Lincoln Electric SVM100-A service manual Output Rectification and Feedback Control

Page 35

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THEORY OF OPERATION

E-2

OUTPUT RECTIFICATION AND FEEDBACK CONTROL

 

 

 

 

POLARITY

 

 

BY-PASS

 

 

 

 

 

 

BOARD

 

 

 

 

SWITCH

 

 

 

 

 

 

 

 

WORK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HI-FREQ

 

 

 

 

 

 

 

 

TRANSFORMER

LINE

 

 

 

 

 

 

 

ELECTRODE

MAIN

 

 

 

 

 

 

 

SWITCH

 

 

 

 

 

 

 

TRANSFORMER

 

 

 

 

 

 

 

R

X2

 

AC

DC+

 

 

 

E

 

SHUNT

 

 

 

 

SCR

 

 

C

 

 

 

 

 

 

 

 

 

BRIDGE

 

 

 

O

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

N

 

 

 

 

 

 

 

 

E

X1

 

AC

DC-

 

 

 

C

 

 

CHOKE

 

 

T

 

 

 

 

 

 

 

 

SIGNALSGATE

 

 

 

 

 

 

POWER

 

 

 

 

 

 

FEEDBACK

 

 

 

 

 

 

 

 

FACTOR

 

 

 

 

 

 

 

 

CAPACITORS

 

 

 

 

 

 

 

 

 

 

 

ARC START

 

 

LCD DISPLAY

 

 

 

 

 

 

 

 

 

115VAC

PROTECTION

115 VAC

CONTROL

KEYPAD

FAN

 

 

 

SNUBBER

 

GATE SIGNALS

BOARD

 

LED

 

 

BOARD

 

 

BOARD

 

 

 

 

 

 

 

 

 

 

 

 

HI-FREQ

 

 

KEYPAD

 

 

 

 

 

115 VAC

 

 

 

 

115

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

VAC

 

 

24 VAC

 

 

 

 

 

 

CONTROL

18 VAC

 

 

 

115 VAC

 

 

TRANSFORMER

 

 

 

 

 

16 VAC

 

 

 

 

 

 

 

 

 

RECEPTACLE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

115 VAC

 

HIGH VOLTAGE

HIGH FREQUENCY SPARK

 

 

 

TRANSFORMER

 

REMOTE

 

 

 

 

 

 

 

 

 

CIRCUIT

 

 

 

RECEPTACLE

 

 

 

 

 

 

 

 

 

 

 

 

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The AC output from the main transformer secondary is rectified and controlled through the SCR bridge. Output current is sensed at the shunt, as a low volt- age signal, and fed back to the control board. The control board compares the commands of the keypad (or remote control) with the shunt feedback signal. The appropriate gate firing pulses are generated by

the control board and applied to the SCR bridge through the protection / snubber board. The control board controls the firing of the SCRs, thus controlling the output of the machine. See SCR Operation. The control board also powers and commands the keypad LED board and the display board.

