Lincoln Electric SVM157-A service manual Perform the Output Contactor

Page 39

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F-5

 

TROUBLESHOOTING AND REPAIR

F-5

 

 

 

 

 

 

 

Troubleshooting Guide – See Wiring Diagrams for location of specified

Observe Safety Guidelines

components and for troubleshooting of specific circuits.

detailed in the beginning of this manual.

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

 

RECOMMENDED

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS (Continued)

 

 

 

(continued from previous page)

3. Check the gun trigger leads.

 

 

 

 

 

 

Leads #324 to #325 should

 

 

 

 

 

 

have continuity (zero ohms)

 

 

 

 

 

 

when the gun trigger is activat-

 

 

 

 

 

 

ed. If not, the gun trigger or

 

 

 

 

 

 

cable may be faulty. Check or

 

 

 

 

 

 

replace.

 

 

 

 

 

 

4. If a spool gum option kit is

 

 

 

 

 

 

installed, check to make sure it

 

 

 

 

 

 

is set to the “normal” position if

 

 

 

 

 

 

using the POWER MIG 200 built

 

 

 

 

 

 

in wire feeder.

 

 

 

 

 

 

 

When the gun trigger is activated

1. Make sure the gun cable and

 

1. Check the output selector

and the wire feeds normally, but

work cables are connected

 

switch for proper operation and

there is no open circuit voltage.

properly and in good condition.

 

good connections.

 

 

 

 

2. Make sure the output selector

 

2. Perform the Output Contactor

 

 

 

switch is in a good condition

 

Test.

 

 

 

 

position and not between posi-

 

 

 

 

 

 

tions.

 

3. Perform the Output Bridge

 

 

 

 

 

Rectifier Test.

 

 

 

 

 

 

4. Perform the Main Transformer

 

 

 

 

 

Test.

 

 

 

 

 

 

5. Check the heavy current carry-

 

 

 

 

 

ing leads between the output

 

 

 

 

 

selector switch, output contac-

 

 

 

 

 

tor, output bridge rectifier, and

 

 

 

 

 

the output terminals for loose or

 

 

 

 

 

faulty connections.

See Wiring

 

 

 

 

 

Diagram.

 

 

 

 

 

 

 

 

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 Safety Depends on You Power MIGCalifornia Proposition 65 Warnings SafetyARC Rays can burn Electric Shock can killIii Cylinder may explode if damagedSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Section Table of ContentsTechnical Specifications Power MIG Installation3INSTALLATIONA-3 Figure A.1 Dual Voltage Machine Input Connections Figure A.2 Triple Voltage Machine Input Connections Output Polarity ConnectionsGUN and Cable Installation Shielding GASCylinder may explode if damaged Operation Section B Operation SectionWear eye, ear and body protec- tion OperationRecommended Processes and Equipment Wire Drive RollWire Size Conversion Parts Product DescriptionProcedure for Changing Drive and Idle Roll Sets Wire Reel Loading READI-REELS, Spools or CoilsTo Start the Welder Idle Roll Pressure Setting Feeding Wire Electrode Making a WeldInput Line Voltage Variations Avoiding Wire Feeding ProblemsWire Feed Overload Protection FAN ControlAccessories Section Dual Cylinder Mounting KIT K1702-1 AccessoriesDrive Roll Kits K363P READI-REEL AdapterAdapter KIT and Spool GUN InstalledPower MIG Maintenance Section Maintenance Overtightening will split or collapse the liner Cause poor wire feedingLiner Removal and REPLACE- Ment This screw should only be gently tightenedEnglish Metric Description Size GUN Handle DisassemblyMaintenance Power MIG Theory of Operation Section Line SwitchTheory of Operation Motor Control Board Output Rectification Contactor and Control BoardFigure E.4 Optional Circuits Control BOARD, GUN Trigger and Wire Drive MotorThermal and Overload Protection Wirefeed Overload ProtectionPower MIG Troubleshooting and Repair Section F Troubleshooting and Repair SectionHow To Use Troubleshooting Guide Troubleshooting and RepairPC 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 Main Transformer Test ON/OFF Power Switch will be hot during these testsX10 Input Voltage Test Points Table F.1. Test PointsWire Drive Motor and Tachometer Feedback Test Figure F.4. Plug J4 Test ProcedureTest for Supply Voltage to Tachometer Disconnect the main AC input power to the machineVDC Test for Feedback Voltage to Control BoardOutput Bridge Rectifier Test Output Bridge Rectifier Test Test ProcedureContactor Test Figure F.7. Contactor Terminals and Leads Contactor TestTypical Output Voltage Waveform Machine Loaded MAX TAP G Volts 10.0Normal Open Circuit Voltage Waveform MAX TAP G Volts 20.0Machine Loaded to 180 Amps AT 16 VDC Scope Settings Volts 20.0 Description Control Board ReplacementProcedure Control Board ReplacementWire Drive Motor Assembly Replacement Wire Drive Wire Drive Motor Assembly ReplacementBolt Gas Hose TOC Output Diode Bridge Rectifier Replacement Output Diode Bridge Rectifier Mounting Bracket Mounting Bolts Rectifier Power MIG Output Capacitors Replacement Figure F.14. Capacitor Bank Location Output Capacitors ReplacementLead Mounting Bolts Nuts & Lock washers Places Power MIG Main Transformer Replacement 41TROUBLESHOOTING and REPAIRF-41See Figure F.17 Main Transformer ReplacementFigure F.17. Leads X9, X10, 104B,104C, & H1B ReplacementX2 X3 X4 X5 X6 X7 Lead Power MIG FAN BLADE/MOTOR Replacement Perform the Output Capacitor Bank Removal Procedure FAN BLADE/MOTOR ReplacementOutput Contactor Replacement Figure F.24 Output Contactor ReplacementMounting Bolts Retest After Repair Table of Contents Electrical Diagrams Section Electrical DiagramsWiring Diagram Power MIG 200 208/230VSchematic Control PC Board G3851-1 PC Board ASSEMBLY-CONTROLSVM Error Reporting Form
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