Stick Welding Problems | Lincoln Electric SVM162-B manual

PRECISION TIG 275

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	F-14	TROUBLESHOOTING & REPAIR			F-14
	Observe Safety Guidelines			TROUBLESHOOTING GUIDE
	detailed in the beginning of this manual.
	PROBLEMS		POSSIBLE AREAS OF	RECOMMENDED
	(SYMPTOMS)		MISADJUSTMENT(S)	COURSE OF ACTION
			STICK WELDING PROBLEMS
	The stick electrode “blasts-off”		1. Welding current may be too high	1. Perform the SCR Bridge Test.
	when touched to the work piece.		for the electrode size. Reduce	2. The control board may be faulty.
			current control setting or use a	2. The control board may be faulty.
	NOTE: BEFORE REPLACING A		larger diameter electrode.
	NOTE: BEFORE REPLACING A
	CONTROL BOARD
	If an Advanced Control Panel is
	installed, remove it and replace
	the Jumper in connector J-3. If
	the machine functions normally,
	the Advanced Process panel or
	harness is defective.

Variable or sluggish welding arc 1.	Check the work and electrode	1.	Check the polarity switch for
when welding in the Stick mode.	cables for loose or poor connec-		excessive wear or faulty connec-
2.	tions.	2.	tions.
2.	The welding cables may be too	2.	Check the interior heavy current
	small or too long to permit the		carrying leads and connections.
3.	desired current to flow.
3.	The welding current may be set
	too low.

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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.

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Lincoln Electric SVM162-B service manual Stick Welding Problems, Stick electrode blasts-off Welding current may be too high

Contents

Safety Depends on You Precision TIG Safety Powered equipmentFor Engine Mar ʻ95 ARC Rays can burn Fumes and GasesAug ʻ06 Welding Sparks can Cylinder may explode If damagedIii 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 Safety Precautions ProtectionSelect 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 Operation Product DescriptionPipe 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 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 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 Accessories for Codes below Optional EquipmentMagnum PTA and PTW Series Torches Accessories for Codes Above Return to Section TOC Maintenance Component Location and Access Safety Precautions Overload Protection 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 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 Control Board TransformerSCR Bridge Test Installed, remove it and replace Machine functions normallyPerform the Protection Board T1 Transformer See Note below Protection BoardPerform the T1 Transformer Perform the SCR Bridge Test Perform the SCR Bridge Tests Est Perform the Gas Solenoid Test Maintenance Electric ShockCan 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 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 Protection Board Test Resistance Between Reading 27TROUBLESHOOTING & REPAIRF-27 T1 Main Transformer Test 28TROUBLESHOOTING & REPAIRF-28 Test ProceduresT1 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 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 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 49TROUBLESHOOTING & REPAIRF-49 Control Board Removal and ReplacementNut Driver Phillips Head Screwdriver Wire Cutters 50TROUBLESHOOTING & REPAIRF-50 Control Board Removal and Replacement 51TROUBLESHOOTING & REPAIRF-51 J10 J11 J12 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 57TROUBLESHOOTING & REPAIRF-57 Polarity Switch Removal and Replacement 58TROUBLESHOOTING & REPAIRF-58 Polarity Switch Removal and Replacement 59TROUBLESHOOTING & REPAIRF-59 SCR Removal and Replacement 60TROUBLESHOOTING & REPAIRF-60 SCR Removal and ReplacementSpecial 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 Wiring Diagram Entire Machine Code 11158 G5692 Precision TIG 275 Wiring DiagramSchéma 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