Manuals / Lincoln Electric / Power Tools / Welding System

Lincoln Electric SVM162-B service manual Table of Contents Theory of Operation Section

Models: SVM162-B

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E-1			TABLE OF CONTENTS	E-1
		-THEORY OF OPERATION SECTION-
Theory of Operation				Section E
	General Description	....................................................................................................................		E-2
	Input Power Circuit			E-2
	Output Rectification, Control Board and Feedback			E-3
	High Voltage/High Frequency Circuit			E-4
	DC Welding Output			E-5
	AC Welding Output			E-6
	SCR Operation			E-7
	Protective Circuits			E-8
	Fan As Needed (F.A.N.)			E-8
	Thermal Protection			E-8
	Overload Protection			E-8
		FIGURE E.1 – PRECISION TIG 275 BLOCK LOGIC DIAGRAM

FROM

CONTROL

BOARD

OPTIONAL POWER

CORRECTIONFACTOR

CAPACITORS

POWER

BACKGROUND

CIRCUIT

63.5 VAC

REAR GANG	WORK

POLARITY

SWITCH

BYPASS BOARD

FRONT ELECTRODE

HIGH FREQUENCY

to Master TOC

SWITCH

PANEL

RECONNECT

X1

VAC78 X2

AC	DC	CHOKE
AC	DC
	SCR
BRIDGE
AC	DC	SHUNT

TRANSFORMER

HIGH VOLTAGE TRANSFORMER

REAR ELECTRODE

Return

115 VAC

GAS

VAC

FAN

THERMOSTAT

GATELEADS FEEDBACK

SOLENOID

115

VAC

VAC

115 VAC

115

115

Master TOC

20 VAC

20 VAC

MINIMUM

OUTPUT

CONTROL

MAXIMUM

OUTPUT

CONTROL

CONTROL BOARD

ADVANCED CONTROL

PANEL RECEPTACLE

PROTECTION

METER

STICK

BOARD

TIG

SWITCH

BALANCE

POST

LOCAL/REMOTE

CONTROL

FLOW

SWITCH

REMOTE

RECEPTACLE

THERMOSTAT

LED's

Return to

PRECISION TIG 275

Image 39

Lincoln Electric SVM162-B service manual Table of Contents Theory of Operation Section

