Lincoln Electric SVM118-A - page 125

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F-76 F-76

TROUBLESHOOTING & REPAIR

SQUARE WAVE TIG 355

OUTPUT RECTIFIER REMOVALAND REPLACEMENT (continued)

FIGURE F.26 – OUTPUT RECTIFIER CONNECTION DETAILS

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Contents

Main SERVICE MANUAL SVM118-A SQUARE WAVE TIG 355 i i ARC WELDING can be hazardous. ELECTRIC SHOCK can kill. ARC RAYS can burn. FUMES AND GASES can be dangerous. ii ii SQUARE WAVE TIG 355 WELDING SPARKS can cause fire or explosion. CYLINDER may explode if damaged. FOR ELECTRICALLYpow- ered equipment. iii iii FOR ENGINE powered equipment. ELECTRIC AND MAGNETIC FIELDS may be dangerous iv iv SQUARE WAVE TIG 355 PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFOR- MATEUR ET REDRESSEUR MASTER TABLE OF CONTENTS FOR ALL SECTIONS - INSTALLATION SECTION - TECHNICAL SPECIFICATIONS - SQUARE WAVE TIG 355 INPUT - SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE SAFETY PRECAUTIONS SELECT SUITABLE LOCATION STACKING LIFTING TILTING INPUT CONNECTIONS GROUND CONNECTION INPUT SUPPLYCONNECTION RECONNECT PROCEDURE Page OUTPUT CONNECTIONS TIG TORCH CONNECTION STICK ELECTRODE CABLE CONNECTION - OPERATION SECTION - OPERATING INSTRUCTIONS SAFETY INSTRUCTIONS GENERAL DESCRIPTION RECOMMENDED PROCESSES OPERATIONAL FEATURES AND CONTROLS DESIGN FEATURES AND ADVANTAGES WELDING CAPABILITY LIMITATIONS CONTROLS AND SETTINGS UPPER CASE FRONT CONTROLS UPPER CASE FRONT CONTROL PANEL Page Page Page Page LOWER CASE FRONT CONTROLS Page HAND AND FOOT AMPTROL OPERATION Page WELDING OPERATION INITIAL START-UP STICK WELDING TIG WELDING GUIDELINES Page Page Page B-19 B-19 TABLE B.2 TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES TIG WELDING SEQUENCE OF OPERATION (2-STEP MODE) TIG WELDING SEQUENCE OF OPERATION (4-STEP MODE) OVERLOAD PROTECTION AUXILIARY POWER ALL MACHINES 50/60Hz MACHINES Page ACCESSORIES OPTIONS/ACCESSORIES Page SAFETY PRECAUTIONS INPUT POWER FACTOR CAPACITOR DISCHARGE PROCEDURE ROUTINE AND PERIODIC MAINTENANCE Page -THEORY OF OPERATION SECTION- Section E-1 Section E-1 FIGURE E.1 SQUARE WAVE TIG BLOCK LOGIC DIAGRAM GENERAL DESCRIPTION INPUT POWER CIRCUIT OUTPUT RECTIFICATION AND FEEDBACK CONTROL E-3 E-3 FIGURE E.3 OUTPUT RECTIFICATION AND FEEDBACK CONTROL E-4 E-4 HIGH VOLTAGE/ HIGH FREQUENCY CIRCUIT FIGURE E.4 HIGH VOLTAGE/HIGH FREQUENCY CIRCUIT E-5 E-5 DC WELDING OUTPUT FIGURE E.5a SCR BRIDGE AND CHOKE CONFIGURATION FOR DC WELDING FIGURE E.5 DC WELDING OUTPUT CIRCUIT E-6 E-6 AC WELDING OUTPUT X2 FIGURE E.6 AC WELDING OUTPUT CIRCUIT FIGURE E.6a SCR BRIDGE AND CHOKE CONFIGURATION FOR AC WELDING X1 SCR OPERATION PROTECTIVE CIRCUITS THERMAL PROTECTION OVERLOAD PROTECTION -TROUBLESHOOTING & REPAIR SECTION- HOW TO USE TROUBLESHOOTING GUIDE PC BOARD TROUBLESHOOTING PROCEDURES AND REPLACEMENT Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page STICK WELDING PROBLEMS INPUT POWER