AC Welding Output | Lincoln Electric SVM162-B guide

REMOTE

RECEPTACLE

electrically across the negative and positive SCR bridge connections. With the ability of the choke to store energy and the SCRs to turn on at the appropri- ate times, an AC square wave is developed and applied to the output terminals. The bypass board pro- tects the internal circuitry from interference.

ADVANCED CONTROL PANEL RECEPTACLE

TOC TOC

E-6

THEORY OF OPERATION

E-6

FIGURE E.7 – AC WELDING OUTPUT

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FROM

CONTROL

BOARD

OPTIONAL POWER

CORRECTIONFACTOR

CAPACITORS

POWER

SWITCH

PANEL

RECONNECT

BACKGROUND

CIRCUIT

63.5 VAC

			REAR GANG		WORK
		POLARITY			WORK
		POLARITY
		SWITCH	BYPASS	BOARD
			BYPASS	BOARD	FRONT
					FRONT
				HIGH FREQUENCY	ELECTRODE
X1				HIGH FREQUENCY
X1				TRANSFORMER	REAR
78 VAC			CHOKE		ELECTRODE
78 VAC	AC	DC	CHOKE
X2	AC	DC
X2	SCR			HIGH VOLTAGE
	SCR			TRANSFORMER
	BRIDGE
	AC	DC	SHUNT

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115 VAC THERMOSTAT

115 VAC VAC115

20 VAC

20 VAC

LEADSGATE	FEEDBACK	GAS
LEADSGATE	FEEDBACK	VAC
FAN		SOLENOID
		115

CONTROL BOARD

115 VAC

THERMOSTAT

LED's

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MINIMUM
OUTPUT	PROTECTION	METER	STICK
CONTROL	PROTECTION	METER	STICK
	BOARD		TIG
			SWITCH	BALANCE	POST	LOCAL/REMOTE
				CONTROL	FLOW	SWITCH

MAXIMUM

OUTPUT

CONTROL

AC WELDING OUTPUT

Rotating the polarity switch to the AC position changes the welding power circuit. One lead (X1) of the main transformer secondary is connected to the machineʼs output work terminal. The other secondary lead (X2) is connected to one of the AC connections of the SCR bridge. The electrode terminal is connected to the other AC side of the bridge. The choke is now

