Lincoln Electric SVM157-A service manual Output Diode Bridge Rectifier

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F-34

TROUBLESHOOTING AND REPAIR

F-34

 

 

 

OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED)

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PROCEDURE

1.Using a 3/8” nutdriver, remove the left side of the case wraparound cover.

2.Locate the output diode bridge rectifier. See Figure F.12.

3.Using a 1/2” nutdriver label and remove the four thick black leads connected to the rectifier. NOTE: Be sure to label lead terminals also. Take note of washer placement upon removal.

4.Label and remove leads 104A and 104B. See Wiring Diagram.

5.Using a 5/16” nutdriver locate and remove the four bolts mounting the rectifier bracket to the bottom of the machine. These bolts can be accessed easily from the bottom of the machine.

See Figure F.13.

6.Carefully manipulate the output diode bridge rectifier and the mounting bracket out of the left side of the machine.

7.Using a 1/2” nutdriver remove the three bolts mounting the bracket to the rectifier. The rectifi- er is now ready for repair or replacement. See

Figure F.13.

8.Mount the new rectifier to the mounting bracket using the three 1/2” bolts.

9.Carefully manipulate the rectifier and mounting bracket as a one back into the machine to its proper location.

10.Mount the unit to the bottom of the machine using the four 5/16” mounting bolts previously removed.

11.Reconnect leads 104A and 104B previously removed.

12.Reconnect the four thick black leads previously labeled and removed using a 1/2” nutdriver.

13.Replace the left side of the case wraparound cover.

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FIGURE F.12. - OUTPUT DIODE BRIDGE RECTIFIER LOCATION

OUTPUT DIODE

BRIDGE

RECTIFIER

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 ConnectionsCylinder may explode if damaged GUN and Cable InstallationShielding GAS Operation Section Operation Section BOperation Wear eye, ear and body protec- tionWire Drive Roll Wire Size Conversion PartsProduct Description Recommended Processes and EquipmentTo Start the Welder Procedure for Changing Drive and Idle Roll SetsWire Reel Loading READI-REELS, Spools or Coils 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 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 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