 

 

 

 

 

 

 

 

 

SECTIONS

 

MAIN

 

RECTIFIER

 

 

 

 

 

 

20KHZ

 

 

CHOKE

 

 

 

 

 

 

 

 

TRANSFORMER

 

 

 

 

 

 

 

 

HEATSINK

 

 

 

 

 

LEFT SWITCH BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FET MODULES

 

TOP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1 DIODE

 

 

 

 

 

 

FET MODULES

CURRENT

 

 

 

 

 

 

1ø OR 3ø DETETCTION (H5)

 

 

 

 

 

 

 

 

 

 

 

 

TRANSFORMER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PRE-CHARGE

 

 

 

 

 

 

 

 

 

LINE

INPUT

DRIVER

 

 

 

 

 

 

 

 

 

SWITCH

RECTIFIER

BOARD

 

 

 

CONTROL

 

 

5 DIODES

 

 

 

 

CR1

 

 

 

 

 

 

 

1

 

 

 

 

 

BOARD

 

 

 

 

 

AC1

 

PROTECTION

 

 

 

 

 

 

PULSE

 

 

 

 

 

 

2

 

AC2

BOARD

 

Y-Y FEEDBACK

BOTTOM

 

 

 

 

TRAIN

 

 

 

 

3

 

AC3

 

 

 

 

 

 

 

 

3A

CR2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A-LEAD

 

 

 

 

 

 

 

 

 

 

 

24VDC

PRE-CHARGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FAN

AUXILIARY

 

 

RIGHT SWITCH BOARD

 

 

 

 

 

 

 

 

 

 

 

 

5 DIODES

 

TRANSFORMER

 

2ND STEP PWM

 

 

 

 

 

 

 

 

18VAC

 

FET MODULES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

24VAC

POWERBOARD

 

CAP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TOP

 

 

 

 

 

 

 

 

FET MODULES

 

 

 

 

 

 

 

<1 VDC

 

 

 

 

1 DIODE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TO

 

 

 

 

 

 

 

CHOKE

 

CHOKE

 

WIREFEEDER

 

 

 

 

 

 

 

 

 

 

 

 

 

LOCAL

METER

MODE

POT

POT

VOLTAGE FEEDBACK

 

 

 

 

 

REMOTE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1ST STEP PWM VOLTAGE

 

 

CURRENT FEEDBACK-PROTECTION

SHUNT

 

 

 

15VDC-CONTROL BOARD FUNCTION VOLTAGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

24VAC-THERMOSTATS-GUN TRIGGERING

 

 

 

 

 

 