FIGURE E.8 DC WELDING CURRENT GENERATION

G	CHOKE	G	ELECTRODE
		G

G			G
G

Section TOC Master TOC

PRIMARY 10

DC

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WORK

PRECISION TIG 275

Image 44

Lincoln Electric SVM162-B service manual Figure E.7 AC Welding Output

Contents

Safety Depends on You Precision TIG Safety Powered equipmentFor Engine Mar ʻ95 Aug ʻ06 ARC Rays can burnFumes and Gases Iii Welding Sparks canCylinder may explode If damaged Précautions DE Sûreté Précautions DE Sûreté PourLES Machines À Souder À Transformateur ET À Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Unbalance 70% Penetration AC TIG 16.1 255 60% 29.0 225Unbalance 70% Penetration AC TIG 15.4 200 100% 28.0 Unbalance 70% Penetration AC TIG 14.8 150 Output Current Maximum Open Select Suitable Location Safety PrecautionsProtection Turn the input power OFF at Disconnect switch or fuse boxBefore working on this equip Ment Work Cable Connection Figure A.2 Auxiliary Power Connections Figure A.3 Robotic Interface Connection Figure A.4 Return to Section TOC Table of Contents Operation Section Pipe Thawing OperationProduct Description Recommended Processes Equipment Controls and Settings When the Power Source is onStick mode the Electrode circuits Both the Stick and TIG torch cables AC Balance Ontrol Maximum Output Control The large knob Menu Button and Display Switch Codes TIG Mode MenuOperation for Codes Above 11000 only Select Advanced Panel Controls Gure B.3 Pulse Background Current Control Pulse Frequency ControlTime Control PULSE% on Stick Welding Features Internal SET UP ControlsTIG Welding Features Step Trigger Modes Figure B.4 TIG Weld Cycle Chart Codes below 11000 K1829-1 Setup Guidelines for TIG Welding With AN Amptrol Figure B.6 Making a TIG Weld with AN Amptrol Recommended Electrode Amperage Ranges Precision TIGSmaw Process Gtaw Process Table of Contents Magnum PTA and PTW Series Torches Accessories for Codes belowOptional Equipment Accessories for Codes Above Return to Section TOC Maintenance Component Location and Access Safety Precautions Overload Protection UNDER-COOLER Service Service ProceduresSpark GAP Adjustment Warni Table of Contents Theory of Operation Section General Description Input Power CircuitTheory of Operation See SCR Operation Output RectificationControl board also monitors the thermostats High VOLTAGE/HIGH Frequency Circuit Figure E.4 High Voltage / High Frequency Circuit DC Welding Output Figure E.5 DC Welding Output AC Welding Output Figure E.7 AC Welding Output SCR Operation Figure E.9 SCR Operation 8THEORY of OPERATIONE-8 Protection CircuitsFAN-AS-NEEDED F.A.N Thermal Protection Table of Contents Troubleshooting & Repair Section 2TROUBLESHOOTING & REPAIRF-2 HOW to USE Troubleshooting Guide Troubleshooting & Repair Troubleshooting Guide ProcedureReconnect Test SCR Bridge Test Control BoardTransformer Installed, remove it and replace Machine functions normallyPerform the Protection Board T1 Transformer Perform the T1 Transformer See Note belowProtection Board Perform the SCR Bridge Test Perform the SCR Bridge Tests Est Perform the Gas Solenoid Test Can Kill MaintenanceElectric Shock Maintenance Section High frequency transformer Problems Possible Areas Symptoms Misadjustments Course of ActionSee the Maintenance Secti To Technical Specifications Stick Welding Problems Stick electrode blasts-off Welding current may be too high Function Problems Installation Manual Be plugged into J3 Display switch may be faulty Precision TIG 19TROUBLESHOOTING & REPAIRF-19 Meter Calibration AdjustmentsVoltmeter/Ohmmeter Nut Driver Wiring Diagram Description Calibration Check 20TROUBLESHOOTING & REPAIRF-20Meter Calibration Adjustments Control board. See Figure F1 21TROUBLESHOOTING & REPAIRF-21Ammeter Calibration Procedure Return to Section TOC Nut Driver Electrical Insulating Tape 23TROUBLESHOOTING & REPAIRF-23High Frequency Circuit Disable Procedure Procedure 24TROUBLESHOOTING & REPAIRF-24High Frequency Circuit Disable Procedure Test Description 