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E-4

E-4

THEORY OF OPERATION

FIGURE E.4 – DIODE CONTROL RECTIFIER AND POWER BOARD

 

 

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

 

 

 

 

 

VOLTAGE

 

SWITCH

VAC

 

 

 

 

 

 

BOARD

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

INPUT RECTIFIER, CHOPPER

ASSEMBLY AND FEEDBACK

The 60 VAC output from the main transformer sec- ondary is connected to an input rectifier. The resultant 80 VDC is applied to four parallel capacitors incorpo- rated within the Chopper Assembly. These capacitors function as filters and also as power supplies for the insulated gate bipolar transistors or IGBT. See IGBT Operation in this section. The IGBT acts as a high- speed switch operating at 20KHZ. This device is switched on and off by the Weld Control Board through pulse width modulation circuitry. See Pulse Width Modulation in this section. This "chopped" DC output is applied through an output choke coil to the positive output terminal and through a current transducer to the negative output terminal. The choke functions as a current filter. A free-wheeling diode is incorporated in the Chopper Assembly to provide a current path for the stored energy in the choke when the IGBT is turned off. See Chopper Technology Fundamentals in this sec- tion.

Output voltage and current feedback information is fed to the Weld Control Board. This information is sensed from the current transducer and voltage sense circuitry on the output terminal circuits. If current or voltage become abnormally high, the Weld Control Board will shut off the IGBTs, thus disabling the machine's output.

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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

POWER MIG 300

Page 37
Image 37
Lincoln Electric SVM160-B service manual Input RECTIFIER, Chopper Assembly and Feedback, Return to Section Section TOC

SVM160-B specifications

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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.

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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.