Lincoln Electric SVM155-A service manual PC Board Troubleshooting Procedures and Replacement

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TROUBLESHOOTING & REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES AND REPLACEMENT

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WARNING

ELECTRIC SHOCK can kill.

Have an electrician install and ser- vice this equipment. Turn the machine OFF before working on

equipment. Do not touch electrically hot parts.

Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure:

1.Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2.Check for loose connections at the PC board to assure that the PC board is properly connected.

3.If the problem persists, replace the suspect PC board using standard practices to avoid static elec- trical damage and electrical shock. Read the warn- ing inside the static resistant bag and perform the following procedures.

•Remove the PC Board from the static-shielding bag and place it directly into the equipment. Don’t set the PC Board on or near paper, plastic or cloth which could have a static charge. If the PC Board can’t be installed immediately, put it back in the sta- tic-shielding bag.

•If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete.

•If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shield- ing bag. This will prevent further damage and allow proper failure analysis.

4.Perform any necessary PC Board calibration pro- cedures. See the flow chart on the next page.

5.Test the machine to determine if the failure symp- tom has been corrected by the replacement PC board.

NOTE: Allow the machine to heat up so that all elec- trical components can reach their operating temperature.

6. Remove the replacement PC board and substitute

it with the original PC board to recreate the original

problem. Recalibrate if required.

a. If the original problem does not reappear

by substituting the original board, then the

PC board was not the problem. Continue

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ATTENTION

Static-Sensitive

Devices

Handle only at

Static-Safe

Workstations

Reusable

Container

Do Not Destroy

PC Board can be damaged by static electricity.

•Remove your body’s static charge before opening the stat- ic-shielding bag. Wear an anti- static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.

•If you don’t have a wrist strap, touch an unpainted, grounded, part of the equipment frame. Keep touching the frame to pre- vent static build-up. Be sure not to touch any electrically live parts at the same time.

to look for bad connections in the control

wiring harness, junction blocks, and termi-

nal strips.

b. If the original problem is recreated by the

substitution of the original board, then the

PC board was the problem. Reinstall the

replacement PC board, recalibrate if

required, and test the machine.

7. Always indicate that this procedure was followed

when warranty reports are to be submitted.

NOTE: Following this procedure and write on the war- ranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

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•Tools which come in contact with the PC Board must be either conductive, anti-static or static-dis- sipative.