25TROUBLESHOOTING & REPAIRF-25Protection Board Test Protection Board Test Resistance Between Reading 27TROUBLESHOOTING & REPAIRF-27 T1 Main Transformer Test T1 Main Transformer Test 28TROUBLESHOOTING & REPAIRF-28Test Procedures Test Points Acceptable Voltages Primary Windings Return to Section TOC 31TROUBLESHOOTING & REPAIRF-31 GAS Water Solenoid Test Test Procedure Disable ProcedureGAS Water Solenoid Test Perform the High Frequency Circuit 33TROUBLESHOOTING & REPAIRF-33 Static SCR Test 34TROUBLESHOOTING & REPAIRF-34 Removal and ReplacementAssembly. See SCR Bridge Assembly Static SCR Test Service and repair Active SCR Test 36TROUBLESHOOTING & REPAIRF-36 Active SCR Test Active SCR Test Figure F.9 SCR Gate Locations 39TROUBLESHOOTING & REPAIRF-39 DC TIG ModeScope Settings Typical Output Voltage Waveform Machine Loaded to 2 Amps 40TROUBLESHOOTING & REPAIRF-40 AC TIG ModeMilliseconds in time. The machine Was loaded with a resistance grid bank 41TROUBLESHOOTING & REPAIRF-41 Typical AC Voltage Waveform Machine Loaded to 50 AmpsThis is the typical DC + output voltage Horizontal Sweep Ms/Div AC Balance Control in Auto Output Control AT Minimum 42TROUBLESHOOTING & REPAIRF-42Typical AC Voltage Waveform Machine Loaded to 2 Amps 43TROUBLESHOOTING & REPAIRF-43 Return to Section TOC Nut Driver Phillips Head Screwdriver Off-set Wire Cutters 45TROUBLESHOOTING & REPAIRF-45High Voltage Transformer Removal and Replacement 46TROUBLESHOOTING & REPAIRF-46 Removal and ReplacementRemoval Procedure Replacement Procedure 47TROUBLESHOOTING & REPAIRF-47 Figure F.11 3/8 Screw & Leads S and F Locations Return to Section TOC Nut Driver Phillips Head Screwdriver Wire Cutters 49TROUBLESHOOTING & REPAIRF-49Control Board Removal and Replacement 50TROUBLESHOOTING & REPAIRF-50 Control Board Removal and Replacement 51TROUBLESHOOTING & REPAIRF-51 J10 J11 J12 Return to Section TOC Nut Driver Pliers Crimp Wire Cutters 53TROUBLESHOOTING & REPAIRF-53SCR Bridge Assembly Removal and Replacement See Figure F.14 54TROUBLESHOOTING & REPAIRF-54SCR Bridge Assembly Removal and Replacement SCR Bridge Removal and Replacement 25-27 300-324 10±.5 125+0/-5 22-25 Mounting of Stud Type Diodes to Aluminum Heat Sinks CONT’DDiode Stud Foot Inch Size Pounds 57TROUBLESHOOTING & REPAIRF-57 Polarity Switch Removal and Replacement 58TROUBLESHOOTING & REPAIRF-58 Polarity Switch Removal and Replacement 59TROUBLESHOOTING & REPAIRF-59 SCR Removal and Replacement Special Instructions 60TROUBLESHOOTING & REPAIRF-60SCR Removal and Replacement Retest After Repair Input Idle AmpsOpen Circuit Voltages Recommended Meters for Machine Output Tests Return to Section TOC Electrical Diagrams Section Section G Control P.C. Board Schematic Electrical Diagrams Wiring Diagram Entire Machine Code 10806 G4031 Wiring Diagram Entire Machine Code 10807 G4031-1 SCR2 Precision TIG 275 Wiring Diagram Wiring Diagram Entire Machine Code 10893 G4031-2 Schéma DE Câblage Diagramas DE Cableado Wiring Diagram Entire Machine Code 11158 G5692Precision TIG 275 Wiring Diagram Wiring Diagram Entire Machine Code 11159 G5692-1 Robotic Interface Connection Connexion Interface Robotique Schematic Entire Machine below Code 11000 G4075 Return to Section Schematic Entire Machine Above Code 11000 G5691 Change Detail Released from X A.02 Schematic Control PC Board below Code 11000 G3908 Electrical Diagrams Electrical Diagrams PC Board ASSEMBLY-CONTROL below Code 11000 G3909-2 G3909 Schematic Control PC Board Above Code 11000 G4762 Electrical Diagrams Electrical Diagrams Electrical Diagrams Electrical Diagrams PC Board ASSEMBLY-CONTROL Above Code 11000 G4763-1 G4763 SCHEMATIC-PROTECTION P.C. Board M16115 16115 M PC Board ASSEMBLY-PROTECTION M16062-1 Reqd Identification SCHEMATIC-BYPASS / Stabilizer P.C. Board S22530-1 Code 10806 PC Board ASSEMBLY-BYPASS / Stabilizer L10121-1 Code 10806 L10121-1 SCHEMATIC-BYPASS and CE P. C. Board S24206 Code Frame Ground PC Board ASSEMBLY-BYPASS and CE L10882-1 Code Bottom View Schematic 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