SQUARE WAVE TIG 255

Image 35
Contents Square Wave TIG Fumes and Gases can be dangerous SafetyElectric Shock can kill ARC Rays can burnWelding Sparks can cause fire or explosion Cylinder may explode if damagedMay be dangerous Electric and Magnetic FieldsSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Section Table of ContentsTechnical Specifications Square Wave TIG InstallationStacking Safety PrecautionsHigh Frequency Interference Protection Select Suitable LocationInput Supply Connections Input ConnectionsGround Connection TIG Torch Connection Reconnect ProcedureOutput Connections Stick Electrode Cable Connection Table A.1Operation Section Fumes and Gases OperationOperating Instructions General WarningsSection TOC Coolant Tion Output Polarity Do not Switch AC & DC Recti Fier Power SourceWhile Weld ING TIG Gtaw Single Phase Work ConnecRecommended Processes and Equipment Design Features AdvantagesOperational Features and Controls General DescriptionLimitations Welding CapabilityControl Panel Keys Controls and SettingsLoad Case Front ControlsTIG Welding Guidelines Accessory Operation TIG WeldingTable B.1 Recommended Polarity Settings for TIG Welding Hand and Foot Amptrol Welding OperationSquare Wave TIG 255 12/95 TIG Welding Sequence Operation 2-STEP ModeTable B.2 Typical Current Ranges 1 for Tungsten Electrodes TIG Welding Sequence Operation 4-STEP Mode AC Wave Balance and Auto Balance Auxiliary PowerAdvanced TIG Welding Features ALL MachinesOverload Protection Square Wave TIG Accessories Section Undercarriage Function AccessoriesOptions / Accessories Installation of Field Installed OptionsMaintenance Section Safety Precautions MaintenanceMaintenance Routine and Periodic MaintenanceFigure D.1 General Assembly Exploded View Square Wave TIG Theory of Operation Section Power Supply Block Logic DiagramInput Line Voltage and Main Transformer Theory of OperationOutput Rectification and Feedback Control High Voltage / High Frequency Circuit DC Welding Circuit DC Welding OutputAC Welding Circuit AC Welding OutputSCR Operation Square Wave TIG SCR OperationThermal Protection Troubleshooting & Repair Section HOW to USE Troubleshooting Guide 1TROUBLESHOOTING & RepairPC Board Troubleshooting Procedures Troubleshooting & RepairOutput Problems Troubleshooting Guide12/95 Square Wave TIG Troubleshooting & Repair Recommended Course of Action Problems SymptomsPossible Areas of Misadjustments Function Problems Troubleshooting Guide Troubleshooting & Repair TIG Mode Problems Troubleshooting & Repair Troubleshooting Guide TIG Welding Problems Troubleshooting & Repair Stick Welding Problems Figure F.1 Control Board Connectors PC Board Connector LocationsMaterials Needed Control Transformer T2 Voltage TestTest Description Control BOX Test ProcedureFigure F.4 Control Board and Transformer Control Transformer T2 Voltage TestPROTECTION/SNUBBER Board Continuity Test PROTECTION/SNUBBER Board Continuity Test Table F.6 Square Wave TIG Figure F.6 PROTECTION/SNUBBER Board Test PointsARC Start Trigger Circuit Test ARC Start Trigger Circuit Test Figure F.9 PROTECTION/SNUBBER Board Test Points Static SCR Test Figure F.11 Protection Board Plug Locations Static SCR TestActive SCR Test Figure F.13 PROTECTION/SNUBBER Board Plug Locations Active SCR TestSilicon Controlled Rectifier Test Battery TestScope Settings Normal Open Circuit Voltage Waveform DC Stick ModeNormal Open Circuit Voltage Waveform AC Stick Mode Normal Open Circuit Voltage Waveform DC TIG Mode Normal Open Circuit Voltage Waveform AC TIG Mode Machine Loaded to 200 Amps AT 50 VDC Typical Output Voltage Waveform Machine Loaded DC TIG ModeMachine Loaded to 200 Amps AT 46 VAC AC TIG Mode Auto Balance onMachine Loaded to 50 Amps AT 26VAC Typical SCR Gate Voltage Waveform Volts 5msVolts 2ms Troubleshooting & Repair Tools Required FAN Motor and Blade RemovalFAN Motor and Blade Removal Materials Required SCR Heat Sink Assembly RemovalSCR Heat Sink Assembly Removal Recommended Meters for Machine Output Tests Retest After RepairInput Idle Amps Figure F.16 Transformer Lead Test Points Retest After Repair cont’dElectrical Diagrams Electrical Diagrams PTC1,PTC2 THERMISTOR-PTC,56 OHMS,90MA Control Board G2150Control Board G2150 cont’d Square Wave TIG PROTECTION/SNUBBER Board L9255 CAPACITOR-CEMO,4700P,50V,10% Square Wave TIG Wiring Diagram Square Wave TIG 6 a 0 a 7 a 8 a 3 C Machine Schematic Square Wave TIGA C C T G2150Y P a D Control Board Schematic Square Wave TIG 255 cont’d G2150PROTECTION/SNUBBER Board Schematic Square Wave TIG 255 L9255 Keypad LED Board Square Wave TIG 255 L9212