MULTI-SOURCE

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Contents MULTI-SOURCE TM California Proposition 65 Warnings SafetyElectric Shock can kill Welding Sparks can cause fire or explosion Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Multi-Source K1752-1 InstallationTilting Safety PrecautionsSelect Proper Location StackingInput and Grounding Connections Fuse and Wire SizesParalleling Output ConnectionsMULTI-SOURCE Table of Contents Operation Section Operation Safety InstructionsGeneral Description Design Features and ADVAN- TagesRecommended EQUIPMENT/PROCESSES Recommended EQUIPMENT/CONNECTIONS Controls and SettingsTable of Contents Accessories Field Installed Options / Accessories Factory Installed Options / AccessoriesTable of Contents Maintenance Routine and Periodic MAINTE- Nance Safety PrecautionsFigure D.1 Major Component Location MULTI-SOURCE Table of Contents Theory of Operation Input VOLTAGE, FILTER, Contac TOR and Control Trans Former General DescriptionReturn to Section Section TOC Troubleshooting & RepairOperation Protection Devices and CIR Cuits Figure E.5 SCR Operation SCR OperationTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Electric Shock can kill PC Board Troubleshooting Procedures and ReplacementTroubleshooting Guide T1 Test Calibration ProcedurePerform the Firing Board Test Perform the Main TransformerCircuit external to the Multi Main Transformer Test Technical SpecificationsInput Contactor Test Functions ProblemsControl Transformer T2 Voltage Test Test DescriptionFigure F.1. Control Transformer Location & Leads Test Procedure575 VAC 43.0 VAC 460 VAC 34.50 VAC 380 VAC 28.50 VAC Secondary Thermostat Input Contactor Test 241COIL Input Contactor TestTest for Contact Continuity Removal and Replacement ProcedureMULTI-SOURCE Main Transformer T1 Voltage Test Contactor Test Main Transformer T1 Voltage TestFigure F.6. Main Secondary Lead Test Points MULTI-SOURCE Static SCR Test Static SCR Test Leads Remove Red Paint Active SCR Test Active SCR Test Active SCR Test Remove Red Paint SW1 MULTI-SOURCE Control Board Test See Figure F.15 Control Board Test#341 #230 #215 #231 #263 #201 J1 MULTI-SOURCE Firing Board Test Static and Active SCR Tests Figure F.17Then Table F.2. LED 7, 8 and 9 Check List#231 #215 #340 J8 #287 MULTI-SOURCE Meter Accuracy Check Control Board Normal Open Circuit Voltage Waveform no Load Volts Typical SCR Gate Voltage Waveform no Load MULTI-SOURCE Description Input Contactor Cleaning AND/OR ReplacementRemoval Procedure Coil 240MULTI-SOURCE Control Board Replacement Procedure Control Board Firing Board Replacement Procedure Firing Board SCR Bridge / Heat Sink Assembly Replacement Procedure Bridge Assembly Mount #251 Mounting Bolt Removal of Individual SCR Heat Sink Assemblies Figure F.27 See Figure F.26Maximum Open Circuit Voltage No Load Readings FAN OFFPerform Meter Accuracy Test MULTI-SOURCE Table of Contents Electrical Diagrams Section Electrical DiagramsMULTI-SOURCE Wiring DiagramSchematic Control PC Board Return to Section PC Board ASSEMBLY-CONTROLSchematic Firing Printed Circuit Board TP1 PC Board ASSEMBLY-FIRINGM14312 PC Board Assembly SnubberSVM Error Reporting Form

SVM155-A specifications

The Lincoln Electric SVM155-A is a state-of-the-art welding machine that excels in versatility and performance, making it ideal for both professional welders and hobbyists. This multi-process welder supports MIG, TIG, and stick welding processes, allowing users to tackle a wide range of applications with a single device. Its user-friendly design and advanced technology make it an exceptional choice for those looking to enhance their welding capabilities.

One of the main features of the SVM155-A is its robust power output, which can handle welding materials ranging from thin sheets to heavier stock. The welder offers a high duty cycle, ensuring that users can work efficiently without the need for prolonged breaks. This is especially important in industrial settings where productivity is key. Additionally, the SVM155-A is equipped with a digital display that allows for easy monitoring and precise control of the welding parameters, ensuring consistency in weld quality.

The European-designed INVERTER technology embedded in the SVM155-A significantly contributes to its lightweight and compact design. Weighing in at only 19.4 lbs, this welder is portable and ideal for fieldwork or workshops where space is limited. The inverter technology not only reduces the size and weight but also improves energy efficiency, leading to lower operational costs over time.

The SVM155-A also features advanced safety mechanisms, including over-current protection to safeguard the machine from potential damage during excessive use. It also includes a thermal overload shut-off, which prevents overheating, ensuring a longer lifespan for the welder.

Another standout characteristic of the SVM155-A is its exceptional arc stability and ease of use. The machine is designed to provide a smooth and consistent arc, reducing spatter and ensuring clean welds. Moreover, the welder is compatible with a wide range of materials, including stainless steel, aluminum, and carbon steel, further enhancing its versatility.

In conclusion, the Lincoln Electric SVM155-A is a powerful, durable, and multifunctional welding machine that incorporates advanced technologies to meet the needs of modern welding applications. Its portability, safety features, and ability to deliver high-quality welds make it an excellent investment for anyone looking to improve their welding skills or expand their capabilities in various welding projects.
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