Electric Shock, Maintenance, Can Kill | Lincoln Electric SVM162-B

PRECISION TIG 275

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F-11

TROUBLESHOOTING & REPAIR

F-11

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

TIG WELDING PROBLEMS

No high frequency. The machine is

1. If the machine is in a dirty envi-

1. Check the high voltage trans-

in the TIG mode and has normal

ronment with conductive contam-

former (T2). The normal resis-

output.

inants, check and clean the

tance of the secondary winding is

spark gap with a low pressure air

12.5k ohms.

stream

per

the maintenance

WARNING

2. Check the spark gap operations

instructions.

and setting. Normal is (0.015”).

NOTE: BEFORE REPLACING A

ELECTRIC SHOCK

Refer

to

the

Maintenance

CAN KILL.

When

CONTROL BOARD

Section of this manual.

115 VAC is applied

If an Advanced Control Panel is

3. Check

circuit

breaker CB1.

to T2, a very high

installed, remove it and replace

voltage

is

devel-

the Jumper in connector J-3. If

Reset if necessary.

oped on the secondary winding. For

the machine functions normally,

4. Check connection J12 on the

assistance, call the Lincoln Electric

the Advanced Process panel or

control board.

Service Department.

1-888-935-

harness is defective.

3877.

2. Check R5, C6, C7, L2 and L3.

Replace if defective.

3. The control board may be faulty.

The High frequency is on continu-

1. None

1. Check plug J11 on the control

ously in DC TIG or shuts off in AC

board. See the Wiring Diagram.

TIG.

2. Check micro-switch

S2A for

proper operation. See the Wiring

Diagram.

3. The control board may be faulty.

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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.

