Lincoln Electric SVM157-A service manual Function Problems

Page 41

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F-7

 

TROUBLESHOOTING AND REPAIR

F-7

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

FUNCTION PROBLEMS

 

 

 

 

There is no gas flow when the gun

1. If a spool gun adapter is installed,

 

1. Check plug J1 on the control board

trigger is activated . The wire feeds

make certain the toggle switch in

 

for loose or faulty connections. See

and the arc voltage is present.

the spool gun kit in the correct

 

wiring diagram.

 

 

 

 

position.

 

 

 

 

 

 

 

2. If a spool gun adapter is NOT

 

2. Check the gas solenoid by discon-

 

 

 

 

necting it from leads #108A and

 

 

 

installed, make certain the jumper

 

#116A&B. Apply a 12VDC external

 

 

 

plug is installed in J5. See

the

 

supply to the solenoid.

If the sole-

 

 

 

wiring diagram.

 

 

noid does NOT activate then it may

 

 

 

3. Check the gas source and hoses

 

be faulty. Replace.

 

 

 

 

 

 

 

 

 

 

for kinks or leaks.

 

 

 

 

 

 

 

 

The machine stops feeding wire

1. Check for a mechanical restric-

 

1. Check the motor armature current.

while welding.

When the gun trig-

tion in the wire feed path.

The

 

Normal armature current is 2.0 to 2.7

ger is released and pulled again,

gun may be clogged.

 

 

amps maximum. If the motor arma-

the wire feed starts.

2. Make sure the drive rolls and

 

ture current is normal, and the motor

 

 

 

 

continues to shut-off, the control

 

 

 

guide plates are clean and are

 

board may be faulty. Replace.

 

 

 

the correct size.

 

 

 

 

 

 

 

3. Check the spindle for ease of

 

2. If the motor armature current is high

 

 

 

 

(over 2.7 amps) and there are NO

 

 

 

rotation.

 

 

restrictions in the wire feeding path

 

 

 

 

 

 

then the motor or gearbox may be

 

 

 

 

 

 

defective. Replace.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 ConnectionsCylinder may explode if damaged GUN and Cable InstallationShielding GAS Operation Section B Operation SectionWear eye, ear and body protec- tion OperationWire Size Conversion Parts Wire Drive RollProduct Description Recommended Processes and EquipmentTo Start the Welder Procedure for Changing Drive and Idle Roll SetsWire Reel Loading READI-REELS, Spools or Coils Idle Roll Pressure Setting Feeding Wire Electrode Making a WeldWire Feed Overload Protection Avoiding Wire Feeding ProblemsFAN Control Input Line Voltage VariationsAccessories Section Drive Roll Kits AccessoriesK363P READI-REEL Adapter Dual Cylinder Mounting KIT K1702-1Adapter KIT and Spool GUN InstalledPower MIG Maintenance Section Maintenance Liner Removal and REPLACE- Ment Cause poor wire feedingThis screw should only be gently tightened Overtightening will split or collapse the linerEnglish 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 Your body These capacitors is toxicAvoid contact with any portion Function Problems Tachometer Feedback Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Materials Needed Main Transformer TestTest Description 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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