Lincoln Electric SVM170-A service manual Input Line Voltage, Main Transformer

Page 34

E-2

THEORY OF OPERATION

E-2

 

 

 

TOC

TOC

FIGURE E.2 — INPUT LINE VOLTAGE AND MAIN TRANSFORMER.

 

 

 

 

 

 

 

 

Section

Master

 

GAS

FAN

SPOOL

 

 

 

 

SOLENOID

MOTOR

 

GUN

WIRE

 

 

 

 

 

 

 

 

 

 

 

 

DRIVE

 

 

 

 

 

 

MOTOR

 

to

to

WIRE

 

 

 

 

 

 

 

SPEED

 

 

 

 

 

 

 

Return

Return

ARC

CONTROL

 

 

 

 

 

VOLTAGE

BOARD

 

 

 

 

 

AUX

 

 

 

 

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

 

 

 

 

 

 

RECTIFIER

 

 

I

B

 

 

Return

Return

 

 

 

 

T

A

 

 

 

 

 

 

O

C

 

NEGATIVE

 

 

 

 

R

K

 

 

 

 

 

 

TERMINAL

 

 

 

 

S

 

 

 

 

 

 

 

 

 

 

 

 

 

SHUNT

 

 

 

 

 

 

 

 

 

 

INPUT LINE VOLTAGE

gate drive circuitry. The weld power windings connect

 

 

AND MAIN TRANSFORMER

to the main SCR Rectifier and via the Snubber Board

 

 

to the Rectifier Diode Bridge. This AC voltage is recti-

 

 

 

 

 

The desired single phase input power is connected to

fied and then regulated by the control board. The

 

 

resultant +15 VDC and +5 VDC voltages supply power

TOC

TOC

the POWER MIG 255C through a line switch located

to the control board circuitry. The 115 VAC winding

on the front panel.

supplies power, through the control board, to the ther-

 

 

Section

Master

A reconnect panel allows the user to configure the

mostatically controlled fan motor and also provides

voltage for the auxiliary receptacle

 

 

machine for the desired input voltage. This AC input

 

to

to

voltage is applied to the primary of the main trans-

The fan is designed to come on automatically when

former. The main transformer converts the high

weld arc is established. The fan will stay on for a mini-

Return

Return

voltage, low current input power to a low voltage, high

mum of six minutes after the weld arc is terminated.

 

 

current output. In addition, the main transformer also

The fan will also stay on when the machine’s welding

 

 

has an isolated center tapped 30 VAC auxiliary winding

and feeding are disabled during thermostatic over-tem-

 

 

that supplies power to the Control Board for the SCR

perature protection. (See Thermal and Overload

 

 

 

Protection.)

Section TOC

Master TOC

 

to

to

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

Return

Return

 

POWER MIG 255C

 

 

