Lincoln Electric SVM101-B Theory of Operation, Input Line Voltage & Auxiliary Transformer

Page 24

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E-2

THEORY OF OPERATION

 

E-2

 

FIGURE E-2 --- INPUT CIRCUITS

 

 

 

 

POWER SWITCH

 

 

 

 

SECTIONS

MAIN

 

RECTIFIER

 

20KHZ

CHOKE

 

TRANSFORMER

 

HEATSINK

 

LEFT SWITCH BOARD

 

 

 

 

 

 

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LINE

 

SWITCH

1

 

2

 

3

3A

 

FAN

AUXILIARY

TRANSFORMER

 

TO

WIREFEEDER

 

 

FET MODULES

 

TOP

 

 

 

 

 

 

 

 

 

CAP

 

 

 

 

 

 

 

 

1 DIODE

 

 

 

FET MODULES

CURRENT

 

 

1ø OR 3ø DETETCTION (H5)

 

 

 

 

 

 

TRANSFORMER

 

 

 

 

 

 

 

 

 

PRE-CHARGE

 

 

 

 

 

INPUT

DRIVER

 

 

 

 

 

RECTIFIER

BOARD

 

 

CONTROL

5 DIODES

 

 

CR1

 

 

 

 

 

 

 

BOARD

 

 

AC1

 

PROTECTION

 

 

 

PULSE

 

 

 

 

AC2

BOARD

 

Y-Y FEEDBACK

BOTTOM

 

TRAIN

 

 

AC3

 

 

 

 

 

CR2

 

 

 

 

 

 

 

 

 

 

 

A-LEAD

 

 

 

 

 

 

24VDC

PRE-CHARGE

 

 

 

 

 

 

 

 

 

 

 

 

 

RIGHT SWITCH BOARD

 

 

18VAC

2ND STEP PWM

FET MODULES

 

5 DIODES

 

 

 

 

 

 

 

 

 

 

 

24VAC

POWERBOARD

CAP

 

 

 

 

 

 

 

 

 

 

 

 

 

TOP

 

 

 

FET MODULES

 

 

 

<1 VDC

 

 

 

 

 

 

 

1 DIODE

 

 

 

 

 

 

 

 

 

 

 

 

CHOKE

CHOKE

 

 

 

 

 

 

 

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

 

 

 

 

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INPUT LINE VOLTAGE & AUXILIARY TRANSFORMER

The V300-I can be connected for a variety of three phase or single phase input voltages. Power is applied through the Line Switch to the Input Rectifier and the Auxiliary Transformer.

The Reconnect Panel has switches to select high or low operating voltage. The “A” lead must then be set for the proper input voltage. It is important to set the switches and “A” lead to the proper positions before applying input power. Changing the switch position with the power applied will result in major damage to the machine

The auxiliary transformer provides 18v.a.c. and 24v.a.c. supplies to the Control and Power Boards. It also provides 115v.a.c., 42v.a.c. and 24v.a.c. supplies to the wirefeeder amphenol. (CE machines do not have 115v.a.c. supply)

The Power Board provides a 15v.d.c. supply to the Control Board and a 24v.d.c.supply to the Driver Board to operate the Pre-charge Relays.

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NOTE: Unshaded areas of block logic diagram are the subject of discussion

