25TROUBLESHOOTING & REPAIRF-25 | Lincoln Electric SVM162-B instruction

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F-25TROUBLESHOOTING & REPAIRF-25

PROTECTION BOARD TEST

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.

TEST DESCRIPTION

This procedure will determine if the Protection board is functioning properly.

MATERIALS NEEDED

3/8” Nut Driver

Voltmeter/Ohmmeter (Multimeter)

Tig 275 Wiring Diagrams

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PRECISION TIG 275

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Lincoln Electric SVM162-B service manual 25TROUBLESHOOTING & REPAIRF-25, Protection Board Test, Test Description

Contents

Precision TIG Safety Depends on You Mar ʻ95 SafetyPowered equipment For Engine Aug ʻ06 ARC Rays can burnFumes and Gases Iii Welding Sparks canCylinder may explode If damaged Transformateur ET À Précautions DE SûretéPrécautions DE Sûreté Pour LES Machines À Souder À Master Table of Contents for ALL Sections Table of Contents Installation Section Unbalance 70% Penetration AC TIG 14.8 150 InstallationUnbalance 70% Penetration AC TIG 16.1 255 60% 29.0 225 Unbalance 70% Penetration AC TIG 15.4 200 100% 28.0 Maximum Open Output Current Select Suitable Location Safety PrecautionsProtection Ment Turn the input power OFF atDisconnect switch or fuse box Before working on this equip 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 Pipe Thawing OperationProduct Description Equipment Recommended Processes Both the Stick and TIG torch cables Controls and SettingsWhen the Power Source is on Stick mode the Electrode circuits Maximum Output Control The large knob AC Balance Ontrol Select Menu Button and Display Switch CodesTIG Mode Menu Operation for Codes Above 11000 only Gure B.3 Advanced Panel Controls 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 Codes below 11000 K1829-1 TIG Weld Cycle Chart Figure B.6 Setup Guidelines for TIG Welding With AN Amptrol Gtaw Process Making a TIG Weld with AN AmptrolRecommended Electrode Amperage Ranges Precision TIG Smaw Process Table of Contents Magnum PTA and PTW Series Torches Accessories for Codes belowOptional Equipment Accessories for Codes Above Return to Section TOC Component Location and Access Maintenance Overload Protection Safety Precautions 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 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 Thermal Protection 8THEORY of OPERATIONE-8Protection Circuits FAN-AS-NEEDED F.A.N Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide 2TROUBLESHOOTING & REPAIRF-2 Troubleshooting & Repair Test Troubleshooting GuideProcedure Reconnect SCR Bridge Test Control BoardTransformer T1 Transformer Installed, remove it and replaceMachine functions normally Perform the Protection Board Perform the T1 Transformer See Note belowProtection Board Perform the SCR Bridge Test Perform the SCR Bridge Tests Perform the Gas Solenoid Test Est Can Kill MaintenanceElectric Shock High frequency transformer Maintenance Section To Technical Specifications Problems Possible AreasSymptoms Misadjustments Course of Action See the Maintenance Secti 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 Description 19TROUBLESHOOTING & REPAIRF-19Meter Calibration Adjustments Voltmeter/Ohmmeter Nut Driver Wiring Diagram 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 Resistance Between Reading Protection Board Test T1 Main Transformer Test 27TROUBLESHOOTING & REPAIRF-27 T1 Main Transformer Test 28TROUBLESHOOTING & REPAIRF-28Test Procedures Primary Windings Test Points Acceptable Voltages Return to Section TOC GAS Water Solenoid Test 31TROUBLESHOOTING & REPAIRF-31 Perform the High Frequency Circuit Test ProcedureDisable Procedure GAS Water Solenoid Test Static SCR Test 33TROUBLESHOOTING & REPAIRF-33 Static SCR Test 34TROUBLESHOOTING & REPAIRF-34Removal and Replacement Assembly. See SCR Bridge Assembly Active SCR Test Service and repair Active SCR Test 36TROUBLESHOOTING & REPAIRF-36 Active SCR Test Figure F.9 SCR Gate Locations Typical Output Voltage Waveform Machine Loaded to 2 Amps 39TROUBLESHOOTING & REPAIRF-39DC TIG Mode Scope Settings Was loaded with a resistance grid bank 40TROUBLESHOOTING & REPAIRF-40AC TIG Mode Milliseconds in time. The machine Horizontal Sweep Ms/Div 41TROUBLESHOOTING & REPAIRF-41Typical AC Voltage Waveform Machine Loaded to 50 Amps This is the typical DC + output voltage 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 Replacement Procedure 46TROUBLESHOOTING & REPAIRF-46Removal and Replacement Removal Procedure Figure F.11 3/8 Screw & Leads S and F Locations 47TROUBLESHOOTING & REPAIRF-47 Return to Section TOC Nut Driver Phillips Head Screwdriver Wire Cutters 49TROUBLESHOOTING & REPAIRF-49Control Board Removal and Replacement Control Board Removal and Replacement 50TROUBLESHOOTING & REPAIRF-50 J10 J11 J12 51TROUBLESHOOTING & REPAIRF-51 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 Polarity Switch Removal and Replacement 57TROUBLESHOOTING & REPAIRF-57 Polarity Switch Removal and Replacement 58TROUBLESHOOTING & REPAIRF-58 SCR Removal and Replacement 59TROUBLESHOOTING & REPAIRF-59 Special Instructions 60TROUBLESHOOTING & REPAIRF-60SCR Removal and Replacement Recommended Meters for Machine Output Tests Retest After RepairInput Idle Amps Open Circuit Voltages 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 Schéma DE Câblage Diagramas DE Cableado Wiring Diagram Entire Machine Code 11158 G5692Precision TIG 275 Wiring Diagram 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