Lincoln Electric SVM100-A Troubleshooting & Repair, PC Board Troubleshooting Procedures

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TROUBLESHOOTING & REPAIR

F-2

PC BOARD TROUBLESHOOTING PROCEDURES

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WARNING

ELECTRIC SHOCK can kill.

Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.

CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replac- ing PC boards, please use the following procedure:

1.Determine to the best of your technical ability that the PC board is the most like- ly component causing the failure symp- tom.

2.Check for loose connections at the PC board to assure that the PC board is properly connected.

3.If the problem persists, replace the sus- pect PC board using standard practices to avoid static electrical damage and electrical shock. (Read the warning inside the static resistant bag.)

NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

4.Test the machine to determine if the fail- ure symptom has been corrected by the replacement PC board.

NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

5.Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.

a.If the original problem does not reap- pear by substituting the original board, then the PC board was not the prob- lem. Continue to look for bad connec- tions in the control wiring harness, junction blocks, and terminal strips.

b.If the original problem is recreated by the substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.

6.Always indicate that this procedure was followed when warranty reports are to be submitted.

NOTE: Following this procedure and writ- ing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legiti- mate PC board warranty claims.

SQUARE WAVE TIG 255

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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 LocationGround Connection Input ConnectionsInput Supply Connections Output Connections Reconnect ProcedureTIG Torch Connection 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 OperationTable 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 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 Operation Thermal 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 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 Figure F.1 Control Board Connectors PC Board Connector LocationsTest Description Control Transformer T2 Voltage TestMaterials Needed 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 50 Amps AT 26VAC AC TIG Mode Auto Balance onMachine Loaded to 200 Amps AT 46 VAC 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 Input Idle Amps Retest After RepairRecommended Meters for Machine Output Tests 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