Lincoln Electric SVM100-A Control Board G2150, PTC1,PTC2 THERMISTOR-PTC,56 OHMS,90MA

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ELECTRICAL DIAGRAMS

G-3

 

 

CONTROL BOARD (G2150)

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Item

Identification

X12

IC-VOLT REG,FIXED,3-T,(+),1A,5V

C22,C32

CAPACITOR-CEMO,22P,100V,5%

C51,C52,C53,C54,

CAPACITOR-CEMO,100P,100V,5%

C55,C56,C57,C58,

 

C59,C60,C82,C83,

 

C84,C85,C86

 

C5,C20,C25,C34,C41,

CAPACITOR-CEMO,.022,50V,20%

C73,C74,C76,C77

 

C19,C21

CAPACITOR-CEMO,150P,100V,5%

J7

CONNECTOR,MOLEX,MINI,PCB,4-PIN

J4

CONNECTOR,MOLEX,MINI,PCB,6-PIN

J1

CONNECTOR,MOLEX,MINI,PCB,8-PIN

PTC1,PTC2

THERMISTOR-PTC,56 OHMS,90MA

D1,D2,D3,D4,D5,D6,D7, DIODE-AXLDS,1A,400V

D18,D19,D20,D23,D24,

D25,D30,D34,D37,D38,

D39,D40,D41,D43,D44,

D45,D46,D47,D48,D49,

D50,D51,D52,D53,D54,

D55,D56,D57,D58,D59,

D71,D72,D73,D74,D75,

D76,D77,D78,D79,D80,

D81,D92,D99,D100,D101

L1

CHOKE-330UH,10%,110MA,MOLDED

L2,L3

CHOKE-390UH,5%,225MA,CONFORMAL

C16,C35

CAPACITOR-TAEL,18,15V,10%

C23,C44,C47,C48,C71

CAPACITOR-TAEL,1.0,35V,10%

C43

CAPACITOR-ALEL,20,50V,+75/-10%

C27,C28,C29,C30

CAPACITOR-TAEL,27,35V,10%

OCI1,OCI2,OCI3,

OPTOCOUPLER-PHOTO-Q,70V,

OCI4,OCI5,OCI6*

CNY17-3

X16

IC-VOLT REG,FIXED,3-T,(-),1A,15V

C3,C7,C10,C11,C12,

CAPACITOR-CEMO,0.1,50V,10%

C14,C15,C33,C38,

 

C45,C62,C69,C70,

 

C72,C75,C78,C81

 

J5

CONNECTOR,MOLEX,MINI,PCB,10-PIN

J8

CONNECTOR,MOLEX,MINI,PCB,12-PIN

J6

CONNECTOR,MOLEX,MINI,PCB,14-PIN

DZ1,DZ6,DZ7,DZ10

ZENER DIODE-1W,30V,5%,1N4751A

DZ4,DZ5,DZ8,DZ9

ZENER DIODE-1W,18V,5%,1N4746A

Q1,Q3,Q5,Q8,Q10,

TRANSISTOR-N,T226,0.5A,40V,2N4401

Q11,Q13,Q14,Q16,Q17

 

Q2,Q4,Q6,Q12

TRANSISTOR-NMF,4PDIP,1A,100V,

 

RFD110

D42

DIODE-AXLDS,1A,30V,SCHOTTKY

ItemIdentification

C42CAPACITOR-ALEL,1000,35V,+30/-20% R14,R17,R18,R21,R24, RESISTOR-MF,1/4W,100,1% R26,R109,R154,R155,

R156,R157,R158,R159,

R160,R162,R163,R168,

R169,R170,R171,R182,

R183*

R20,R25,R41,R56,R57, RESISTOR-MF,1/4W,1.00K,1% R68,R69,R74,R77,R84,

R87,R91,R92,R93,R94,

R112,R113,R114,R115,

R118,R120,R123,R124,

R127,R129,R140,R144,

R214,R225,R226,R227,

R228,R229

R9,R22,R49,R76,R122, RESISTOR-MF,1/4W,10.0K,1% R125,R128,R172,R187,

R211,R223,R224*

R39,R44,R67,R199,

RESISTOR-MF,1/4W,100K,1%

R222,R236

 

R38,R54,R55,R71

RESISTOR-MF,1/4W,1.00M,%

R51,R52

RESISTOR-MF,1/4W,150,1%

R72,R85

RESISTOR-MF,1/4W,1.50K,1%

R137

RESISTOR-MF,1/4W,15.0K,1%

R50,R101,R134,R212

RESISTOR-MF,1/4W,2.21K,1%

R27,R63,R142

RESISTOR-MF,1/4W,221K,1%

R12,R23,R64,R106, RESISTOR-MF,1/4W,267,1% R107,R108,R181,R184,

R185

R34RESISTOR-MF,1/4W,2.67K,1%

R138,R139RESISTOR-MF,1/4W,26.7,1% R88,R143,R146,R147, RESISTOR-MF,1/4W,3.32K,1% R148,R149,R150,R151,

R152,R153,R166,R167

R141RESISTOR-MF,1/4W,33.2K,1%

R73,R75,R82,R83, RESISTOR-MF,1/4W,475,1% R102,R103,R104*

R42,R48,R53,R66, RESISTOR-MF,1/4W,4.75K,1% R79,R81,R97,R130,

R131,R132,R201,R202,

R203,R204,R205,R206,

R207,R208,R209,R210,

R213,R215,R216,R217,

R218

R28,R29,R30,R31, RESISTOR-MF,1/4W,47.5K,1% R32,R40

R16,R19,R43,R65, RESISTOR-MF,1/4W,475K,1% R70,R116,R136,R200

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NOTE: Lincoln Electric assumes no responsibility for liabilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not avail- able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

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 Supply Connections Input ConnectionsGround Connection TIG Torch Connection Reconnect ProcedureOutput Connections 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 GuidelinesSquare 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 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 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
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