FACTOR CAPACITOR VOLTAGE CHECK AND DISCHARGE PROCEDURE PURPOSE FOR THE PROCEDURE INPUT POWER FACTOR CAPACITOR VOLTAGE CHECK AND DISCHARGE PROCEDURE (continued) ARC START TRIGGER CIRCUIT TEST ARC START TRIGGER CIRCUIT TEST (continued) F-24 F-24 ARC START TRIGGER CIRCUIT TEST (continued) FIGURE F.3 ARC START TRIGGER CIRCUIT POWER BOARD TEST POWER BOARD TEST (continued) POWER BOARD VOLTAGE TEST CHART INPUT CONTACTOR TEST Page Page F-31 F-31 FIGURE F.6 - INPUT CONTACTOR (CR1) SIMPLIFIED CONTROL CIRCUIT FEED - THRU BOARD POWER BOARD CONTROL BOARD PILOT TRANSFORMER TEST PILOT TRANSFORMER TEST (continued) FEED-THRU PC BOARD TEST FEED-THRU PC BOARD TEST (continued Page FEED-THRU PC BOARD TEST (continued) PROTECTION PC BOARD TEST Page PROTECTION PC BOARD TEST (continued) MAIN TRANSFORMER TEST Page MAIN TRANSFORMER TEST (continued) CONTROL TRANSFORMER (T5) VOLTAGE TEST CONTROL TRANSFORMER (T5) VOLTAGE TEST (continued) CONTROL TRANSFORMER (T5) VOLTAGE TEST (continued) CONTROL PC BOARD TEST CONTROL PC BOARD TEST (continued) CONTROL PC BOARD TEST (continued) CONTROL PC BOARD TEST (continued) STATIC SCR TEST Page STATIC SCR TEST (continued) ACTIVE SCR TEST Page Page SILICON CONTROLLED RECTIFIER TEST BATTERYTEST DC STICK MODE AC STICK MODE DC TIG MODE AC TIG MODE TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED DC TIG MODE AC TIG MODE (BALANCED WAVEFORM) 8/98 ABNORMAL OPEN CIRCUIT VOLTAGE DC TIG MODE ONE OUTPUT SCR NOT FUNCTIONING ABNORMAL OPEN CIRCUIT VOLTAGE AC TIG MODE ONE OUTPUT SCR NOT FUNCTIONING CONTROL PC BOARD REMOVAL AND REPLACEMENT CONTROL PC BOARD REMOVALAND REPLACEMENT (continued) POWER PC BOARD REMOVAL AND REPLACEMENT POWER PC BOARD REMOVALAND REPLACEMENT (continued) INPUT CONTACTOR REMOVAL AND REPLACEMENT Page INPUT CONTACTOR REMOVALAND REPLACEMENT (continued) FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT FAN MOTOR AND BLADE REMOVALAND REPLACEMENT (continued) OUTPUT RECTIFIER REMOVAL AND REPLACEMENT Page OUTPUT RECTIFIER REMOVALAND REPLACEMENT (continued) SCR REMOVAL AND AND REPLACEMENT SPECIAL INSTRUCTIONS Page Page Page Page RETEST AFTER REPAIR RETEST AFTER REPAIR - ELECTRICAL DIAGRAMS SECTION - G-1G-1 Page ELECTRICAL DIAGRAMS Wiring Diagram G 2519 DUAL VOLTAGE MACHINE SINGLE VOLTAGE MACHINE } ** * * LEAD COLOR CODING CONNECTOR PIN NUMBERS: Meter PC Board (M15893) Schematic THE LINCOLN ELECTRIC CO. NONE X4 M Feed Through PC Board (L8096) Schematic THE LINCOLN ELECTRIC CO. M CLEVELAND, OHIO U.S.A. NOTES : Protection PC Board (M16062) Schematic THE LINCOLN ELECTRIC CO. M CLEVELAND, OHIO U.S.A. C4 Power PC Board (G2081) Schematic G-8 Control PC Board (G2512) Schematic X41 R30 R102 R159 M16062 G-10 Power PC Board (G2081) Layout G-10 G2081 Bypass PC Board (M15299) Layout M15299 ITEM REQD IDENTIFICATION CAPACITORS = MFD/VOLTS G-12 Feed Through PC Board (L9096) Layout G-12 L8096 G-13 Control PC Board (G2512) Layout G-13 G2512 Meter PC Board (M15893) Layout M15893