Image 34
Contents Power MIG 255C Safety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents For ALL Sections Installation Table of Contents Installation SectionTechnical Specifications Power MIG 255C Input POWER, Grounding and Connection Diagrams Safety PrecautionsUncrating the Power MIG 255C LocationInstallation Figure A.2 Triple Voltage Machine Input Connections Auxiliary Power Receptacles GUN and Cable InstallationShielding GAS Table of Contents Operation Section OperationOPERATIONB-2 Wear eye, ear and body protec- tionWelding Capability Product DescriptionRecommended Processes and Equipment LimitationsWire Drive Roll Wire Size Conversion PartsDescription of Controls Wire Reel Loading Readi REELS, Spools or Coils Procedure for ChangingDrive and Idle Roll Sets Wire Drive Configuration Feeding Wire ElectrodeIdle Roll Pressure Setting To Start the WelderFigure B.4 Instructions to Enter Fast RUN-IN When Timer Option is not installedInstructions to Enter Slow RUN-IN Making a WeldFAN Control Avoiding Wire Feeding ProblemsWire Feed Overload Protection Input Line Voltage ProtectionWelding Thermal Overload Protection Overcurrent ProtectionAccessories Table of Contents Accessories SectionK363P READI-REEL Adapter Drive Roll KitsMagnum GUN Connection KIT Dual Cylinder Mounting KIT K1702-1K1738-1 Spool Gun Hanger Accessory Operating Instructions for Timer KITConnecting the Spool GUN to the Power MIG 255C Spool GUNMaking a Weld with the Prince XL Spool GUN Making a Weld with the Magnum SG Spool GUNSG Spool Gun Wire Feed Speed Power MIG Maintenance Table of Contents Maintenance SectionContact TIP and GAS Nozzle Installation GUN Tubes and Nozzles General MaintenanceGUN Cable Cleaning Liner Removal and ReplacementGUN Handle Disassembly Table D.1MAINTENANCED-4 English Metric DescriptionTable of Contents Theory of Operation Section Theory of OperationInput Line Voltage Main TransformerOutput Rectification Feedback ControlConstant Voltage Output Figure E.4 Constant Voltage OutputWire Drive Motor FeedbackWire Feed Overload Protection Thermal and Overload ProtectionSCR Operation Figure E.6 SCR OperationPower MIG 255C Troubleshooting and Repair Table of Contents Troubleshooting and Repair Section2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Troubleshooting Guide Output ProblemsTrolyte in these capacitors is Problems Possible AreasSymptoms Misadjustments Course of Action Toxic. Avoid contact with anyPerform the SCR Rectifier Function Problems Wire Feeding Problems Welding Problems Welding Problems Test Description Test ProceduresMain Transformer Test Materials NeededTest Procedure ON/OFF Power Switch will be hot during these tests115VAC 16J5 8J5206 3J5 Rectifier Diode Bridge Test 16TROUBLESHOOTING and REPAIRF-16 Figure F.2 G3521 Rectifier Diode Bridge Location208 206 28 VAC 209 354 206 36 VDCPower MIG 255C Static SCR Rectifier Assembly Test Static SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Power MIG 255C Active SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Figure F.7 Location Leads X2 Figure F.8 Wire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test 4J1Test for Supply Voltage to Tachometer 515B 206B 15 VDC 5J1 1J1Test for Feedback Voltage to Control Board 555 206B To 3.5 VDC 6J1 1J1Normal Open Circuit Voltage Waveform VoltsMachine Loaded to 250 Amps AT 26 VDC Scope Settings Typical Output Voltage Waveform Machine LoadedMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting and Repair Typical SCR Gate Voltage Waveform Power MIG 255C Control PC Board Removal and Replacement Component Replacement ProceduresDescription Removal and Replacement ProcedureFigure F.11 Control Board Mounting Power MIG 255C Wire Drive Assembly Removal and Replacement Wire Drive Assembly Removal and Replacement Procedure Power MIG 255C SCR Output Rectifier Removal and Replacement SCR Output Rectifier Removal and Replacement Figure F.15 Right Heat Sink Lead Disconnection Power MIG 255C Capacitor Bank Removal and Replacement Capacitor Bank Removal and Replacement Main Transformer and Output Choke Removal and Replacement 52TROUBLESHOOTING and REPAIRF-52 Main Transformer and Output ChokeTOC Power MIG 255C FAN Motor Assembly Removal and Replacement FAN Motor Assembly Removal and Replacement Open Circuit Voltage Wire Speed RangeRetest After Repair Input Volts/HertzPower MIG 255C Electrical Diagrams Section Section G-1Electrical Diagrams Wiring Diagram Entire Machine Code 11192 L12464Wiring Diagram Entire Machine Code 11218 L12506 Schematic Entire Machine G4752 Schematic Control PC Board G4823-2D1 Sheet Electrical Diagrams Electrical Diagrams PC Board Assembly Control G4824-2D1 Item Used with QTY Part Number DescriptionSchematic Display PC Board L10951 PowermigPC Board Assembly Display L10952 Lincoln Electric COSVM Error Reporting Form