Figure E.4 Optional Circuits | Lincoln Electric SVM167-A guide

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E-4

THEORY OF OPERATION

E-4

FIGURE E.4 – OPTIONAL CIRCUITS.

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

Return

Return

RECONNECT

PANEL

	MAIN	NEGATIVE
	TRANSFORMER
		TERMINAL

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CONTROL BOARD, GUN TRIGGER AND WIRE DRIVE MOTOR

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When the control board receives an activation command from the trigger circuit the control board supplies 12VDC which activates the gas solenoid and output contactor. It also supplies 2 to 29 VDC (depending on the wire speed setting) to the wire drive motor. The control board monitors 0-5VDC signal from the wire speed potentiometer and adjusts the motor speed accordingly. The proper armature voltage is then applied to the wire drive motor. The drive motor speed is thus controlled which in turn regulates the electrode wire feed speed through the gun.

Two self re-setting thermostats are included in the trigger circuitry. If either of these thermostats would “open” due to excessive heat, the trigger circuit would be interrupted and the machine’s output and the wire feed would be disabled. The board also contains overload protection circuitry which protects the drive motor from excessive current draw.

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

POWER MIG® 215

Image 34

Lincoln Electric SVM167-A service manual Control BOARD, GUN Trigger and Wire Drive Motor, Figure E.4 Optional Circuits

Contents

Power MIG Safety Depends on You Safety California Proposition 65 Warnings Electric Shock can kill ARC Rays can burn Can be dangerous Cylinder may explode if damaged Welding and Cutting Sparks can cause fire or explosionIii 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 Installation Safety PrecautionsUncrating the Power MIG Location Output Polarity Connections Shielding GAS GUN and Cable InstallationAUXILIARY POWER RECEPTACLES Cylinder may explode if damaged Power MIG Operation SECTION OPERATIONB-2 Wear eye, ear and body protec- tion Operation Wire Reel Loading READI-REELS, Spools or Coils Procedure for Changing Drive AND IDLE Roll SetsTo Start the Welder Idle Roll Pressure Setting Feeding Wire ElectrodeWire Drive Configuration Making a Weld Figure B.2b FAN Control Avoiding Wire Feeding ProblemsWire Feed Overload Protection Input Line Voltage Variations Power MIG Accessories SECTION Accessories Making a Weld with the Spool GUN 3ACCESSORIESC-3Installed 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 Protective Devices and Circuits Wirefeed Overload ProtectionThermal and Overload Protection 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 Avoid contact with any portion These capacitors is toxicYour body Function Problems Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Test Description Main Transformer TestMaterials Needed ON/OFF Power Switch will be hot during these tests Test ProcedureMain Transformer Test X10 Table F.1. Test Points Input Voltage Test Points Wire Drive Motor and Wire Speed Potentiometer Test Black White 1109 a Test for Feedback Voltage to Control BoardVDC 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