Troubleshooting Guide, Reconnect, Test | Lincoln Electric SVM162-B

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	F-4	TROUBLESHOOTING & REPAIR							F-4
	Observe Safety Guidelines							TROUBLESHOOTING GUIDE
	detailed in the beginning of this manual.
	PROBLEMS		POSSIBLE AREAS OF					RECOMMENDED
	(SYMPTOMS)		MISADJUSTMENT(S)					COURSE OF ACTION
				OUTPUT PROBLEMS
	The machine is dead. No weld out-		1.	Check the input voltage. The				1. Check the input power switch,
	put – no 115 VAC at the receptacle.			input voltage must match the rat-				reconnect panel and associated
				ing plate and the voltage con-				wires for loose or faulty connec-
				nection.	Refer	to	Reconnect	tions.
				Procedure in		the	Installation	2. The input power switch may be
			2.	section of this manual.				faulty.
			2.	Make sure that the input power				3. Perform the T1 Transformer
			3.	switch is in the “ON” position.				Test.
			3.	Check for blown or missing
			4.	fuses in the input lines.
			4.	Check	circuit	breaker CB1.
				Reset if necessary.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

PRECISION TIG 275

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Lincoln Electric SVM162-B service manual Troubleshooting Guide, Reconnect, Procedure, Test

Contents

Safety Depends on You Precision TIG For Engine SafetyPowered equipment Mar ʻ95 Aug ʻ06 ARC Rays can burnFumes and Gases Iii Welding Sparks canCylinder may explode If damaged LES Machines À Souder À Précautions DE SûretéPrécautions DE Sûreté Pour Transformateur ET À Master Table of Contents for ALL Sections Table of Contents Installation Section Unbalance 70% Penetration AC TIG 15.4 200 100% 28.0 InstallationUnbalance 70% Penetration AC TIG 16.1 255 60% 29.0 225 Unbalance 70% Penetration AC TIG 14.8 150 Output Current Maximum Open Select Suitable Location Safety PrecautionsProtection Before working on this equip Turn the input power OFF atDisconnect switch or fuse box 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 Stick mode the Electrode circuits Controls and SettingsWhen the Power Source is on Both the Stick and TIG torch cables AC Balance Ontrol Maximum Output Control The large knob Operation for Codes Above 11000 only Menu Button and Display Switch CodesTIG Mode Menu 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 Smaw Process Making a TIG Weld with AN AmptrolRecommended Electrode Amperage Ranges Precision TIG 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 FAN-AS-NEEDED F.A.N 8THEORY of OPERATIONE-8Protection Circuits Thermal Protection Table of Contents Troubleshooting & Repair Section 2TROUBLESHOOTING & REPAIRF-2 HOW to USE Troubleshooting Guide Troubleshooting & Repair Reconnect Troubleshooting GuideProcedure Test SCR Bridge Test Control BoardTransformer Perform the Protection Board Installed, remove it and replaceMachine functions normally 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 See the Maintenance Secti Problems Possible AreasSymptoms Misadjustments Course of Action 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 Voltmeter/Ohmmeter Nut Driver Wiring Diagram 19TROUBLESHOOTING & REPAIRF-19Meter Calibration Adjustments 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 GAS Water Solenoid Test Test ProcedureDisable Procedure Perform the High Frequency Circuit 33TROUBLESHOOTING & REPAIRF-33 Static SCR Test Assembly. See SCR Bridge Assembly 34TROUBLESHOOTING & REPAIRF-34Removal and Replacement Static SCR Test Service and repair Active SCR Test 36TROUBLESHOOTING & REPAIRF-36 Active SCR Test Active SCR Test Figure F.9 SCR Gate Locations Scope Settings 39TROUBLESHOOTING & REPAIRF-39DC TIG Mode Typical Output Voltage Waveform Machine Loaded to 2 Amps Milliseconds in time. The machine 40TROUBLESHOOTING & REPAIRF-40AC TIG Mode Was loaded with a resistance grid bank This is the typical DC + output voltage 41TROUBLESHOOTING & REPAIRF-41Typical AC Voltage Waveform Machine Loaded to 50 Amps 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 Removal Procedure 46TROUBLESHOOTING & REPAIRF-46Removal and Replacement 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 Open Circuit Voltages Retest After RepairInput Idle Amps 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