Lincoln Electric SVM 119-A service manual Figure E.4 Constant Voltage Output

Page 46

E-3

THEORY OF OPERATION

E-3

 

 

to Section TOC

to Master TOC

 

CONSTANT VOLTAGE OUTPUT

 

 

 

 

 

 

Return

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WIRE

GAS

 

 

 

 

SPEED

SOLENOID

 

 

 

 

 

 

 

WIRE

 

 

 

 

 

 

 

DRIVE

 

 

 

ARC

 

 

 

MOTOR

 

 

 

VOLTAGE

 

 

 

 

 

 

 

CONTROL BOARD

 

 

 

 

 

 

 

G

 

 

TACH

 

 

 

 

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

T

 

GUN TRIGGER AND THUMB SWITCH

 

 

LINE

MAIN

E

 

 

 

S

 

 

 

 

 

TRANSFORMER

 

 

 

 

 

SWITCH

I

 

 

FEEDBACK

 

 

 

 

G

 

 

 

 

 

 

N

 

 

 

TOC

 

 

 

A

 

 

 

TOC

 

 

L

 

 

 

 

RECONNECT

 

 

 

POSITIVE

 

 

 

 

 

Section

Master

 

 

 

 

 

 

 

 

 

 

TERMINAL

 

 

 

C

 

CHOKE

 

 

 

 

 

 

 

 

A

F

 

 

 

 

P

E

 

 

 

 

A

E

 

to

to

 

 

 

 

 

 

 

C

D

 

 

SCR

I

B

 

Return

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RECTIFIER

T

A

 

 

 

 

O

C

 

 

FAN

 

R

K

NEGATIVE

 

 

S

 

 

MOTORS

 

 

TERMINAL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SHUNT

 

Figure E.4 - Constant Voltage Output.

TOC

TOC

CONSTANT VOLTAGE OUTPUT

Section

Master

The controlled DC output from the SCR rectifier

 

 

to

to

assembly is filtered by the capacitor bank resulting is a

constant voltage DC output. Since the output choke is

Return

Return

in series with the positive leg of the rectifier and also in

 

 

 

 

series with the gun and welding load, a filtered con-

 

 

stant voltage output is applied to the output terminals

 

 

of the machine.

Section TOC

Master TOC

 

to

to

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

Return

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WIRE-MATIC 255

 

 

Image 46
Contents WIRE-MATIC Safety Depends on YouARC Rays can burn SafetyElectric Shock can kill Fumes and Gases can be dangerousCylinder may explode if damaged Welding Sparks can cause fire or explosionMay be dangerous Electric and MAG- Netic FieldsIii Précautions DE Sûreté Sûreté Pour Soudage a L’ArcWIRE-MATIC Table of Contents Table of Contents Installation Table of Contents Installation SectionTechnical Specifications Wire-Matic-255 Input Connections Safety PrecautionsSelect Proper Location StackingFuse and Wire Sizes Connect Shielding GAS Reconnect Procedure Figure A.4 Input Gas Supply ConnectionsFigure A.5 Reconnect Diagram For 208/230/1/60 Machines Connect Output Components ConnectionsWire Size Conversion Parts GUN and Cable InstallationWIRE-MATIC Table of Contents Operation Section OperationGeneral Description Safety InstructionsWELDING, Cutting Design Features Advantages Recommended Processes and EquipmentLimitations Machine CapabilityDuty Cycle Amps Volts Controls and Settings Figure B.1 Operator ControlsUsing the Wire Drive Roll Figure B.2 Wire Reel LoadingFeeding Electrode Setting Idle Roll Pressure Operating StepsMaking a Weld WIRE-MATIC Accessories Table of Contents Accessories SectionMagnum GUN Connection KIT Optional K466-6 OPTIONS/ACCESSORIESK672-1 Spool GUN Adapter KIT Making a Weld with the Spool GUN Adapter K672-1 Installed Timer KIT K585-1 Timer KIT Installation Optional K585-1K468 8 Spool Adapter Drive Roll Kits64 1.2mm Aluminum Feeding KIT K673-1 K363P READI-REEL AdapterDual Cylinder Mounting KIT K671-1 Maintenance Table of Contents Maintenance SectionRoutine and Periodic Maintenance Perform the following dailyMaintenance Drive Rolls and Guide Tubes Cable CleaningContact TIP and GAS Nozzle Installation GUN Tubes and NozzlesLiner Removal Replacement Figure D.2 Liner maintenanceGUN Handle Disassembly To open up the handleDescription English Size Metric Size WIRE-MATIC Table of Contents Theory of Operation Section Theory of OperationInput Line Voltage and Main TransformerOutput Rectification Feedback ControlConstant Voltage Output Figure E.4 Constant Voltage OutputWire Drive Motor FeedbackThermal Protection SCR Operation Figure E.6 SCR OperationWIRE-MATIC Troubleshooting & Repair Table of Contents Troubleshooting & Repair SectionHOW to USE Troubleshooting Guide Recommended Course of ActionElectric Shock can kill PC Board Troubleshooting ProceduresBoard can be dam- aged by static electricity Main Transformer Rectifier Assembly Test To Section TOC SCR Rectifier Perform the Wire Drive Motor Liquid elec Trolyte in these capacitors isPerform the Output Rectifier Test Description Main Transformer TestMaterials Needed Main Transformer Test Test Procedure ON/OFF Power Switch will be hot during these testsLead Plug Location Static SCR Rectifier Assembly Test Leads Figure F.4 SCR 1 Test Points Active SCR Rectifier Assembly Test Leads Figure F.7 SCR Tester Circuit SCR connectionsWire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test Procedure Test for Supply Voltage to Tachometer Test for Feedback Voltage to the Control BoardScope Settings Normal Open Circuit Voltage WaveformMachine 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 & Repair Typical SCR Gate Voltage Waveform Control PC Board Removal and Replacement Removal and Replacement ProcedureRemoval and REPLACE- Ment Procedure Wire Drive Assembly Removal and Replacement Procedure Figure F.11 Wire Drive Assembly RemovalSCR Output Rectifier Removal & Replacement Right side heat sink See Figure F.14 Disconnection Heat Sink LeadCapacitor Bank Removal and Replacement Bank Removal Replacement ComponentsMain Transformer Removal and Replacement Power Switch FAN Motor and FAN Removal and Replacement FAN Motor and FAN Removal and Replacement Procedure Figure F.16 Fan Motor and Fan Removal ComponentsTroubleshooting & Repair Input Volts/Hertz Wire Speed RangeOpen Circuit Voltage 230/60 375WIRE-MATIC Table of Contents Electrical Diagrams Section WIRE-MATIC Electrical Diagrams Wiring Diagram 208/230 CodeWire Matic 255 230 / 460 Wiring Diagram 230/460/575 CodeControl PC Board G2803 Schematic Wirematic 255 Control Control PC Board G2803 Layout