Lincoln Electric SVM157-A service manual Main Transformer Test

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F-12	TROUBLESHOOTING AND REPAIR	F-12
	MAIN TRANSFORMER TEST (continued)

FIGURE F.1. – OUTPUT SELECTOR SWITCH TERMINALS

X2 X3 X4 X5 X6 X7 X8

TEST PROCEDURE	6. Locate leads X9 and X10. See Figure
	F.3.

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WARNING

THE ON/OFF POWER SWITCH will be “hot” during these tests.

NOTE: Secondary voltages will vary proportionately with the primary input voltage.

1.Disconnect the main input power supply to the machine.

2.Remove the case top and side panels with a 3/8” nutdriver.

7.Connect main input power to the machine.

8.Turn the POWER MIG 200 ON/OFF Power Switch to the ON position.

WARNING

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such as output terminals or internal wiring.

•All input power must be electri- cally disconnected before pro- ceeding.

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3.Remove the tool tray with a 5/16” nut driver.

4.Locate leads X2 thru X8 located on the output selector switch. See Figure F.1.

5.Locate lead X1 located on the output rectifier assembly. See Figure F.2.

9.Carefully make the following voltage tests. See Table F.1.

10.Turn Off the machine.

11.If any of the voltages are incorrect or missing, check for loose or broken connections between the main transformer and the test points.

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- tionProduct Description Wire Drive RollWire Size Conversion Parts 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 SettingFAN Control Avoiding Wire Feeding ProblemsWire Feed Overload Protection Input Line Voltage VariationsAccessories Section K363P READI-REEL Adapter AccessoriesDrive Roll Kits Dual Cylinder Mounting KIT K1702-1Installed Adapter KIT and Spool GUNPower MIG Maintenance Section Maintenance This screw should only be gently tightened Cause poor wire feedingLiner Removal and REPLACE- Ment 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