Lincoln Electric SVM100-A instruction

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MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page
Safety						i-iv

				Installation		Section A
					Technical Specifications	A-1
					Location	A-2
					High Frequency Interference Protection	A-2
					Input Connections	A-3
					Output Connections	A-4

Operation						Section B
					Safety Precautions	B-1
					Graphic Symbols	B-2 – B-3
					General Description	B-4
					Design Features and Advantages	B-4
					Welding Capability	B-5
					Limitations	B-5
					Controls and Settings	B-6
					Hand and Foot Amptrol Operation	B-8
					Welding Operation	B-8 – B-11
					Auxillary Power	B-11
					Overload Protection	B-12

Accessories						Section C

Maintenance						Section D
					Safety Precautions	D-1
					Routine and Periodic Maintenance	D-1
					General Assembly Exploded View	D-2

Theory of Operation						Section E
					Power Supply Operation	E1 – E-5
					SCR Operation	E-6
					Thermal Protection	E-7

Troubleshooting and Repair						Section F
					How To Use Troubleshooting Guide	F-1
					PC Board Troubleshooting Procedures	F-2
					Troubleshooting Guide	F-3 – F-15
					Test Procedures	F-17 – F-28
					Oscilloscope Waveforms	F-31 – F-39
					Replacement Procedures	F-40 – F-42
					Re-Test After Repair	F-44

Electrical Diagrams						Section G

Parts Manual						P-241

SQUARE WAVE TIG 255

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Lincoln Electric SVM100-A service manual Master Table of Contents for ALL Sections

Contents

Square Wave TIG ARC Rays can burn SafetyElectric Shock can kill Fumes and Gases can be dangerous Cylinder may explode if damaged Welding Sparks can cause fire or explosion Electric and Magnetic Fields May be dangerous Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Square Wave TIG Select Suitable Location Safety PrecautionsHigh Frequency Interference Protection Stacking Input Connections Ground ConnectionInput Supply Connections Reconnect Procedure Output ConnectionsTIG Torch Connection Table A.1 Stick Electrode Cable Connection Operation Section General Warnings OperationOperating Instructions Fumes and Gases Section TOC Work Connec Polarity Do not Switch AC & DC Recti Fier Power SourceWhile Weld ING TIG Gtaw Single Phase Coolant Tion Output General Description Design Features AdvantagesOperational Features and Controls Recommended Processes and Equipment Welding Capability Limitations Controls and Settings Control Panel Keys Case Front Controls Load Hand and Foot Amptrol Welding Operation Accessory Operation TIG WeldingTable B.1 Recommended Polarity Settings for TIG Welding TIG Welding Guidelines TIG 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 ALL Machines Auxiliary PowerAdvanced TIG Welding Features AC Wave Balance and Auto Balance Overload Protection Square Wave TIG Accessories Section Installation of Field Installed Options AccessoriesOptions / Accessories Undercarriage Function Maintenance Section Routine and Periodic Maintenance MaintenanceMaintenance Safety Precautions Figure D.1 General Assembly Exploded View Square Wave TIG Power Supply Block Logic Diagram Theory of Operation Section Theory of Operation Input Line Voltage and Main Transformer Output Rectification and Feedback Control High Voltage / High Frequency Circuit DC Welding Output DC Welding Circuit AC Welding Output AC Welding Circuit SCR Operation SCR Operation Square Wave TIG Thermal Protection Troubleshooting & Repair Section 1TROUBLESHOOTING & Repair HOW to USE Troubleshooting Guide Troubleshooting & Repair PC Board Troubleshooting Procedures Troubleshooting Guide Output Problems 12/95 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 PC Board Connector Locations Figure F.1 Control Board Connectors Control Transformer T2 Voltage Test Test DescriptionMaterials Needed Test Procedure Control BOX Control Transformer T2 Voltage Test Figure F.4 Control Board and Transformer PROTECTION/SNUBBER Board Continuity Test PROTECTION/SNUBBER Board Continuity Test Figure F.6 PROTECTION/SNUBBER Board Test Points Table F.6 Square Wave TIG ARC 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 Locations Active SCR Test Active SCR Test Figure F.13 PROTECTION/SNUBBER Board Plug Locations Battery Test Silicon Controlled Rectifier Test Normal Open Circuit Voltage Waveform DC Stick Mode Scope Settings Normal 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 VDC AC TIG Mode Auto Balance on Machine Loaded to 50 Amps AT 26VACMachine Loaded to 200 Amps AT 46 VAC Volts 5ms Typical SCR Gate Voltage Waveform Volts 2ms Troubleshooting & Repair FAN Motor and Blade Removal Tools Required FAN Motor and Blade Removal SCR Heat Sink Assembly Removal Materials Required SCR Heat Sink Assembly Removal Retest After Repair Input Idle AmpsRecommended Meters for Machine Output Tests Retest After Repair cont’d Figure F.16 Transformer Lead Test Points Electrical Diagrams Electrical Diagrams Control Board G2150 PTC1,PTC2 THERMISTOR-PTC,56 OHMS,90MA Control 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 C G2150 A C C T Control Board Schematic Square Wave TIG 255 cont’d G2150 Y P a D PROTECTION/SNUBBER Board Schematic Square Wave TIG 255 L9255 Keypad LED Board Square Wave TIG 255 L9212