V300-I

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Contents Invertec Safety Electric Shock can kill ARC Rays can burnFumes and Gases can be dangerous Safety Welding Sparks can cause fire or explosionCylinder may explode if damaged IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionSection A-1 Installation Three Phase Single Phase3INSTALLATIONA-3 Product Description Electrical InstallationInput Voltage Setup LocationPower Input Connection Connection of Wire Feeders to the InvertecSingle Phase Input Three Phase InputRemote Control of Invertec K900-1 DC TIG Starter ConnectionParallel Operation 6INSTALLATIONA-6 Output CablesQuick Disconnect Plugs Operation Section Section B-1Operation Operating InstructionsDuty Cycle Control Function / OperationMode Switch Full Range Is Is Very Soft, 10 Is Very CrispMeter Polarity Switch Auxiliary PowerAccessories Section Section C-1Accessories Options / AccessoriesMaintenance Section Section D-1Maintenance Input Filter Capacitor Discharge ProcedurePreventive Maintenance Overload ProtectionFigure D.2 Location of Maintenance Components Theory of Operation Section Section E-1Theory of Operation Input Line Voltage & Auxiliary TransformerPrecharge & Protection Circuits Return to Return to Section TOCSwitch Boards Figure E-4 ---SWITCH Circuits & TransformerOutput and Control Circuits Figure E-5 --OUTPUT & Control CircuitsPassive Pulse Width Modulation Minimum OutputMaximum Output Protective Circuits Overload ProtectionThermal Protection Troubleshooting & Repair Section Section F-1Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Additional Information Oscilloscope Warning Input Filter Capacitor CONDITION- INGMatched Parts Feeding Problems DepartmentFeeding Problems See Input Rectifier test See Output Diodes test See Switch Board test V300-I 11TROUBLESHOOTING & REPAIRF-11 Input Filter Capacitor Discharge ProcedureInput Filter Capacitor Discharge Procedure Figure F.I Location of Input Filter Capacitor TerminalsOutput Pilot Circuit Test Test Procedure G2527 J2 J4 J3V300-I Protection Board Output Test Test Procedure Turn Power Switch OFF313 306 J15 275F 311 V300-I Protection Figure F.6 Inserting ProbesCapacitor Balance Test Static Capacitor Test 912 V300-I Switch Board Test Switch Board Test Switch Board Test Table F.3 Snubber Resistor Test Snubber Resistor Test Check Test Result Conclusion Next Test Step Repair ActionOutput Diode Test Test Procedure Output Diode TestInput Rectifier Test Table F.5 Points StepsProbe Acceptable Meter Reading Overcurrent Protection Current Trigger Test Overcurrent Protection Current Trigger Test 302 G2527 Control J1 275DControl Overvoltage Protection DC Trigger Circuit Test Overvoltage Protection DC Trigger Circuit Test Figure F.16 PC Boards Removed306 275F 309 310 1J8 #311 1J14 6J6 #302 #313 #275D3J8 2J14 1J6 #301 #305Thermal Protection AC Trigger Circuit Figure F.20 PC Boards Moved for Access Thermal Protection AC Trigger CircuitFigure F.21 Thermal Protection AC Trigger Circuit V300-I Power Board Test Power Board Test Test aTest B Figure F.23 Power Board Test Points Simplified Trigger Circuit Capacitor Removal and Replacement Procedure Capacitor Removal and Replacement ProcedureFigure F.27 -- Removing Capacitor Nuts Figure F.27 Switch Board Removal and Replacement Procedure Switch Board Replacement ProcedureTest After Switch Board or Capacitor Replacement Test After Switch Board or Capacitor Replacement Perform Retest After RepairOutput Diode Replacement Procedure 60TROUBLESHOOTING & REPAIRF-60 Output Diode Replacement Procedure61TROUBLESHOOTING & REPAIRF-61 Procedure Diode ModulesRetest After Repair OCV at rated Input V300-PROOutput Min. Acceptable Max. All Modes V300-I V300-PROElectrical Diagrams Section Section G-1Wiring Diagram Entire Machine Code 9826 L8657 #0#Wiring Diagram Entire Machine Code 9827 L8938 ReturnWiring Diagram Entire Machine Code 10036 L9299 Wiring Diagram Entire Machine Code 10037 L9300 $ $Wiring Diagram Entire Machine Code 10132 L9567 SectionWiring Diagram Code Wiring Diagram Entire Machine Code 10133 L9568Wiring Diagram Entire Machine Code 10258 L10189 $& $V300-I Wiring Diagram European Wiring Diagram Entire Machine Code 10336, 10450 L10205Schematic Entire Machine # . $ #$ !#$ #! %&$Schematic Driver PC Board S20216 PC Board Assembly Driver L8660 IdentificationSchematic Driver PC Board S20799 PC Board Assembly Driver DescriptionSchematic Switch PC Board L8440 PC Board Assembly Switch L8441 CAPACITOR, Cemo 2700P 50V 5%Schematic Switch PC Board L10956 PC Board Assembly Switch L10958-1 Reqd IdentificationSchematic Control PC Board G2525 Electrical Diagrams CAPACITOR, Cemo 150P Schematic Protection PC Board M16097 PC Board Assembly Protection L7915-2 DZ1Schematic Power PC Board M16018 PC Board Assembly Power L8033-7 VOLT. REG. & Heat Sink Asbly