Lincoln Electric SVM100-A TIG Welding Sequence Operation 2-STEP Mode, Square Wave TIG 255 12/95

Page 22

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B-9

 

 

 

 

 

OPERATION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE B.2

 

 

 

(2)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AC

 

 

 

Approximate Argon

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Gas Flow Rate

 

 

 

 

 

 

 

 

DCEN ( - )

DCEP ( + )

Unbalanced Wave

 

Balanced Wave

 

 

C.F.H. (1/min.)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Tungsten

 

 

 

 

 

1%, 2%

 

 

1%, 2%

 

 

 

 

 

 

 

 

 

Electrode

 

1%, 2%

1%, 2%

 

 

Thoriated

 

 

Thoriated

 

 

 

 

 

TIG Torch

 

 

Diameter

 

Thoriated

Thoriated

Pure

 

Tungsten

 

Pure

Tungsten

 

 

 

Stainless

Nozzle

 

 

in. (mm)

 

Tungsten

Tungsten

Tungsten

 

Zirconiated

 

Tungsten

Zirconiated

 

Aluminum

Steel

Size (4), (5)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

.010

(.25)

 

2-15

(3)

2-15

 

2-15

 

2-15

---

3-8

(2-4)

3-8

(2-4)

#4, #5, #6

 

 

0.020

(.50)

 

5-20

(3)

5-15

 

5-20

 

10-20

5-20

5-10

(3-5)

5-10

(3-5)

 

 

 

 

0.040

(1.0)

 

15-80

10-60

 

15-80

 

20-30

20-60

5-10

(3-5)

5-10

(3-5)

 

 

 

 

 

(3)

 

 

 

 

 

 

1/16

(1.6)

 

70-150

10-20

50-100

 

70-150

 

30-80

60-120

5-10 (3-5)

9-13 (4-6)

#5, #6

 

 

3/32

(2.4)

 

150-250

15-30

100-160

 

140-235

 

60-130

100-180

13-17 (6-8)

11-15 (5-7)

#6, #7, #8

 

 

1/8

(3.2)

 

250-400

25-40

150-210

 

225-325

 

100-180

160-250

15-23 (7-11)

11-15 (5-7)

 

 

 

 

5/32

(4.0)

 

400-500

40-55

200-275

 

300-400

 

100-240

200-320

21-25 (10-12)

13-17 (6-8)

#8, #10

 

 

3/16

(4.8)

 

500-750

55-80

250-350

 

400-500

 

190-300

290-390

23-27 (11-13)

18-22 (8-10)

 

 

 

 

1/4

(6.4)

 

750-1000

80-125

325-450

 

500-630

 

250-400

340-525

28-32 (13-15)

23-27(11-13)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(1)When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gasses.

(2)Tungsten electrodes are classified as follows by the American Welding Society (AWS): Pure . . . . . . . . . . . . . . . EWP

1% Thoriated . . . . . . . . EWTh-1 2% Thoriated . . . . . . . . EWTh-2

Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.

(3)DCEP is not commonly used in these sizes.

(4)TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:

#4

= 1/4 in.

(6 mm)

#5

= 5/16 in.

(8 mm)

#6

= 3/8 in.

(10 mm)

#7

= 7/16 in.

(11 mm)

#8

= 1/2 in.

(12.5 mm)

#10

= 5/8 in.

(16 mm)

(5)TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot with- stand high temperatures and high duty cycles.

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TIG WELDING SEQUENCE OF

OPERATION (2-STEP MODE)

In TIG 2-Step Mode the welding arc is established by depressing the Arc Start Switch or Amptrol (Step 1). Output continues as long as the switch or Amptrol is depressed. Releasing the switch or Amptrol (Step 2) turns off the arc. Hence the name 2-Step Mode.

1.Connect an Arc Start Switch or an Amptrol to the Remote Receptacle.

2.Turn on the welder, gas supply and water supply (if so equipped). The Control Panel Display and red LEDS will illuminate when the power is on.

3.Select the TIG 2-Step Weld Mode.

4.Select Local (if using an Arc Start Switch) or Remote (if using an Amptrol) current control. Set the output current using the Amps Up/Down keys. The output current setting will be displayed on the Ammeter.

5.Select Continuous High Frequency if welding with AC polarity, or Start Only High Frequency if welding with DC- polarity. High Frequency Off can be used for scratch start welding.

6.Select AC or DC- electrode polarity. See Table B.1.

7.If welding with AC polarity, select Auto Balance™. This gives the optimum ratio between cleaning and penetration, automatically adjusted for the output current. If manual adjustment of the AC Wave Balance is desired, select Manual Balance, and adjust the wave balance with the Cleaning and Penetration keys. See the Advanced Features section for more information on setting and using the AC Wave Balance.

8.Select TIG Pulser On or Off. If the TIG Pulser is on, adjust the pulse frequency with the Pulses Per Second Up/Down keys. See the Advanced Features section for more information on setting and using the TIG Pulser.