V300-I

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Contents Invertec Safety Fumes and Gases can be dangerous Electric Shock can killARC Rays can burn Iii SafetyWelding Sparks can cause fire or explosion Cylinder may explode if damagedSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Section A-1 Table of ContentsInstallation Section Three Phase Single Phase InstallationLocation 3INSTALLATIONA-3Product Description Electrical Installation Input Voltage SetupThree Phase Input Power Input ConnectionConnection of Wire Feeders to the Invertec Single Phase InputParallel Operation Remote Control of InvertecK900-1 DC TIG Starter Connection Quick Disconnect Plugs 6INSTALLATIONA-6Output Cables Section B-1 Operation SectionControl Function / Operation OperationOperating Instructions Duty CycleFull Range Is Is Very Soft, 10 Is Very Crisp Mode SwitchAuxiliary Power Meter Polarity SwitchSection C-1 Accessories SectionOptions / Accessories AccessoriesSection D-1 Maintenance Section Input Filter Capacitor Discharge Procedure MaintenanceOverload Protection Preventive MaintenanceFigure D.2 Location of Maintenance Components Section E-1 Theory of Operation SectionInput Line Voltage & Auxiliary Transformer Theory of OperationReturn to Return to Section TOC Precharge & Protection CircuitsFigure E-4 ---SWITCH Circuits & Transformer Switch BoardsFigure E-5 --OUTPUT & Control Circuits Output and Control CircuitsPassive Maximum Output Pulse Width ModulationMinimum Output Thermal Protection Protective CircuitsOverload Protection Section F-1 Troubleshooting & Repair SectionHOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board Troubleshooting Procedures Matched Parts Additional Information Oscilloscope WarningInput Filter Capacitor CONDITION- ING Department Feeding ProblemsFeeding Problems See Input Rectifier test See Output Diodes test See Switch Board test V300-I Input Filter Capacitor Discharge Procedure 11TROUBLESHOOTING & REPAIRF-11Figure F.I Location of Input Filter Capacitor Terminals Input Filter Capacitor Discharge ProcedureOutput Pilot Circuit Test Test Procedure J2 J4 J3 G2527V300-I Protection Board Output Test Turn Power Switch OFF Test Procedure313 306 J15 275F 311 V300-I Figure F.6 Inserting Probes ProtectionCapacitor Balance Test Static Capacitor Test 912 V300-I Switch Board Test Switch Board Test Switch Board Test Table F.3 Snubber Resistor Test Check Test Result Conclusion Next Test Step Repair Action Snubber Resistor TestOutput Diode Test Output Diode Test Test ProcedureInput Rectifier Test Probe Acceptable Meter Reading Table F.5Points Steps Overcurrent Protection Current Trigger Test 302 G2527 Control J1 275D Overcurrent Protection Current Trigger TestControl Overvoltage Protection DC Trigger Circuit Test Figure F.16 PC Boards Removed Overvoltage Protection DC Trigger Circuit Test306 275F 309 310 #301 #305 1J8 #311 1J14 6J6 #302#313 #275D 3J8 2J14 1J6Thermal Protection AC Trigger Circuit Thermal Protection AC Trigger Circuit Figure F.20 PC Boards Moved for AccessFigure F.21 Thermal Protection AC Trigger Circuit V300-I Power Board Test Test B Power Board TestTest a Figure F.23 Power Board Test Points Simplified Trigger Circuit Capacitor Removal and Replacement Procedure Procedure Capacitor Removal and ReplacementFigure F.27 -- Removing Capacitor Nuts Figure F.27 Switch Board Removal and Replacement Procedure Procedure Switch Board ReplacementTest After Switch Board or Capacitor Replacement Perform Retest After Repair Test After Switch Board or Capacitor ReplacementOutput Diode Replacement Procedure Output Diode Replacement Procedure 60TROUBLESHOOTING & REPAIRF-60Procedure Diode Modules 61TROUBLESHOOTING & REPAIRF-61Min. Acceptable Max. All Modes V300-I V300-PRO Retest After RepairOCV at rated Input V300-PRO OutputSection G-1 Electrical Diagrams Section#0# Wiring Diagram Entire Machine Code 9826 L8657Return Wiring Diagram Entire Machine Code 9827 L8938Wiring Diagram Entire Machine Code 10036 L9299 $ $ Wiring Diagram Entire Machine Code 10037 L9300Section Wiring Diagram Entire Machine Code 10132 L9567Wiring Diagram Entire Machine Code 10133 L9568 Wiring Diagram Code$& $ Wiring Diagram Entire Machine Code 10258 L10189Wiring Diagram Entire Machine Code 10336, 10450 L10205 V300-I Wiring Diagram European# . $ #$ !#$ #! %&$ Schematic Entire MachineSchematic Driver PC Board S20216 Identification PC Board Assembly Driver L8660Schematic Driver PC Board S20799 Description PC Board Assembly DriverSchematic Switch PC Board L8440 CAPACITOR, Cemo 2700P 50V 5% PC Board Assembly Switch L8441Schematic Switch PC Board L10956 Reqd Identification PC Board Assembly Switch L10958-1Schematic Control PC Board G2525 Electrical Diagrams CAPACITOR, Cemo 150P Schematic Protection PC Board M16097 DZ1 PC Board Assembly Protection L7915-2Schematic Power PC Board M16018 VOLT. REG. & Heat Sink Asbly PC Board Assembly Power L8033-7
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