Lincoln Electric SVM157-A These capacitors is toxic, Avoid contact with any portion, Your body

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F-6

 

TROUBLESHOOTING AND REPAIR

 

 

 

F-6

 

 

 

 

 

 

 

 

 

 

 

 

 

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)

 

 

 

 

 

 

Output voltage and wire feed speed

1.

Remove the gun assembly.

If

 

1. Check for “shorts” in the trigger

is present when the gun trigger is

 

the problem is resolved, the gun

 

circuitry within the POWER MIG

NOT activated.

 

 

assembly

is faulty. Repair

or

 

200 machine.

See

the wiring

 

 

 

 

replace.

If the problem is NOT

 

diagram.

 

 

 

 

 

 

 

 

resolved, the fault is within the

 

 

 

 

 

 

 

 

 

 

POWER MIG 200 machine.

 

 

2. The control board may be faulty.

 

 

 

 

 

The machines output is low. Welds

1.

Check the input voltage. Make

 

1. Check for loose or faulty con-

are “cold”. The

weld beads are

 

sure the machine is configured

 

nections on the heavy current

rounded or “humped” demonstrat-

 

properly for the input voltage

 

carrying

leads inside

the

ing poor wetting into the plate. The

 

being applied.

 

 

POWER MIG

200.

See

the

machine cannot obtain full rated

 

 

 

 

 

Wiring Diagram.

 

 

output of 200 amps at 22VDC.

2.

Make sure the settings for wire

 

 

 

 

 

 

 

 

 

 

feed speed and voltage are cor-

 

2. The output capacitors may be

 

 

 

 

rect for the process being used.

 

faulty. Check for loose connec-

 

 

 

 

 

 

 

 

tions at the capacitors. Also

 

 

 

3. Make sure the electrode polarity

 

check for

leaky

capacitors.

 

 

 

 

is correct for the process being

 

Replace if necessary.

 

 

 

 

 

used.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WARNING: The liquid electrolyte

 

 

 

4. Check the welding cables and

 

in these capacitors is toxic.

 

 

 

 

gun for loose or faulty connec-

 

Avoid contact with any portion of

 

 

 

 

tions.

 

 

 

your body.

 

 

 

 

 

 

 

 

 

 

 

 

3. The output selector switch may

 

 

 

 

 

 

 

 

be faulty. Check for good con-

 

 

 

 

 

 

 

 

tact and continuity (zero ohms)

 

 

 

 

 

 

 

 

through the switch. See the

 

 

 

 

 

 

 

 

Wiring Diagram.

 

 

 

 

 

 

 

 

 

 

4. Perform the Output Contactor

 

 

 

 

 

 

 

 

Test.

 

 

 

 

 

 

 

 

 

 

 

 

5. Perform the Output Bridge

 

 

 

 

 

 

 

 

Rectifier Test.

 

 

 

 

 

 

 

 

 

 

 

6. Perform the Main Transformer

 

 

 

 

 

 

 

 

Test.

 

 

 

 

 

 

 

The output voltage is continuous

1. The output contactor may be

1. Perform the Output Contactor

when the gun trigger is NOT activat-

 

stuck closed.

 

 

Test.

 

 

 

 

ed. The wire feed functions normal-

 

 

 

 

 

 

 

 

 

 

ly.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 ConnectionsShielding GAS GUN and Cable InstallationCylinder 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 EquipmentWire Reel Loading READI-REELS, Spools or Coils Procedure for Changing Drive and Idle Roll SetsTo 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 CircuitsWirefeed 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 Avoid contact with any portion These capacitors is toxicYour body Function Problems Tachometer Feedback 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 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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