Lincoln Electric SVM157-A service manual Table F.1. Test Points, Input Voltage Test Points

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F-14	TROUBLESHOOTING AND REPAIR			F-14
		TABLE F.1. Test Points

	INPUT VOLTAGE	TEST POINTS	EXPECTED VOLTAGE READING

	230 VAC	X1-X2		11.9-13.0 VAC

	230 VAC	X1-X3		14.1-15.2 VAC

	230 VAC	X1-X4		16.2-17.5 VAC

	230 VAC	X1-X5		18.4-19.7 VAC

	230 VAC	X1-X6		20.5-22.0 VAC

	230 VAC	X1-X7		22.7-24.2 VAC

	230 VAC	X1-X8		24.8-26.5 VAC

	230 VAC	X9-X10		26.9-28.8 VAC

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12.If ALL the voltages tested are incorrect or missing, test for correct nameplate input voltage between the H1 lead at the ON/OFF POWER SWITCH to H2 or H3 at the reconnect panel. Voltage tested will vary depending on input voltage con- nection. See wiring diagram for test point locations.

A.If the input voltage test is incorrect, check for loose or broken leads between the reconnect panel and the ON/OFF POWER SWITCH.

B.Test the ON/OFF POWER SWITCH for proper operation.

13.If the correct nameplate voltage is being applied to the main transformer and one or more of the secondary voltages are missing or are incorrect, the main trans- former may be faulty. Replace.

14.When test is complete, replace tool tray, case sides and top.

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 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 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