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Lincoln Electric SVM153-A service manual Normal Weld Voltage Waveform Wire CV

Models: SVM153-A

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F-55

F-55

TROUBLESHOOTING & REPAIR

NORMAL WELD VOLTAGE WAVEFORM (WIRE CV)

MACHINE LOADED TO 500 AMPS AT 40 VOLTS

0 volts

20V0.1ms

This is the typical DC output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time.

The machine was loaded with a resistance grid bank to 500 amps at 40 volts.

SCOPE SETTINGS

Volts/Div	20V/Div.
Horizontal Sweep ..	0.1 ms/Div.
Coupling	DC
Trigger	Internal

COMMANDER 500

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Lincoln Electric SVM153-A service manual Normal Weld Voltage Waveform Wire CV

Contents

CommanderTM Safety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Commander 500 K1639-1Safety Precautions Location / VentilationStoring StackingHigh Temperature Operation LiftingTowing High Altitude OperationPRE-OPERATION Engine Service Muffler Outlet Pipe Spark ArresterAuxiliary Power Receptacles Standby Power ConnectionsWelding Output Cables Machine GroundingCompany Table of Contents Operation Section Safety Instructions OperationOperating Instructions General DescriptionDesign Features and Advantages Recommended ApplicationsControls and Settings K1639-1 Commander 500 Standard ModelWelding Capability RUN/STOP Switch Idler SwitchStart Pushbutton Fuel Level Gauge and LightWeld Mode Output Control Welding Terminals SwitchTable B.1 Weld Mode and Output Control Functions Hour MeterAuxiliary Power Controls Engine Operation Starting the EngineBREAK-IN Period Typical Fuel ConsumptionWelder Operation Stick WeldingConstant Current CC Welding TIG WeldingCommander 500 Settings When Using the K799 HI-FREQ Unit Commander 500 Settings When Using the K930-1 TIG ModuleTable B.3 Typical Current RANGES1 for Tungsten ELECTRODES2 TIG TorchAuxiliary Power Operation Wire Feed Constant Voltage WeldingSimultaneous Welding and Auxiliary Power Loads ARC GougingExtension Cord Recommendations Permissible Permissible AuxiliaryTable of Contents Accessories Section Accessories OPTIONS/ACCESSORIESField Installed Options Stick Welding AccessoriesSemiautomatic Welding Accessories Connection of Lincoln Electric Wire FeedersOther Wire Feeders for the Commander High Frequency Generators for TIG ApplicationsTo Work Electrode Cable To Wire Feed Unit ING CV ING CV ING CV Figure C.5 Commander 500/LN-23P Connection Diagram ING Terminals Always on Table of Contents Maintenance Section Maintenance Routine and Periodic MaintenanceEngine Maintenance DailyFigure D.1 OIL Drain and Refill Figure D.2 Fuel PRE-FILTER/WATER Separator Assembly Fuel FiltersFigure D.3 Secondary Fuel Filter AIR Filter Maintenance Frequency Maintenance Required Table D.2 Engine Maintenance Parts Manufacturer Part NumberBattery Maintenance Connecting a Battery ChargerWELDER/GENERATOR Maintenance Figure D.5 Major Component Locations Commander Table of Contents Theory of Operation SectionCommander Theory of OperationWeld WINDINGS, RECTIFIER, Power Modules and Feedback Analog Control Power Supply Board and Weld Control Board Insulated Gate Bipolar Transistor Igbt Operation Pulse Width Modulation 6E-6Minimum Output Maximum OutputExternal DC Solid State Inductor ARC Source Switch Diode Chopper Technology Fundamentals70-80VDC Table of Contents Troubleshooting & Repair SectionSection F-1 Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures PC Board can be damaged by static electricityTroubleshooting Guide Observe Safety GuidelinesDetailed in the beginning of this manual Perform the Rotor Resistance Justment Test Function Problems Charging Circuit Test Engine Problems Shutdown Perform the Idler Solenoid Problems Possible Areas Symptoms Misadjustments Course of ActionEngine Starting Diagnostic Chart START-UP and OCV Diagnostic Chart ReturnCase Cover Removal and Replacement Procedure DescriptionMaterials