Contents

Precision TIG Safety Depends on YouMar ʻ95 SafetyPowered equipment For EngineARC Rays can burn Fumes and GasesAug ʻ06 Welding Sparks can Cylinder may explode If damagedIii Transformateur ET À Précautions DE SûretéPrécautions DE Sûreté Pour LES Machines À Souder ÀMaster Table of Contents for ALL Sections Table of Contents Installation Section Unbalance 70% Penetration AC TIG 14.8 150 InstallationUnbalance 70% Penetration AC TIG 16.1 255 60% 29.0 225 Unbalance 70% Penetration AC TIG 15.4 200 100% 28.0Maximum Open Output CurrentSafety Precautions ProtectionSelect Suitable Location Ment Turn the input power OFF atDisconnect switch or fuse box Before working on this equipWork Cable Connection Figure A.2 Figure A.3 Auxiliary Power ConnectionsFigure A.4 Robotic Interface ConnectionReturn to Section TOC Table of Contents Operation Section Operation Product DescriptionPipe Thawing Equipment Recommended ProcessesBoth the Stick and TIG torch cables Controls and SettingsWhen the Power Source is on Stick mode the Electrode circuitsMaximum Output Control The large knob AC Balance OntrolSelect Menu Button and Display Switch CodesTIG Mode Menu Operation for Codes Above 11000 onlyGure B.3 Advanced Panel ControlsPulse Frequency Control Time Control PULSE% onPulse Background Current Control Internal SET UP Controls TIG Welding FeaturesStick Welding Features Step Trigger Modes Figure B.4 Codes below 11000 K1829-1 TIG Weld Cycle ChartFigure B.6 Setup Guidelines for TIG Welding With AN AmptrolGtaw Process Making a TIG Weld with AN AmptrolRecommended Electrode Amperage Ranges Precision TIG Smaw ProcessTable of Contents Accessories for Codes below Optional EquipmentMagnum PTA and PTW Series Torches Accessories for Codes Above Return to Section TOC Component Location and Access MaintenanceOverload Protection Safety PrecautionsService Procedures Spark GAP AdjustmentUNDER-COOLER Service Warni Table of Contents Theory of Operation Section Input Power Circuit Theory of OperationGeneral Description Output Rectification Control board also monitors the thermostatsSee SCR Operation Figure E.4 High Voltage / High Frequency Circuit High VOLTAGE/HIGH Frequency CircuitFigure E.5 DC Welding Output DC Welding OutputFigure E.7 AC Welding Output AC Welding OutputFigure E.9 SCR Operation SCR OperationThermal Protection 8THEORY of OPERATIONE-8Protection Circuits FAN-AS-NEEDED F.A.NTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide 2TROUBLESHOOTING & REPAIRF-2Troubleshooting & Repair Test Troubleshooting GuideProcedure ReconnectControl Board TransformerSCR Bridge Test T1 Transformer Installed, remove it and replaceMachine functions normally Perform the Protection BoardSee Note below Protection BoardPerform the T1 Transformer Perform the SCR Bridge Test Perform the SCR Bridge Tests Perform the Gas Solenoid Test EstMaintenance Electric ShockCan Kill High frequency transformer Maintenance SectionTo Technical Specifications Problems Possible AreasSymptoms Misadjustments Course of Action See the Maintenance SectiStick electrode blasts-off Welding current may be too high Stick Welding ProblemsFunction Problems Be plugged into J3 Installation ManualDisplay switch may be faulty Precision TIG Description 19TROUBLESHOOTING & REPAIRF-19Meter Calibration Adjustments Voltmeter/Ohmmeter Nut Driver Wiring Diagram20TROUBLESHOOTING & REPAIRF-20 Meter Calibration AdjustmentsCalibration Check 21TROUBLESHOOTING & REPAIRF-21 Ammeter Calibration ProcedureControl board. See Figure F1 Return to Section TOC 23TROUBLESHOOTING & REPAIRF-23 High Frequency Circuit Disable ProcedureNut Driver Electrical Insulating Tape 24TROUBLESHOOTING & REPAIRF-24 High Frequency Circuit Disable ProcedureProcedure 25TROUBLESHOOTING & REPAIRF-25 Protection Board TestTest Description Resistance Between Reading Protection Board TestT1 Main Transformer Test 27TROUBLESHOOTING & REPAIRF-2728TROUBLESHOOTING & REPAIRF-28 Test ProceduresT1 Main Transformer Test