Lincoln Electric SVM157-A service manual 3INSTALLATIONA-3

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Section TOC

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A-3INSTALLATIONA-3

Read entire installation section before starting

INPUT POWER, GROUNDING AND

installation.

CONNECTION DIAGRAMS

SAFETY PRECAUTIONS

 

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WARNING

ELECTRIC SHOCK can kill.

•Only qualified personnel should perform this installation.

•Only personnel that have read and under- stood the POWER MIG 200 Operating Manual should install and operate this equipment.

•Machine must be grounded per any national, local or other applicable electri- cal codes.

•The POWER MIG power switch is to be in the OFF position when installing work cable and gun and when connecting other equipment.

WARNING

ELECTRIC SHOCK can kill.

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

•All input power must be electrically dis- connected before proceeding.

1.Before starting the installation, check with the local power company if there is any question about whether your power supply is adequate for the volt- age, amperes, phase, and frequency specified on the welder nameplate. Also be sure the planned installation will meet the U.S. National Electrical Code and local code requirements. This welder may be operated from a single phase line or from one phase of a two or three phase line.

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UNCRATING THE POWER MIG 200

Cut banding and lift off cardboard carton. Cut banding holding the machine to the skid. Remove foam and corrugated packing material. Untape accessories from Gas Bottle Platform. Unscrew the two wood screws (at the Gas Bottle Platform) holding the machine to the skid. Roll the machine off the skid assembly.

2.Models that have multiple input voltages specified on the nameplate (e.g. 208/230) are shipped con- nected for the highest voltage. If the welder is to be operated on lower voltage, it must be reconnected according to the instructions in Figure A.1 for dual voltage machines and Figure A.2 for triple voltage machines.

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LOCATION

 

WARNING

 

Locate the welder in a dry location where there is free

Make certain that the input power is electrically

circulation of clean air into the louvers in the back and

disconnected before removing the screw on the

out the front. A location that minimizes the amount of

reconnect panel access cover.

smoke and dirt drawn into the rear louvers reduces the

 

 

 

chance of dirt accumulation that can block air pas-

 

 

 

sages and cause overheating.

 

 

 

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 Sûreté Master 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 ConnectionsGUN and Cable Installation Shielding GASCylinder may explode if damaged Operation Section B Operation SectionWear eye, ear and body protec- tion OperationWire Size Conversion Parts Wire Drive RollProduct Description Recommended Processes and EquipmentProcedure for Changing Drive and Idle Roll Sets Wire Reel Loading READI-REELS, Spools or CoilsTo Start the Welder 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 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 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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