Needed Case Cover Removal Replacement Procedure ProcedureFigure F.1 Case Front Knobs Removal and Replacement Procedure RemovalPower Module Capacitor Discharge Procedure Procedure Idler Solenoid Test Test DescriptionTest Procedure Figure F.5 Idler Solenoid LeadsShutdown Solenoid Test Figure F.6 Shutdown Solenoid Lead Terminals Engine Throttle Adjustment Test Figure F.7 Strobe Mark Location Mark Blower Paddle Here Strobe-tach MethodLocking NUT 28F-28 Frequency Counter MethodOscilloscope Method Rotor Resistance Test Test Procedure Flashing and Rotor Voltage Test 10 11 12 13 14 15 Lead # 201ATroubleshooting & Repair Stator Voltage Test Figure F.13 Front Control Panel Removal Screws Troubleshooting & Repair Auxiliary Power and Weld Windings Test Auxiliary Leads #5B, #5E, #8, #9, #11, #12Behind Panel W6W1 Weld Winding Lead ConnectionsAnalog Power Supply PC Board Voltage Test Control Circuit Input Power 40F-40J41 Analog Control Power Supply PC Board Test Test Points Component Tested Voltage ReadingOutput Rectifier Bridge Test Perform the Power Module Capacitor Discharge Procedure Troubleshooting & Repair Figure F.20 Diode Lead Removal Power Module Test Temperature Switch Power Module PC Board Diode Lead D4 Positive + StrapW10 Check Igbt For Shorts When all tests are complete Check Diode ModuleCharging Circuit Test Figure F.24 Engine Alternator Location #239 #281 #238Scope Settings Normal Open Circuit Voltage Waveform 115VAC SupplyHigh Idle no Load 15.8 ms Volts 50V5msNormal Open Circuit Voltage Waveform Stick MAX TAP MAX Control POT High Idle no LoadVolts 50V5ms Normal Weld Voltage Waveform Stick CC Machine Loaded to 500 Amps AT 40 VoltsVolts 20V0.1ms Normal Weld Voltage Waveform Wire CV Normal TIG Mode Voltage Waveform Loaded to 200A 16 VoltsVolts 10V50ms Normal Open Circuit Voltage Waveform Wire CV TAP MAX Control POT High Idle no LoadShutdown Solenoid Removal and Replacement Figure F Shutdown Solenoid Lead Connections Reassembly Figure F Shutdown Solenoid Linkage ARM AssemblyDescription Control Panel Removal Screws Front Green Ground Lead Figure F Power Module Capacitor Lead Removal Troubleshooting & Repair Replacement Procedure Description Power Module PC Board Removal Figure F.30 Power Module PC BoardPower Module PC Board Replacement Diode Module Replacement Diode Module RemovalOutput Rectifier Bridge Diode Removal and Replacement Refer to Figure F.32 Turn the engine off Return Section TOC Diode Stud Size Foot Pounds Inch PoundsSTATOR/ROTOR Removal and Replacement Preparation and Lead Removal Procedure Leads #229 #242DPlug Fuel Lines Bolts #200D #5P #201 #201A Filter Field Diode CapacitorFigure F.35 Brush Holder and Lead Removal #232MFigure F.37 Alternator Shroud Removal Screws Acoustical Foam Figure F.38 Lift Frame and Associated Component Removal Stator Removal Procedure Figure F.39 Stator RemovalRotor Removal Procedure Reassembly NotesLead Reconnection Checklist EngineOutput Panel and Control BOX Welder CV Wire Output Retest After RepairEngine RPM Welder DC Stick OutputTouch Start TIG Mode Output Auxiliary Power OutputElectrical Diagrams Table of Contents Electrical Diagrams SectionElectrical Diagrams Schematic Complete Machine Commander G3834Schematic Battery PC Board PC Board Assembly Battery PC Board Return to SectionSchematic Chopper PC Board PWM InputPC Board Assembly Chopper PC Board Return to Section Return to Section TOCSchematic Peripheral PC Board PC Board Assembly Peripheral PC Board Return to SectionSchematic Power Supply Analog PC Board PC Board Assembly Power Supply Analog PC Board PC Board Reference QTY Designators DescriptionSchematic PULL-COIL PC Board PC Board Assembly PULL-COIL PC Board MOSFET/HEATSINK ASBLY,T12704-82&S1810Schematic Weld Control PC Board Sheet Electrical Diagrams Electrical Diagrams Electrical Diagrams Electrical Diagrams PC Board Assembly Weld Control PC Board RESISTOR,SMD,METAL FILM,1/10W,150OHMSSVM Error Reporting Form