Lincoln Electric SVM157-A Troubleshooting and Repair, How To Use Troubleshooting Guide

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TROUBLESHOOTING AND REPAIR

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How To Use Troubleshooting Guide

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and 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.

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This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three step procedure below.

Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machinery may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped according to: feeding problems and function problems.

Step 2. PERFORM EXTERNAL TESTS. The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap- around cover.

Step 3. PERFORM COMPONENT TESTS. The last column labeled “RECOMMENDED COURSE OF ACTION” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either bad or good. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.

All the necessary test specifications and repair procedures are described in detail following the troubleshooting guide. All electrical test points, terminal strips, junctions, etc., can be found on the electrical wiring diagrams and schematics in the Electrical Diagram Section.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353.

POWER MIG 200

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Contents Power MIG Safety Depends on YouSafety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burnCylinder may explode if damaged IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionInstallation Technical Specifications Power MIG3INSTALLATIONA-3 Figure A.1 Dual Voltage Machine Input Connections Output Polarity Connections Figure A.2 Triple Voltage Machine Input ConnectionsGUN and Cable Installation Shielding GASCylinder may explode if damaged Operation Section Operation Section BOperation Wear eye, ear and body protec- tionWire Drive Roll Wire Size Conversion PartsProduct Description Recommended Processes and EquipmentProcedure for Changing Drive and Idle Roll Sets Wire Reel Loading READI-REELS, Spools or CoilsTo Start the Welder Feeding Wire Electrode Making a Weld Idle Roll Pressure SettingAvoiding Wire Feeding Problems Wire Feed Overload ProtectionFAN Control Input Line Voltage VariationsAccessories Section Accessories Drive Roll KitsK363P READI-REEL Adapter Dual Cylinder Mounting KIT K1702-1Installed Adapter KIT and Spool GUNPower MIG Maintenance Section Maintenance Cause poor wire feeding Liner Removal and REPLACE- MentThis screw should only be gently tightened Overtightening will split or collapse the linerGUN Handle Disassembly English Metric Description SizeMaintenance Power MIG Line Switch Theory of Operation SectionTheory of Operation Output Rectification Contactor and Control Board Motor Control BoardControl BOARD, GUN Trigger and Wire Drive Motor Figure E.4 Optional Circuits Wirefeed Overload Protection Thermal and Overload ProtectionPower MIG Troubleshooting and Repair Section Troubleshooting and Repair Section FTroubleshooting and Repair How To Use Troubleshooting GuidePC Board Troubleshooting Procedures Perform the Main Transformer Perform the Output Contactor These capacitors is toxic Avoid contact with any portionYour body Function Problems Tachometer Feedback Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Main Transformer Test Test DescriptionMaterials Needed ON/OFF Power Switch will be hot during these tests Main Transformer TestX10 Table F.1. Test Points Input Voltage Test PointsWire Drive Motor and Tachometer Feedback Test Test Procedure Figure F.4. Plug J4Disconnect the main AC input power to the machine Test for Supply Voltage to TachometerTest for Feedback Voltage to Control Board VDCOutput Bridge Rectifier Test Test Procedure Output Bridge Rectifier TestContactor Test Contactor Test Figure F.7. Contactor Terminals and LeadsVolts 10.0 Typical Output Voltage Waveform Machine Loaded MAX TAP GVolts 20.0 Normal Open Circuit Voltage Waveform MAX TAP GMachine Loaded to 180 Amps AT 16 VDC Scope Settings Volts 20.0 Control Board Replacement DescriptionControl Board Replacement ProcedureWire Drive Motor Assembly Replacement Wire Drive Motor Assembly Replacement Wire DriveBolt 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 LocationLead Mounting Bolts Nuts & Lock washers Places Power MIG 41TROUBLESHOOTING and REPAIRF-41 Main Transformer ReplacementMain Transformer Replacement See Figure F.17Replacement Figure F.17. Leads X9, X10, 104B,104C, & H1BX2 X3 X4 X5 X6 X7 Lead Power MIG FAN BLADE/MOTOR Replacement FAN BLADE/MOTOR Replacement Perform the Output Capacitor Bank Removal ProcedureOutput Contactor Replacement Output Contactor Replacement Figure F.24Mounting Bolts Retest After Repair Electrical Diagrams Table of Contents Electrical Diagrams SectionPower MIG 200 208/230V Wiring DiagramSchematic Control PC Board PC Board ASSEMBLY-CONTROL G3851-1SVM Error Reporting Form
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