Theory of Operation | Lincoln Electric SVM167-A specification

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E-2

THEORY OF OPERATION

E-2

FIGURE E.2 – INPUT POWER CIRCUIT.

WIRE

GASSPEED

SOLENOIDCONTROL

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FAN

MOTOR

LINE

SWITCH

RECTIFIER

DIODE

BRIDGE

VAC28TAP SELECTOR SWITCH

CONTROL BOARD

CONTACTOR

CONTROL

CONTACTOR

WIRE

DRIVE

MOTOR

TACH

GUN TRIGGER

OUTPUT DIODE

BRIDGE

+

OUTPUT

CHOKE

OUTPUT

CAPACITORS

-

TRANSFORMER			OUTPUT BRIDGE
THERMOSTAT			THERMOSTAT

+

POSITIVE

TERMINAL

-

GUN

ASSEMBLY

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RECONNECT

PANEL

	MAIN	NEGATIVE
	TRANSFORMER
		TERMINAL

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INPUT LINE VOLTAGE, MAIN TRANSFORMER, VOLTAGE SELECTOR SWITCH AND BAFFLE MOUNTED DIODE BRIDGE

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The single phase input power is connected to the POWER MIG® 215 through a line switch located on the front panel.

A reconnect panel allows the user to configure the machine for the desired input voltage. The AC input voltage is applied to the primary of the main transformer. The cooling fan motor (120VAC) is powered from a portion of the primary winding. For welding purposes, the main transformer converts the high voltage, low current input power to a low voltage, high current output. This tapped secondary winding is coupled to a voltage selector switch. By selecting one of seven positions on the switch the user can preset the desired voltage output

from a minimum setting (A) to a maximum voltage setting (G). In addition, the main transformer also has a 28VAC winding. This 28VAC is rectified at the baffle mounted diode bridge. The resultant DC voltage (approx. 35VDC) is used to power the electronics on the control board.

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NOTE: Unshaded areas of block logic diagrams are the subject of discussion.

POWER MIG® 215

Image 32

Lincoln Electric SVM167-A service manual Theory of Operation, Figure E.2 Input Power Circuit

Contents

Power MIG Safety Depends on You Safety California Proposition 65 Warnings Electric Shock can kill ARC Rays can burn Can be dangerous Iii Welding and Cutting Sparks can cause fire or explosionCylinder may explode if damaged Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Table of Contents Installation SECTION Installation Technical Specifications Power MIG Safety Precautions Uncrating the Power MIGInstallation Location Output Polarity Connections GUN and Cable Installation AUXILIARY POWER RECEPTACLESShielding GAS Cylinder may explode if damaged Power MIG Operation SECTION OPERATIONB-2 Wear eye, ear and body protec- tion Operation To Start the Welder Procedure for Changing Drive AND IDLE Roll SetsWire Reel Loading READI-REELS, Spools or Coils Wire Drive Configuration Feeding Wire ElectrodeIdle Roll Pressure Setting Making a Weld Figure B.2b Avoiding Wire Feeding Problems Wire Feed Overload ProtectionFAN Control Input Line Voltage Variations Power MIG Accessories SECTION Accessories 3ACCESSORIESC-3 InstalledMaking a Weld with the Spool GUN Adapter KIT and Spool GUN Power MIG Maintenance SECTION Maintenance Liner Removal and Replace Ment Table D.1 GUN Handle Disassembly English Metric Description Size Figure D.2 Major Component Locations Power MIG Line Switch Theory of Operation SECTION Figure E.2 Input Power Circuit Theory of Operation Output Rectification Contactor and Control Board Figure E.3 Control Circuits Control BOARD, GUN Trigger and Wire Drive Motor Figure E.4 Optional Circuits Thermal and Overload Protection Wirefeed Overload ProtectionProtective Devices and Circuits Power MIG TROUBLESHOOTING AND REPAIR SECTION Troubleshooting and Repair How To Use Troubleshooting Guide PC Board Troubleshooting Procedures Perform the Main Transformer Perform the Output Contactor Your body These capacitors is toxicAvoid contact with any portion Function Problems Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Materials Needed Main Transformer TestTest Description Main Transformer Test Test ProcedureON/OFF Power Switch will be hot during these tests X10 Table F.1. Test Points Input Voltage Test Points Wire Drive Motor and Wire Speed Potentiometer Test Black White VDC Test for Feedback Voltage to Control Board1109 a Power MIG Output Bridge Rectifier Test Negative Lead Output Bridge Rectifier Test Contactor Test Contactor Test Figure F.7. Contactor Terminals and Leads Volts 10.0 Typical Output Voltage Waveform Machine Loaded MAX TAP G Volts 20.0 Normal Open Circuit Voltage Waveform MAX TAP G Machine Loaded to 180 Amps AT 16 VDC Scope Settings Volts 20.0 Control Board Replacement Description Control Board Replacement Procedure Wire Drive Motor Assembly Replacement Wire Drive Wire Drive Motor Assembly Replacement Bolt Gas Hose TOC Output Diode Bridge Rectifier Replacement Output Diode Bridge Rectifier Mounting Bracket Mounting Bolts Rectifier Power MIG Output Capacitors Replacement Output Capacitors Replacement Figure F.14. Capacitor Bank Location Lead Mounting Bolts Nuts Lock washers 3 places Power MIG 41TROUBLESHOOTING and Repair F-41 Main Transformer Replacement Main Transformer Replacement See Figure F.17 Replacement Figure F.17. Leads X9, X10, 104B,104C, & H1B X2 X3 X4 X5 X6 X7 Lead Power MIG FAN BLADE/MOTOR Replacement FAN BLADE/MOTOR Replacement Perform the Output Capacitor Bank Removal Procedure Output Contactor Replacement Output Contactor Replacement Figure F.24 Mounting Bolts Retest After Repair Electrical Diagrams Table of Contents Electrical Diagrams Section Power MIG 215 208/220/230V POWEr miG Power MIG 215 208/220/230V for Codes 11099 SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG1 L12308 SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG2 ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS