Machine functions normally | Lincoln Electric SVM162-B specification

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F-6			TROUBLESHOOTING & REPAIR				F-6
	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
	No output from the machine in			1. The welding application may	1. One of the thermostats may be
	either Stick or TIG	modes. The		have exceeded the recommend-	faulty. Check or replace.		See
	thermal light is on.			ed duty cycle. Allow the fan to	the Wiring Diagram.
				cool the until the thermal light is	2. Check for loose or faulty wires
	NOTE: BEFORE REPLACING A			off.	on the thermostats and associat-
	NOTE: BEFORE REPLACING A			2. The air louvers may be blocked.	ed circuitry.	See the Wiring
	CONTROL BOARD			Remove the air obstruction and	Diagram.
	If an Advanced Control Panel is			allow the unit to cool.	3. The fan motor may be faulty or
	installed, remove it and replace				3. The fan motor may be faulty or
	the Jumper in connector J-3. If				mechanically	obstructed.	The
	the machine functions normally,				fan should run when welding or
	the Advanced Process panel or				when a thermostat is open.
	harness is defective.				4. The control board may be faulty.

	The machine does not respond (no			1. Make sure the machine is in the	1. Perform the Protection Board
	gas flow, no high frequency and no			TIG mode.	Test.
	open circuit voltage) when the arc			2. The Amptrol or arc start switch	2. Perform the	T1 Transformer
	start switch or Amptrol is activated.			may be defective. Check for	Test.
	The thermal light is not lit.			continuity ( zero ohms) between	3. The control board may be faulty.
	NOTE: BEFORE REPLACING A			pins “D” and “E” on the cable	3. The control board may be faulty.
	NOTE: BEFORE REPLACING A			connector when the Amptrol or
	CONTROL BOARD			arc start is pressed.
	If an Advanced Control Panel is			3. Check the Local/Remote switch
	installed, remove it and replace			for proper operation.
	the Jumper in connector J-3. If
	the machine functions normally,
	the Advanced Process panel or
	harness is defective.

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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

Image 52

Lincoln Electric SVM162-B service manual Machine functions normally, Perform the Protection Board, T1 Transformer

Contents

Safety Depends on You Precision TIG Safety Powered equipmentFor Engine Mar ʻ95 Fumes and Gases ARC Rays can burnAug ʻ06 Cylinder may explode If damaged Welding Sparks canIii 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 Protection Safety PrecautionsSelect Suitable Location 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 Product Description OperationPipe Thawing 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 Time Control PULSE% on Pulse Frequency ControlPulse Background Current Control TIG Welding Features Internal SET UP ControlsStick 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 Optional Equipment Accessories for Codes belowMagnum PTA and PTW Series Torches Accessories for Codes Above Return to Section TOC Maintenance Component Location and Access Safety Precautions Overload Protection Spark GAP Adjustment Service ProceduresUNDER-COOLER Service Warni Table of Contents Theory of Operation Section Theory of Operation Input Power CircuitGeneral Description Control board also monitors the thermostats Output RectificationSee SCR Operation 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 Transformer Control BoardSCR Bridge Test Installed, remove it and replace Machine functions normallyPerform the Protection Board T1 Transformer Protection Board See Note belowPerform the T1 Transformer Perform the SCR Bridge Test Perform the SCR Bridge Tests Est Perform the Gas Solenoid Test Electric Shock MaintenanceCan Kill 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 Meter Calibration Adjustments 20TROUBLESHOOTING & REPAIRF-20Calibration Check Ammeter Calibration Procedure 21TROUBLESHOOTING & REPAIRF-21Control board. See Figure F1 Return to Section TOC High Frequency Circuit Disable Procedure 23TROUBLESHOOTING & REPAIRF-23Nut Driver Electrical Insulating Tape High Frequency Circuit Disable Procedure 24TROUBLESHOOTING & REPAIRF-24Procedure Protection Board Test 25TROUBLESHOOTING & REPAIRF-25Test Description Protection Board Test Resistance Between Reading 27TROUBLESHOOTING & REPAIRF-27 T1 Main Transformer Test Test Procedures 28TROUBLESHOOTING & REPAIRF-28T1 Main Transformer Test 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 Typical AC Voltage Waveform Machine Loaded to 2 Amps 42TROUBLESHOOTING & REPAIRF-42AC Balance Control in Auto Output Control AT Minimum 43TROUBLESHOOTING & REPAIRF-43 Return to Section TOC High Voltage Transformer Removal and Replacement 45TROUBLESHOOTING & REPAIRF-45Nut Driver Phillips Head Screwdriver Off-set Wire Cutters 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 Control Board Removal and Replacement 49TROUBLESHOOTING & REPAIRF-49Nut Driver Phillips Head Screwdriver Wire Cutters 50TROUBLESHOOTING & REPAIRF-50 Control Board Removal and Replacement 51TROUBLESHOOTING & REPAIRF-51 J10 J11 J12 Return to Section TOC SCR Bridge Assembly Removal and Replacement 53TROUBLESHOOTING & REPAIRF-53Nut Driver Pliers Crimp Wire Cutters SCR Bridge Assembly Removal and Replacement 54TROUBLESHOOTING & REPAIRF-54See Figure F.14 SCR Bridge Removal and Replacement Diode Stud Foot Inch Size Pounds Mounting of Stud Type Diodes to Aluminum Heat Sinks CONT’D25-27 300-324 10±.5 125+0/-5 22-25 57TROUBLESHOOTING & REPAIRF-57 Polarity Switch Removal and Replacement 58TROUBLESHOOTING & REPAIRF-58 Polarity Switch Removal and Replacement 59TROUBLESHOOTING & REPAIRF-59 SCR Removal and Replacement SCR Removal and Replacement 60TROUBLESHOOTING & REPAIRF-60Special Instructions 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 Precision TIG 275 Wiring Diagram Wiring Diagram Entire Machine Code 11158 G5692Schéma DE Câblage Diagramas DE Cableado 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