Lincoln Electric SVM186-A POLARITY SWITCH

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

ormachine operator and will invalidate your factory warranty. Foryour 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. Call1-888-935-3877.

TEST DESCRIPTION

This procedure will aid the technician in the removal and replacement of the polarity switch.

MATERIALS NEEDED

3/8” Nutdriver

1/2” Wrench

7/16” Wrench

Phillips head screwdriver

5/64” Allen type Wrench

Needle nose pliers

Slot head screwdriver (2 required)

Wiring diagram

POLARITY SWITCH

REMOVALAND REPLACEMENT PROCEDURE

TROUBLESHOOTING AND REPAIR

F-45 F-45

PRECISION TIG® 225

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WARNING

Contents

Main SVM186-A SERVICE MANUAL PRECISION TIG 225 i i FOR ENGINE powered equipment. Mar 95 WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous ii ii FUMES AND GASES can be dangerous. Aug 06 ARC RAYS can burn. ELECTRIC SHOCK can kill. iii iii FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. WELDING and CUTTING SPARKS can cause fire or explosion. iv iv Mar 93 PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Page Electromagnetic Compatibility (EMC) - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN MENU TABLE OF CONTENTS - INSTALLATION SECTION TECHNICAL SPECIFICATIONS - PRECISION TIG 225 (K2533-1AND K2535-1,-2) INPUT - SINGLE PHASE ONLY OUTPUT RANGE RATED OUTPUT AC/DC Stick and Auto-B alance TIG Output L imits TECHNICAL SPECIFICATIONS - CANADIAN (K2533-2), INTERNATIONALK2534-1) PHYSICAL DIMENSIONS ENVIRONMENTALRANGES OUTPUT RANGE RATED OUTPUT K2533-2 INPUT (at Rated Output) SAFETYPRECAUTIONS SELECT SUITABLE LOCATION MOUNTING LIFTING AND MOVING TILTING MACHINE GROUNDING AND HIGH FRE- QUENCY INTERFERENCE PROTECTION INPUT AND GROUNDING CONNECTIONS INPUT RECONNECT PROCEDURE CONNECTIONS FOR TIG (GTAW)WELDING FIGUREA.1ReconnectLeads OUTPUTCONNECTIONS FIGUREA.2LocationofOutputConnections CONNECTIONS FOR TIG (GTAW)WELDING CONNECTIONS FOR STICK (SMAW) WELDING Page TABLE OF CONTENTS - OPERATION SECTION SAFETYPRECAUTIONS PRODUCT DESCRIPTION RECOMMENDED PROCESSES AND EQUIP- MENT WELDING CAPABILITY(Duty Cycle) CONTROLSAND SETTINGS POWER-UPSEQUENCE Page OPERATING STEPS Page RECOMMENDEDELECTRODEAMPERAGERANGES -PRECISION TIG 225 Page Page STANDARD EQUIPMENT PACKAGES FACTORYINSTALLED OPTIONS FIELD INSTALLED OPTIONS Page MAINTENANCE SAFETYPRECAUTIONS WARNING WARNING TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 E-1 INPUT POWER SWITCH MAIN TRANSFORMER POLARITY SWITCH GENERALDESCRIPTION INPUT POWER CIRCUIT OUTPUT RECTIFICATION AND FEEDBACK CONTROL E-4 E-4 HIGHVOLTAGE/ HIGH FREQUENCY CIRCUIT FIGURE E.2 - High Voltage/HighFrequency Circuit. NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion INPUT POWER SWITCH MAIN TRANSFORMER DC WELDING OUTPUT AC WELDING OUTPUT SCROPERATION PROTECTIVE CIRCUITS THERMALPROTECTION OVERLOAD PROTECTION 115 VACRECEPTACLE TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE PC BOARD TROUBLESHOOTING PROCEDURES Page Page Page Page Page Page Page Page WARNING Page Page HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE HIGH FREQUENCY CIRCUIT DISABLE PROCEDURE (continued) LEFT SIDE OF MACHINE T1 TRANSFORMER TEST Page T1 TRANSFORMER TEST (continued) Page STATICSCR TEST PLUG J2 REMOVED STATICSCR TEST (continued) TEST PROCEDURE CASE COVER REMOVALAND REPLACEMENT PROCEDURE (continued) TEST PROCEDURE (continued) Page ACTIVE SCR TEST ACTIVE SCR TEST (continued) TEST PROCEDURE ACTIVE SCR TEST (continued) TEST PROCEDURE (continued) Page AC TIG MODE DC TIG MODE AC STICK MODE DC STICK MODE AC TIG MODE DC TIG MODE AC STICK MODE DC STICK MODE ABNORMAL OPEN CIRCUIT VOLTAGE- DC TIG MODE ONE OUTPUT SCR NOT FUNCTIONING Page Page Page PROCEDURE (continued) FRONT PANEL MOUNTING SCREWS PLUG J2 REMOVED Page Page POLARITY SWITCH Page POLARITYSWITCH Page Page TRANSFORMER SECONDARY LEADS Page Page Page MAIN TRANSFORMER AND OUTPUT CHOKE ASSEMBLY NOTES RETEST AFTER REPAIR Page TABLE OF CONTENTS - DIAGRAM SECTION ELECTRICAL DIAGRAMS WIRING DIAGRAM - COMPLETE MACHINE - ALL CODES (G5646) IEW) V PTAC ELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE -ALL CODES (G5647) GangF Gang G Page Page Page ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY- CONTROL #1 (G5641) 2 3 4 5 COMPONENT SIDE CONTROL ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY- CONTROL #2 (G5641) OPPOSITE COMPONENT SIDE X XXX S22530-1B0 08/26/2002 NA CRM34563 ION: IT S22530-1B0 MATERIAL DISPOS APPROVAL DATE: PROJECT NUMBER: 1 ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY - BYPASS (L10121) ATI NFORM I