Lincoln Electric SVM160-B service manual Table of Contents Theory of Operation Section

Models: SVM160-B

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Section E-1Section E-1

TABLE OF CONTENTS

-THEORY OF OPERATION SECTION-

Theory of Operation

Section E

General Description

E-2

Input Voltage and Main Transformer

E-3

Input Rectifier, Chopper Assembly And Feedback

E-4

Diode Control Rectifier and Power Board

E-5

Weld Control Board

E-6

Wire Drive Motor and Feedback

E-7

Thermal Protection, Over Current Protection, and Wire Feeder

 

Overload Protection

E-8

Insulated Gate Bipolar Transistor (IGBT) Operation

E-9

Pulse Width Modulation

E-10

Chopper Technology Fundamentals

E-11

FIGURE E.1 – POWER MIG 300 BLOCK LOGIC DIAGRAM

 

 

MAIN

 

 

OUTPUT

 

CHOPPER

 

OUTPUT

 

POS

 

 

TRANSFORMER

 

RECTIFIER

 

ASSEMBLY

 

OUTPUT

GUN

 

 

 

 

 

 

 

 

 

 

 

CHOKE

TERMINAL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

IGBT

 

 

 

+

 

 

 

 

 

 

 

 

+

 

 

 

CURRENT

 

 

 

 

 

 

 

 

 

 

80

 

 

 

 

 

 

 

 

 

 

60

 

 

 

 

 

TRANSDUCER

 

 

 

 

 

 

 

 

VAC

 

 

 

 

 

_

 

 

 

 

 

VAC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RECONNECT

 

 

 

 

 

 

 

 

 

 

 

NEG

 

 

PANEL

 

 

 

 

 

 

 

 

 

 

OUTPUT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

30

 

 

 

 

 

 

CURRENT

TERMINAL

 

LINE

115

 

 

 

40 VDC

 

POWER

20 VDC

FEEDBACK

 

 

 

 

VAC

 

 

 

 

 

 

 

 

SWITCH

VAC

 

 

 

 

 

 

BOARD

 

 

 

VOLTAGE

 

 

 

 

DIODE CONTROL

 

PWM

 

 

FEEDBACK

 

 

 

 

 

 

SIGNALS

 

 

 

 

 

 

 

 

RECTIFIER

 

+15/-15/+5 VDC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RELAY

 

 

 

 

 

 

IGBT

 

 

 

 

 

 

 

 

 

CHOPPER

 

DRIVE

 

 

 

 

 

 

 

 

 

 

 

WELD CONTROL BOARD

 

RS232

 

 

FAN

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONNECTOR

 

 

MOTOR

 

 

 

 

 

 

 

 

 

 

 

 

 

 

40

 

 

SEC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TO FAN RELAY

 

 

FROM WELD

VDC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROL BOARD

 

THERMOSTATS

 

SHIELDED CABLE AND SPI COMMUNICATIONS

 

FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL)

 

 

 

 

ARCLINK

 

 

 

 

 

+5 VDC

 

 

 

 

 

 

 

 

 

SPOOL

40 VDC

 

 

 

 

ENCODER

DISPLAY

 

 

 

 

SHIELDED

FEEDER

MSP

 

 

 

24 VDC

 

GUN

CABLE

 

 

BOARD

BOARD

 

 

 

 

BOARD

BOARD

 

 

 

 

BOARD

 

 

 

(Below code 10900)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL)

 

 

 

 

 

GUN TRIGGER AND THUMB SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPOOL GUN

 

 

 

 

 

 

 

 

GAS

 

 

 

T

 

PUSH-PULL

 

 

 

 

 

 

 

SOLENOID

 

 

 

A

 

SWITCH

 

 

 

 

 

 

 

 

 

 

C

 

Mechanical Encoders

 

 

 

 

 

 

 

 

 

H

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(Above code 10900)

 

 

 

 

 

 

 

 

 

WIRE DRIVE

 

 

 

 

 

 

 

 

 

 

 

 

 

MOTOR

 

 

 

 

 

 

 

POWER MIG 300

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Lincoln Electric SVM160-B service manual Table of Contents Theory of Operation Section

SVM160-B specifications

The Lincoln Electric SVM160-B is a standout model in the realm of portable arc welders, designed specifically for light to medium-duty welding tasks. As part of Lincoln Electric’s renowned line of welding equipment, the SVM160-B combines efficiency with durability, catering to both professional welders and hobbyists alike.

One of the primary features of the SVM160-B is its lightweight and compact design. Weighing in at just around 60 pounds, it offers excellent portability, allowing users to easily transport the unit to various job sites. This mobility is enhanced by an integrated handle and a rugged construction, making it suitable for both indoor and outdoor applications.

The SVM160-B utilizes advanced inverter technology, which significantly enhances its performance capabilities. This technology not only contributes to the welder's energy efficiency but also allows for a more stable arc, reducing spatter and resulting in cleaner welds. The machine can operate on both 120V and 240V power sources, providing flexibility for users to adapt to different settings and requirements.

Among its key characteristics, the SVM160-B features a welding output range that accommodates various welding needs, allowing users to achieve welds from 20 to 160 amps. This versatility makes it ideal for welding different materials, including mild steel, stainless steel, and aluminum. Furthermore, the unit supports a range of welding processes, including MIG, stick, and TIG welding, enhancing its adaptability for various projects.

Another highlight of the SVM160-B is its user-friendly interface. The control panel is designed to facilitate ease of use, with clearly marked dials and indicators that enable quick adjustments of settings. This intuitive design ensures that both novice and experienced users can operate the machine efficiently and effectively.

Safety features are also a crucial aspect of the SVM160-B. It comes equipped with thermal overload protection, which prevents the unit from overheating during extended use. This built-in safeguard extends the welder's lifespan and enhances user safety.

In summary, the Lincoln Electric SVM160-B is a versatile, portable welder that combines advanced technology with user-friendly features, making it an excellent choice for a wide range of welding applications. Its lightweight design, inverter technology, and robust safety features make it a reliable option for both professionals and enthusiasts. Whether tackling small repairs or larger projects, the SVM160-B stands ready to deliver quality results.