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Lincoln Electric SVM135-B service manual Wire Feed Overload Protection

Models: SVM135-B

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B-10

OPERATION

B-10

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WIRE FEED OVERLOAD

PROTECTION

The wire drive has solid-state overload protection of the wire drive motor. If the wire drive motor becomes overloaded for an extended period of time the wire drive will issue a shutdown command to the Control Box and force its STATUS light to blink between green and red. The Control Box turns off the power source, wire feed and gas solenoid. The status light on the wire drive will continue to blink between green

and red for about 30 seconds before the wire drive will automatically reset. At that time, the wire drive will issue a shutdown over command to the Control Box that will return the system to normal operation. The wire drive will force its STATUS light to solid green.

Overloads can result from improper tip size, liner, drive rolls, or guide tubes, obstructions or bends in the gun cable, feeding wire that is larger than the rated capacity of the feeder or any other factors that would impede normal wire feeding.

POWER WAVE 455/POWER FEED 10

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Lincoln Electric SVM135-B service manual Wire Feed Overload Protection

Contents

Power Wave 455/Power Feed Safety Depends on You Safety California Proposition 65 Warnings Electric Shock can kill Welding Sparks can cause fire or explosion Iii Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Installation Table of Contents Installation Section Return to Section TOC Technical Specifications Power Wave Input AT Rated Output Three Phase only Safety Precautions Location and Mounting Control BOX Power Source Mounting Boom Mounting Input Fuse and Supply Wire Considerations Input Voltage Reconnect ProcedureElectrical Connections Grounding Cable Connections Control Cable ConnectionsFlexible Connection Possibilities Typical Bench Feeder Connection Control Cable Specifications Cable ConnectionsElectrode and Work Leads Electrode Positive Applications Available Cable Assemblies Wire Feeder Setup Wire Drive Gear Ratio High or LOW SpeedElectrode and Work Leads Electrode Negative Applications Voltage Sensing AT the WORK- Piece Ratio Change Procedure DIP Switch Setup Setting DIP Switches Control BOX Switch Off LSB Setting DIP Switches in the Wire Drive Figure A.4 See Gun Adapters in Accessories section GUN and Cable Assemblies Gmaw Shielding GAS Standard Panel Installation CONTROL/DISPLAY PanelCV/GOUGE Panel Optional Panels for Control BOX Table of Contents Operation Section Operation Safety Instructions Operating InstructionsSystem Description Recommended Equipment Duty Cycle and Welding Capabilities Limitations Power Feed Controls STEP/4-STEP Switch OperationStatus Light 1 -STEP/ 4-STEP Switch Cold FEED/GAS Purge Switch Display Control Panel Status LightAmps Encoder Volts Blank Panel Trim Encoder Status Weld Mode Descriptions Board Level AdjustmentsElectrode Routing ARC Gouging Wire Spindle Placement Wire Reel Loading READI-REELS, Spools Or Coils KG Coil Using K1504-1 Coil Reel Figure B.5 Innershield Coils Figure B.4 Feeding Electrode and Brake Adjustment Drive Roll KIT Installation KP1505Drive Roll Pressure Setting Procedure for Setting Angle of Feedplate Wire Feed Overload Protection Accessories Table of Contents Accessories Section Table C.1 Power Feed 10 and Power Wave 455 Accessories General 3ACCESSORIESC-3 Power Wave OptionsAccessories Wire Feeder Options and Accessories Control Box Cabinet Procedure Input Cable AssembliesCable Receptacles K1548-1 Receptacle KIT Input and Output Feed Head Enclosure Procedure Receptacle Input Reel Adapters Guns and GUN Adapters Conduit Adapters Chassis Options Dual Procedure Switch OptionsGAS and Water Kits Description and Installation of Optional Control BOX Panels K1542-5 Dual Procedure PanelCC/STICK/GOUGE Mode K1555-1 Insulated Lift Bail Constant Voltage CV/MIG and CV/Flux Cored Procedures K1542-7 MX Panel Large PanelDescriptions Parameter Ranges Mode Selection Parameter AdjustmentParameter Selection K1542-8 MSP Panel Large Panel Gmaw Pulse Procedures Memory Selection K1542-9 Dual PROCEDURE/MEMORY Panel Small PanelDual Procedure Selection K1542-11 MX2 Panel K1542-12 MSP2 Panel Control BOX Panels -- SET UP Controls Description Control BOX -- PC Board Adjustments Control BOX -- Using Operating Limits Operation with Previous Software Version Maintenance Table of Contents Maintenance Section Routine Maintenance Periodic Maintenance Table of Contents Theory of Operation Section Theory of Operation System Diagram a Wire DriveModular Inverter Based Welding System System Diagram B System Diagram C Power Source General Description Input Voltage and Precharge Switch Boards and Main Transformer Operation Discussion and Diagrams in this section Control Board Figure E.6 Control Board Output Rectifier Choke Protective Circuits Thermal Protection Over CurrentUNDER/OVER Voltage Active Insulated Gate Bipolar Transistor Igbt OperationPassive Maximum Output Pulse Width ModulationMinimum Output User Interface See System Diagram a and SystemControl BOX Power Feed Feed Head Lead #67Step Step Power Wave 455/POWER Feed Troubleshooting and Repair Table of