SQUARE WAVE TIG 255 12/95

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Contents Square Wave TIG ARC Rays can burn SafetyElectric Shock can kill Fumes and Gases can be dangerousCylinder may explode if damaged Welding Sparks can cause fire or explosionElectric and Magnetic Fields May be dangerousPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionInstallation Technical Specifications Square Wave TIGSelect Suitable Location Safety PrecautionsHigh Frequency Interference Protection StackingGround Connection Input ConnectionsInput Supply Connections Output Connections Reconnect ProcedureTIG Torch Connection Table A.1 Stick Electrode Cable ConnectionOperation Section General Warnings OperationOperating Instructions Fumes and GasesSection TOC Work Connec Polarity Do not Switch AC & DC Recti Fier Power SourceWhile Weld ING TIG Gtaw Single Phase Coolant Tion OutputGeneral Description Design Features AdvantagesOperational Features and Controls Recommended Processes and EquipmentWelding Capability LimitationsControls and Settings Control Panel KeysCase Front Controls LoadHand and Foot Amptrol Welding Operation Accessory Operation TIG WeldingTable B.1 Recommended Polarity Settings for TIG Welding TIG Welding GuidelinesTable B.2 Typical Current Ranges 1 for Tungsten Electrodes TIG Welding Sequence Operation 2-STEP ModeSquare Wave TIG 255 12/95 TIG Welding Sequence Operation 4-STEP Mode ALL Machines Auxiliary PowerAdvanced TIG Welding Features AC Wave Balance and Auto BalanceOverload Protection Square Wave TIG Accessories Section Installation of Field Installed Options AccessoriesOptions / Accessories Undercarriage FunctionMaintenance Section Routine and Periodic Maintenance MaintenanceMaintenance Safety PrecautionsFigure D.1 General Assembly Exploded View Square Wave TIG Power Supply Block Logic Diagram Theory of Operation SectionTheory of Operation Input Line Voltage and Main TransformerOutput Rectification and Feedback Control High Voltage / High Frequency Circuit DC Welding Output DC Welding CircuitAC Welding Output AC Welding CircuitSCR Operation SCR Operation Square Wave TIGThermal Protection Troubleshooting & Repair Section 1TROUBLESHOOTING & Repair HOW to USE Troubleshooting GuideTroubleshooting & Repair PC Board Troubleshooting ProceduresTroubleshooting Guide Output Problems12/95 Square Wave TIG Troubleshooting & Repair Possible Areas of Misadjustments Problems SymptomsRecommended Course of Action Function Problems Troubleshooting Guide Troubleshooting & Repair TIG Mode Problems Troubleshooting & Repair Troubleshooting Guide TIG Welding Problems Troubleshooting & Repair Stick Welding Problems PC Board Connector Locations Figure F.1 Control Board ConnectorsTest Description Control Transformer T2 Voltage TestMaterials Needed Test Procedure Control BOXControl Transformer T2 Voltage Test Figure F.4 Control Board and TransformerPROTECTION/SNUBBER Board Continuity Test PROTECTION/SNUBBER Board Continuity Test Figure F.6 PROTECTION/SNUBBER Board Test Points Table F.6 Square Wave TIGARC Start Trigger Circuit Test ARC Start Trigger Circuit Test Figure F.9 PROTECTION/SNUBBER Board Test Points Static SCR Test Static SCR Test Figure F.11 Protection Board Plug LocationsActive SCR Test Active SCR Test Figure F.13 PROTECTION/SNUBBER Board Plug LocationsBattery Test Silicon Controlled Rectifier TestNormal Open Circuit Voltage Waveform DC Stick Mode Scope SettingsNormal Open Circuit Voltage Waveform AC Stick Mode Normal Open Circuit Voltage Waveform DC TIG Mode Normal Open Circuit Voltage Waveform AC TIG Mode Typical Output Voltage Waveform Machine Loaded DC TIG Mode Machine Loaded to 200 Amps AT 50 VDCMachine Loaded to 50 Amps AT 26VAC AC TIG Mode Auto Balance onMachine Loaded to 200 Amps AT 46 VAC Volts 5ms Typical SCR Gate Voltage WaveformVolts 2ms Troubleshooting & Repair FAN Motor and Blade Removal Tools RequiredFAN Motor and Blade Removal SCR Heat Sink Assembly Removal Materials RequiredSCR Heat Sink Assembly Removal Input Idle Amps Retest After RepairRecommended Meters for Machine Output Tests Retest After Repair cont’d Figure F.16 Transformer Lead Test PointsElectrical Diagrams Electrical Diagrams Control Board G2150 PTC1,PTC2 THERMISTOR-PTC,56 OHMS,90MAControl Board G2150 cont’d Square Wave TIG PROTECTION/SNUBBER Board L9255 CAPACITOR-CEMO,4700P,50V,10% Square Wave TIG Wiring Diagram Square Wave TIG Machine Schematic Square Wave TIG 6 a 0 a 7 a 8 a 3 CG2150 A C C TControl Board Schematic Square Wave TIG 255 cont’d G2150 Y P a DPROTECTION/SNUBBER Board Schematic Square Wave TIG 255 L9255 Keypad LED Board Square Wave TIG 255 L9212