Image 57

Lincoln Electric SVM162-B service manual Electric Shock, Maintenance, Can Kill

Contents

Precision TIG Safety Depends on You Powered equipment SafetyFor Engine Mar ʻ95 ARC Rays can burn Fumes and GasesAug ʻ06 Welding Sparks can Cylinder may explode If damagedIii Précautions DE Sûreté Pour Précautions DE SûretéLES Machines À Souder À Transformateur ET À Master Table of Contents for ALL Sections Table of Contents Installation Section Unbalance 70% Penetration AC TIG 16.1 255 60% 29.0 225 InstallationUnbalance 70% Penetration AC TIG 15.4 200 100% 28.0 Unbalance 70% Penetration AC TIG 14.8 150 Maximum Open Output Current Safety Precautions ProtectionSelect Suitable Location Disconnect switch or fuse box Turn the input power OFF atBefore working on this equip Ment Work Cable Connection Figure A.2 Figure A.3 Auxiliary Power Connections Figure A.4 Robotic Interface Connection Return to Section TOC Table of Contents Operation Section Operation Product DescriptionPipe Thawing Equipment Recommended Processes When the Power Source is on Controls and SettingsStick mode the Electrode circuits Both the Stick and TIG torch cables Maximum Output Control The large knob AC Balance Ontrol TIG Mode Menu Menu Button and Display Switch CodesOperation for Codes Above 11000 only Select Gure B.3 Advanced Panel Controls Pulse 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 Chart Figure B.6 Setup Guidelines for TIG Welding With AN Amptrol Recommended Electrode Amperage Ranges Precision TIG Making a TIG Weld with AN AmptrolSmaw Process Gtaw Process Table 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 Maintenance Overload Protection Safety Precautions Service 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 Circuit Figure E.5 DC Welding Output DC Welding Output Figure E.7 AC Welding Output AC Welding Output Figure E.9 SCR Operation SCR Operation Protection Circuits 8THEORY of OPERATIONE-8FAN-AS-NEEDED F.A.N Thermal Protection Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide 2TROUBLESHOOTING & REPAIRF-2 Troubleshooting & Repair Procedure Troubleshooting GuideReconnect Test Control Board TransformerSCR Bridge Test Machine functions normally Installed, remove it and replacePerform the Protection Board T1 Transformer See Note below Protection BoardPerform the T1 Transformer Perform the SCR Bridge Test Perform the SCR Bridge Tests Perform the Gas Solenoid Test Est Maintenance Electric ShockCan Kill High frequency transformer Maintenance Section Symptoms Misadjustments Course of Action Problems Possible AreasSee the Maintenance Secti To Technical Specifications Stick electrode blasts-off Welding current may be too high Stick Welding Problems Function Problems Be plugged into J3 Installation Manual Display switch may be faulty Precision TIG Meter Calibration Adjustments 19TROUBLESHOOTING & REPAIRF-19Voltmeter/Ohmmeter Nut Driver Wiring Diagram Description 20TROUBLESHOOTING & 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 Test T1 Main Transformer Test 27TROUBLESHOOTING & REPAIRF-27 28TROUBLESHOOTING & REPAIRF-28 Test ProceduresT1 Main Transformer Test Primary Windings Test Points Acceptable Voltages Return to Section TOC GAS Water Solenoid Test 31TROUBLESHOOTING & REPAIRF-31 Disable Procedure Test ProcedureGAS Water Solenoid Test Perform the High Frequency Circuit Static SCR Test 33TROUBLESHOOTING & REPAIRF-33 Removal and Replacement 34TROUBLESHOOTING & REPAIRF-34Assembly. See SCR Bridge Assembly Static SCR Test Active SCR Test Service and repair Active SCR Test 36TROUBLESHOOTING & REPAIRF-36 Active SCR Test Figure F.9 SCR Gate Locations DC TIG Mode 39TROUBLESHOOTING & REPAIRF-39Scope Settings Typical Output Voltage Waveform Machine Loaded to 2 Amps AC TIG Mode 40TROUBLESHOOTING & REPAIRF-40Milliseconds in time. The machine Was loaded with a resistance grid bank Typical AC Voltage Waveform Machine Loaded to 50 Amps 41TROUBLESHOOTING & REPAIRF-41This is the typical DC + output voltage Horizontal Sweep Ms/Div 42TROUBLESHOOTING & 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 Removal and Replacement 46TROUBLESHOOTING & REPAIRF-46Removal Procedure Replacement Procedure Figure F.11 3/8 Screw & Leads S and F Locations 47TROUBLESHOOTING & REPAIRF-47 Return to Section TOC 49TROUBLESHOOTING & REPAIRF-49 Control Board Removal and ReplacementNut Driver Phillips Head Screwdriver Wire Cutters Control Board Removal and Replacement 50TROUBLESHOOTING & REPAIRF-50 J10 J11 J12 51TROUBLESHOOTING & REPAIRF-51 Return 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-57 Polarity Switch Removal and Replacement 58TROUBLESHOOTING & REPAIRF-58 SCR Removal and Replacement 59TROUBLESHOOTING & REPAIRF-59 60TROUBLESHOOTING & REPAIRF-60 SCR Removal and ReplacementSpecial Instructions Input Idle Amps Retest After RepairOpen Circuit Voltages Recommended Meters for Machine Output Tests Return to Section TOC Control P.C. Board Schematic Electrical Diagrams Section Section G Wiring Diagram Entire Machine Code 10806 G4031 Electrical Diagrams SCR2 Wiring Diagram Entire Machine Code 10807 G4031-1 Wiring Diagram Entire Machine Code 10893 G4031-2 Precision TIG 275 Wiring Diagram Wiring 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 G5692-1 Return to Section Schematic Entire Machine below Code 11000 G4075 Change Detail Released from X A.02 Schematic Entire Machine Above Code 11000 G5691 Schematic Control PC Board below Code 11000 G3908 Electrical Diagrams Electrical Diagrams G3909 PC Board ASSEMBLY-CONTROL below Code 11000 G3909-2 Schematic Control PC Board Above Code 11000 G4762 Electrical Diagrams Electrical Diagrams Electrical Diagrams Electrical Diagrams G4763 PC Board ASSEMBLY-CONTROL Above Code 11000 G4763-1 16115 M SCHEMATIC-PROTECTION P.C. Board M16115 Reqd Identification PC Board ASSEMBLY-PROTECTION M16062-1 SCHEMATIC-BYPASS / Stabilizer P.C. Board S22530-1 Code 10806 L10121-1 PC Board ASSEMBLY-BYPASS / Stabilizer L10121-1 Code 10806 Frame Ground SCHEMATIC-BYPASS and CE P. C. Board S24206 Code Bottom View PC Board ASSEMBLY-BYPASS and CE L10882-1 Code 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