Primary Windings Test Points Acceptable VoltagesReturn to Section TOC GAS Water Solenoid Test 31TROUBLESHOOTING & REPAIRF-31Perform the High Frequency Circuit Test ProcedureDisable Procedure GAS Water Solenoid TestStatic SCR Test 33TROUBLESHOOTING & REPAIRF-33Static SCR Test 34TROUBLESHOOTING & REPAIRF-34Removal and Replacement Assembly. See SCR Bridge AssemblyActive SCR Test Service and repairActive SCR Test 36TROUBLESHOOTING & REPAIRF-36Active SCR Test Figure F.9 SCR Gate Locations Typical Output Voltage Waveform Machine Loaded to 2 Amps 39TROUBLESHOOTING & REPAIRF-39DC TIG Mode Scope SettingsWas loaded with a resistance grid bank 40TROUBLESHOOTING & REPAIRF-40AC TIG Mode Milliseconds in time. The machineHorizontal Sweep Ms/Div 41TROUBLESHOOTING & REPAIRF-41Typical AC Voltage Waveform Machine Loaded to 50 Amps This is the typical DC + output voltage42TROUBLESHOOTING & REPAIRF-42 Typical AC Voltage Waveform Machine Loaded to 2 AmpsAC Balance Control in Auto Output Control AT Minimum 43TROUBLESHOOTING & REPAIRF-43 Return to Section TOC 45TROUBLESHOOTING & REPAIRF-45 High Voltage Transformer Removal and ReplacementNut Driver Phillips Head Screwdriver Off-set Wire Cutters Replacement Procedure 46TROUBLESHOOTING & REPAIRF-46Removal and Replacement Removal ProcedureFigure F.11 3/8 Screw & Leads S and F Locations 47TROUBLESHOOTING & REPAIRF-47Return to Section TOC 49TROUBLESHOOTING & REPAIRF-49 Control Board Removal and ReplacementNut Driver Phillips Head Screwdriver Wire Cutters Control Board Removal and Replacement 50TROUBLESHOOTING & REPAIRF-50J10 J11 J12 51TROUBLESHOOTING & REPAIRF-51Return to Section TOC 53TROUBLESHOOTING & REPAIRF-53 SCR Bridge Assembly Removal and ReplacementNut Driver Pliers Crimp Wire Cutters 54TROUBLESHOOTING & REPAIRF-54 SCR Bridge Assembly Removal and ReplacementSee Figure F.14 SCR Bridge Removal and Replacement Mounting of Stud Type Diodes to Aluminum Heat Sinks CONT’D Diode Stud Foot Inch Size Pounds25-27 300-324 10±.5 125+0/-5 22-25 Polarity Switch Removal and Replacement 57TROUBLESHOOTING & REPAIRF-57Polarity Switch Removal and Replacement 58TROUBLESHOOTING & REPAIRF-58SCR Removal and Replacement 59TROUBLESHOOTING & REPAIRF-5960TROUBLESHOOTING & REPAIRF-60 SCR Removal and ReplacementSpecial Instructions Recommended Meters for Machine Output Tests Retest After RepairInput Idle Amps Open Circuit VoltagesReturn to Section TOC Control P.C. Board Schematic Electrical Diagrams Section Section GWiring Diagram Entire Machine Code 10806 G4031 Electrical DiagramsSCR2 Wiring Diagram Entire Machine Code 10807 G4031-1Wiring Diagram Entire Machine Code 10893 G4031-2 Precision TIG 275 Wiring DiagramWiring Diagram Entire Machine Code 11158 G5692 Precision TIG 275 Wiring DiagramSchéma DE Câblage Diagramas DE Cableado Robotic Interface Connection Connexion Interface Robotique Wiring Diagram Entire Machine Code 11159 G5692-1Return to Section Schematic Entire Machine below Code 11000 G4075Change Detail Released from X A.02 Schematic Entire Machine Above Code 11000 G5691Schematic Control PC Board below Code 11000 G3908 Electrical Diagrams Electrical Diagrams G3909 PC Board ASSEMBLY-CONTROL below Code 11000 G3909-2Schematic Control PC Board Above Code 11000 G4762 Electrical Diagrams Electrical Diagrams Electrical Diagrams Electrical Diagrams G4763 PC Board ASSEMBLY-CONTROL Above Code 11000 G4763-116115 M SCHEMATIC-PROTECTION P.C. Board M16115Reqd Identification PC Board ASSEMBLY-PROTECTION M16062-1SCHEMATIC-BYPASS / Stabilizer P.C. Board S22530-1 Code 10806 L10121-1 PC Board ASSEMBLY-BYPASS / Stabilizer L10121-1 Code 10806Frame Ground SCHEMATIC-BYPASS and CE P. C. Board S24206 CodeBottom View PC Board ASSEMBLY-BYPASS and CE L10882-1 CodeSchematic TIG Option P.C. Board below Code 11000 G4039 Electrical Diagrams Return to Section TOC To Section TOC Schematic TIG Option P.C. Board Above Code 11000 G4760 Electrical Diagrams Electrical Diagrams MAK E Detail SVM Error Reporting Form