Contents Troubleshooting and Repair Section HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures Troubleshooting and Repair Troubleshooting Guide Perform the Power Board TestTransformer Test Perform the Input Rectifier Perform the Main Contactor See LED Code Table Perform the Input Rectifier Perform the Auxiliary Transfor Mer T2 TestPerform the Output Rectifier Ducer Test Perform the Voltage Sense PC Board Test Function Problems Wire Drive/Control Box Troubleshooting Power Wave 455 Status LED Chart Condition Possible Faults Status LED Error Code TableTroubleshooting Guide Thermal LED is lit Green, consult Status LED Error Code Table Welding File Errors Error Code LED Sequence Status LED Error Code TableDigital Communication Error Code LED Errors Sequence Power Source Error Code Errors LED Sequence Power Feed Setting DIP Switches Wire Drive in the Installation Switches in the Wire Drive Perform the Encoder PC BoardRectly. See Figure A.2. Auxiliary Troubleshooting and Repair Troubleshooting and Repair Weld Welding Problems Control BOX/WIRE Drive Error Code Chart Power Feed Error Code Chart Control BOX/WIRE Drive Error Code Chart LED Color and Number Circuit Indicators PW 455 Control Board LED Definitions Test Procedures Input Filter Capacitor Discharge ProcedureTest Description Materials Needed Test Procedure Never USE a Shorting Strap for this Procedure Switch Board Test 26TROUBLESHOOTING and REPAIRF-26 Reconnect SwitchesPerform the Capacitor Discharge Procedure 19D 19C 20 +19 13/14 17/18 27TROUBLESHOOTING and REPAIRF-2711/12 15/16 Power Wave 455/POWER Feed Output Rectifier Test Negative Output Terminal Positive + 30TROUBLESHOOTING and REPAIRF-30Rectifier Module Replacement Procedure Input Rectifier Test Troubleshooting and Repair Probe Acceptable Meter Readings Input Contactor Test Power Wave 455/POWER Feed Input Contactor Test Test Points 36TROUBLESHOOTING and REPAIRF-36X4/X4A 601/601A Auxiliary Transformer no Test High voltage is present at plug P80 38TROUBLESHOOTING and REPAIRF-38P81 Troubleshooting and Repair FAN Motor Leads High voltage is present at primary of Auxiliary Transformer Power Wave 455/POWER Feed Power Board Test 3 4 J32 J31 91011 Power PC Check 65 VDC Power Wave 455/POWER Feed Current Transducer Test P90 48TROUBLESHOOTING and REPAIRF-48Current Transducer 500 450 400 350 300 250 200 150 100 Power Wave 455/POWER Feed Drive Motor Test Box and Drive Motor Removal and Replacement #551 #550Black #551 + Tach Feedback Test Black RED Blue Wire Feed Control Board #3 #1 Voltage Sense PC Board Test 56TROUBLESHOOTING and REPAIRF-56 J1 4 5 Dual Encoder PC Board Test Dual Encoder PC Board Test Control Cable Continuity Test Control Cable Continuity Test Description Component Replacement ProceduresGAS Solenoid Removal and Replacement 62TROUBLESHOOTING and REPAIRF-62 Installation Wire Feeder Control Board Removal Replacement Wire Feeder Control Board Removal and Replacement Tach Hall Effect Assembly Removal Replacement Removal Procedure Replacement Procedure Gear BOX and Drive Motor Removal Replacement Drive Motor Gear BOX #551#550 To Remove the Drive Motor from the Gear BOX To Remove the Wire Drive Assembly from the Gear BOXReplacement Procedures Power Wave 455/POWER Feed Switch Board and Filter Capacitor Removal Replacement Switch Board and Filter Capacitor Removal 11/12 15/16 19+Nylon Screw 13/14 17/18 Replacement Procedure Power Wave 455 / PF-10 Meter Accuracy Check Procedure to Repair if Meters are OUT of RangeMaterial Needed Meter Accuracy Check Control or Power Board Removal and Replacement Control or Power Board Removal and Replacement Installation Procedure Power Wave 455/POWER Feed Auxiliary Transformer no Removal Replacement Procedure Replacement Procedure Auxiliary Transformer no Removal TOC Power Wave 455/POWER Feed Main Input Contactor Removal and Replacement X4/X4A Replacement Procedure Power Wave 455/POWER Feed Input Rectifier Removal and Replacement Figure F.25 Input Rectifier Removal and Replacement NEG Output Rectifier and Module Removal Replacement Rectifier Assembly Removal Procedure Return to Power Wave 455/POWER Feed Power Source Error Interpretation Guide Flowchart Power Source Error Interpretation Guide Performance Troubleshooting Guide Flowchart Performance Troubleshooting Guide Functional Troubleshooting Guide Flowchart Functional Troubleshooting Guide Electrical Diagrams Table of Contents Electrical Diagrams Section Return to Section TOC Power Wave 455 Wiring Diagram Code Rear Reconnect Panel Sense Power Feed 10 Control Box Wiring Diagram Power Feed 10 Wire Drive Wiring Diagram Power Feed 10 Machine Schematic Master Power Wave 455 Machine Schematic Code To Section Switch Board #1 Left Return to Section Return to Section TOC To Section TOC Power Wave 455 Control PC Board Schematic 1 Power Wave 455 Control PC Board Schematic 2 Power Wave 455 Control PC Board Schematic 3 Power Wave 455 Power PC Board Schematic ComF Power Wave 455 Input PC Board Schematic 17921 M Power Wave 455 Switch PC Board Schematic Code 10372 V450 Power Wave 455 Switch PC Board Schematic Code 221K Power Feed 10 Mother Control PC Board Schematic Encoder Supply Power Feed 10 Control PC Board Schematic To Master Power Feed 10 Display PC Board Schematic 14X-5 Power Feed 10 Encoder PC Board Schematic 22920 Power Feed 10 Voltage Sense PC Board Schematic 23918