Manuals / Lincoln Electric / Power Tools / Welding System

Lincoln Electric SVM162-B 23TROUBLESHOOTING & REPAIRF-23, Nut Driver Electrical Insulating Tape

Models: SVM162-B

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F-23TROUBLESHOOTING & REPAIRF-23

HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

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

DESCRIPTION

This procedure will disable the high frequency circuit allowing the technician to take volt- age measurements without the possibility of high frequency damage to his test equipment.

MATERIALS NEEDED

3/8” Nut Driver

Electrical Insulating Tape

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PRECISION TIG 275

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Lincoln Electric SVM162-B service manual 23TROUBLESHOOTING & REPAIRF-23, High Frequency Circuit Disable Procedure

Contents

Precision TIG Safety Depends on YouPowered equipment SafetyFor Engine Mar ʻ95ARC 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 ÀMaster 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 150Maximum Open Output CurrentSafety Precautions ProtectionSelect Suitable Location Disconnect switch or fuse box Turn the input power OFF atBefore working on this equip MentWork Cable Connection Figure A.2 Figure A.3 Auxiliary Power ConnectionsFigure A.4 Robotic Interface ConnectionReturn to Section TOC Table of Contents Operation Section Operation Product DescriptionPipe Thawing Equipment Recommended ProcessesWhen the Power Source is on Controls and SettingsStick mode the Electrode circuits Both the Stick and TIG torch cablesMaximum Output Control The large knob AC Balance OntrolTIG Mode Menu Menu Button and Display Switch CodesOperation for Codes Above 11000 only SelectGure B.3 Advanced Panel ControlsPulse 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 ChartFigure B.6 Setup Guidelines for TIG Welding With AN AmptrolRecommended Electrode Amperage Ranges Precision TIG Making a TIG Weld with AN AmptrolSmaw Process Gtaw ProcessTable 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 MaintenanceOverload Protection Safety PrecautionsService 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 CircuitFigure E.5 DC Welding Output DC Welding OutputFigure E.7 AC Welding Output AC Welding OutputFigure E.9 SCR Operation SCR OperationProtection Circuits 8THEORY of OPERATIONE-8FAN-AS-NEEDED F.A.N Thermal ProtectionTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide 2TROUBLESHOOTING & REPAIRF-2Troubleshooting & Repair Procedure Troubleshooting GuideReconnect TestControl Board TransformerSCR Bridge Test Machine functions normally Installed, remove it and replacePerform the Protection Board T1 TransformerSee Note below Protection BoardPerform the T1 Transformer Perform the SCR Bridge Test Perform the SCR Bridge Tests Perform the Gas Solenoid Test EstMaintenance Electric ShockCan Kill High frequency transformer Maintenance SectionSymptoms Misadjustments Course of Action Problems Possible AreasSee the Maintenance Secti To Technical SpecificationsStick electrode blasts-off Welding current may be too high Stick Welding ProblemsFunction Problems Be plugged into J3 Installation ManualDisplay switch may be faulty Precision TIG Meter Calibration Adjustments 19TROUBLESHOOTING & REPAIRF-19Voltmeter/Ohmmeter Nut Driver Wiring Diagram Description20TROUBLESHOOTING & 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 TestT1 Main Transformer Test 27TROUBLESHOOTING & REPAIRF-2728TROUBLESHOOTING & REPAIRF-28 Test ProceduresT1 Main Transformer Test Primary Windings Test Points Acceptable VoltagesReturn to Section TOC GAS Water Solenoid Test 31TROUBLESHOOTING & REPAIRF-31Disable Procedure Test ProcedureGAS Water Solenoid Test Perform the High Frequency CircuitStatic SCR Test 33TROUBLESHOOTING & REPAIRF-33Removal and Replacement 34TROUBLESHOOTING & REPAIRF-34Assembly. See SCR Bridge Assembly Static SCR TestActive SCR Test Service and repairActive SCR Test 36TROUBLESHOOTING & REPAIRF-36Active SCR Test Figure F.9 SCR Gate Locations DC TIG Mode 39TROUBLESHOOTING & REPAIRF-39Scope Settings Typical Output Voltage Waveform Machine Loaded to 2 AmpsAC TIG Mode 40TROUBLESHOOTING & REPAIRF-40Milliseconds in time. The machine Was loaded with a resistance grid bankTypical AC Voltage Waveform Machine Loaded to 50 Amps 41TROUBLESHOOTING & REPAIRF-41This is the typical DC + output voltage Horizontal Sweep Ms/Div42TROUBLESHOOTING & 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 ProcedureFigure F.11 3/8 Screw & Leads S and F Locations 47TROUBLESHOOTING & REPAIRF-47Return to Section TOC 49TROUBLESHOOTING & REPAIRF-49 Control Board Removal and ReplacementNut Driver Phillips Head Screwdriver Wire Cutters Control Board Removal and Replacement 50TROUBLESHOOTING & REPAIRF-50J10 J11 J12 51TROUBLESHOOTING & REPAIRF-51Return 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-57Polarity Switch Removal and Replacement 58TROUBLESHOOTING & REPAIRF-58SCR Removal and Replacement 59TROUBLESHOOTING & REPAIRF-5960TROUBLESHOOTING & REPAIRF-60 SCR Removal and ReplacementSpecial Instructions Input Idle Amps Retest After RepairOpen Circuit Voltages Recommended Meters for Machine Output TestsReturn to Section TOC Control P.C. Board Schematic Electrical Diagrams Section Section GWiring Diagram Entire Machine Code 10806 G4031 Electrical DiagramsSCR2 Wiring Diagram Entire Machine Code 10807 G4031-1Wiring Diagram Entire Machine Code 10893 G4031-2 Precision TIG 275 Wiring DiagramWiring 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 G5692-1Return to Section Schematic Entire Machine below Code 11000 G4075Change Detail Released from X A.02 Schematic Entire Machine Above Code 11000 G5691Schematic Control PC Board below Code 11000 G3908 Electrical Diagrams Electrical Diagrams G3909 PC Board ASSEMBLY-CONTROL below Code 11000 G3909-2Schematic Control PC Board Above Code 11000 G4762 Electrical Diagrams Electrical Diagrams Electrical Diagrams Electrical Diagrams G4763 PC Board ASSEMBLY-CONTROL Above Code 11000 G4763-116115 M SCHEMATIC-PROTECTION P.C. Board M16115Reqd Identification PC Board ASSEMBLY-PROTECTION M16062-1SCHEMATIC-BYPASS / Stabilizer P.C. Board S22530-1 Code 10806 L10121-1 PC Board ASSEMBLY-BYPASS / Stabilizer L10121-1 Code 10806Frame Ground SCHEMATIC-BYPASS and CE P. C. Board S24206 CodeBottom View PC Board ASSEMBLY-BYPASS and CE L10882-1 CodeSchematic 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