Lincoln Electric SVM100-A service manual 12/95 Square Wave TIG

Page 45

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TROUBLESHOOTING & REPAIR

 

F-4

 

Observe Safety Guidelines

 

 

TROUBLESHOOTING GUIDE

 

detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

 

 

 

 

(SYMPTOMS)

 

 

MISADJUSTMENT(S)

 

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

 

 

 

The voltmeter reads “00” in Stick

 

 

1. Inspect to assure that the arc

 

 

1.

Check for loose connectors at

 

 

 

Mode, and there is no output from

 

 

start switch is in the on

 

 

 

the SCR bridge and at the

 

 

 

 

the machine when in the TIG

 

 

(closed) position when

 

 

 

Protection/Snubber board. (J10)

 

 

 

2-Step Mode.

 

 

welding in the TIG Mode.

 

 

 

and (J11). See Figure F.2 at

 

 

 

 

 

 

 

 

 

 

 

 

end of this Guide for location.

 

 

 

 

 

 

 

 

 

 

2.

Check the wiring to the Control

 

 

 

 

 

 

 

 

 

 

 

Transformer (T2). Observe

 

 

 

 

 

 

 

 

 

 

 

 

directions on decal.

 

 

 

 

 

 

 

 

 

 

 

3.

The Protection/Snubber board

 

 

 

 

 

 

 

 

 

 

 

may be faulty. See

 

 

 

 

 

 

 

 

 

 

 

 

Protection/Snubber Board

 

 

 

 

 

 

 

 

 

 

 

 

Continuity Test.

 

 

 

 

 

 

 

 

 

 

 

4.

Check the Control Transformer

 

 

 

 

 

 

 

 

 

 

 

(T2). See Control Transformer

 

 

 

 

 

 

 

 

 

 

 

Voltage Test.

 

 

 

 

 

 

 

 

 

 

 

5.

Check the polarity switch (S2)

 

 

 

 

 

 

 

 

 

 

 

for loose or broken connections.

 

 

 

 

 

 

 

 

 

 

6.

Check the SCR bridge. See

 

 

 

 

 

 

 

 

 

 

 

 

Static and Active SCR Tests.

 

 

 

 

 

 

 

 

 

 

 

7.

If all previous tests are OK -

 

 

 

 

 

 

 

 

 

 

 

 

then replace the Control board.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Machine does not respond (no gas

 

 

1. Machine MUST be in one of

 

 

1.

Check trigger circuit. See Arc

 

 

 

flow, no high frequency and no

 

 

the TIG Modes.

 

 

 

Start Trigger Circuit Test

 

 

 

 

open circuit voltage) when arc

 

 

 

 

 

2.

Check the Control transformer

 

 

 

switch or amptrol is activated -

 

 

2. The arc start switch or amptrol

 

 

 

 

 

displays and fan working. Note:

 

 

may be defective. Check for

 

 

 

(T2). See Control Transformer

 

 

 

Machine may have OCV in the

 

 

continuity between pins “D”

 

 

 

Voltage Test.

 

 

 

 

Stick Mode.

 

 

and “E” on cable connector

 

 

3.

Protection/Snubber board may

 

 

 

 

 

 

 

when arc switch or amptrol is

 

 

 

 

 

 

 

 

 

activated.

 

 

 

be faulty. See

 

 

 

 

 

 

 

 

 

 

 

 

Protection/Snubber Board

 

 

 

 

 

 

 

 

 

 

 

 

Continuity Test.

 

 

 

 

 

 

 

 

 

 

 

4.

If all previous tests are OK -

 

 

 

 

 

 

 

 

 

 

 

 

then replace the Control board.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.

12/95 SQUARE WAVE TIG 255

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Contents Square Wave TIG Electric Shock can kill SafetyARC Rays can burn Fumes and Gases can be dangerousWelding 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 InstallationHigh Frequency Interference Protection Safety PrecautionsSelect Suitable Location StackingInput Connections Ground ConnectionInput Supply Connections Reconnect Procedure Output ConnectionsTIG Torch Connection Stick Electrode Cable Connection Table A.1Operation Section Operating Instructions OperationGeneral Warnings Fumes and GasesSection TOC While Weld ING TIG Gtaw Single Phase Polarity Do not Switch AC & DC Recti Fier Power SourceWork Connec Coolant Tion OutputOperational Features and Controls Design Features AdvantagesGeneral Description Recommended Processes and EquipmentLimitations Welding CapabilityControl Panel Keys Controls and SettingsLoad Case Front ControlsTable B.1 Recommended Polarity Settings for TIG Welding Accessory Operation TIG WeldingHand and Foot Amptrol Welding Operation TIG Welding GuidelinesTIG Welding Sequence Operation 2-STEP Mode Table B.2 Typical Current Ranges 1 for Tungsten ElectrodesSquare Wave TIG 255 12/95 TIG Welding Sequence Operation 4-STEP Mode Advanced TIG Welding Features Auxiliary PowerALL Machines AC Wave Balance and Auto BalanceOverload Protection Square Wave TIG Accessories Section Options / Accessories AccessoriesInstallation of Field Installed Options Undercarriage FunctionMaintenance Section Maintenance MaintenanceRoutine and Periodic Maintenance Safety PrecautionsFigure 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 Problems Symptoms Possible Areas of MisadjustmentsRecommended 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 LocationsControl Transformer T2 Voltage Test Test DescriptionMaterials 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 ModeAC TIG Mode Auto Balance on Machine Loaded to 50 Amps AT 26VACMachine 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 Retest After Repair Input Idle AmpsRecommended 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