Lincoln Electric SVM167-A service manual Main Transformer Test, Test Procedure

Page 48

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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
			X7 X8

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TEST PROCEDURE

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.

6.Locate leads X9 and X10. See Figure

F.3.

7.Connect main input power to the machine.

8.Turn the POWER MIG 215 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® 215

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Contents Power MIG Safety Depends on YouSafety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn Can be dangerousWelding and Cutting Sparks can cause fire or explosion Cylinder may explode if damagedIii Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SECTION Installation Technical Specifications Power MIGSafety Precautions Uncrating the Power MIGInstallation LocationOutput Polarity Connections GUN and Cable Installation AUXILIARY POWER RECEPTACLESShielding GAS Cylinder may explode if damagedPower MIG Operation SECTION OPERATIONB-2 Wear eye, ear and body protec- tionOperation Procedure for Changing Drive AND IDLE Roll Sets Wire Reel Loading READI-REELS, Spools or CoilsTo Start the Welder Feeding Wire Electrode Idle Roll Pressure SettingWire Drive Configuration Making a Weld Figure B.2bAvoiding Wire Feeding Problems Wire Feed Overload ProtectionFAN Control Input Line Voltage VariationsPower MIG Accessories SECTION Accessories 3ACCESSORIESC-3 InstalledMaking a Weld with the Spool GUN Adapter KIT and Spool GUNPower MIG Maintenance SECTION Maintenance Liner Removal and Replace Ment Table D.1GUN Handle Disassembly English Metric Description SizeFigure D.2 Major Component Locations Power MIG Line Switch Theory of Operation SECTION Figure E.2 Input Power Circuit Theory of OperationOutput Rectification Contactor and Control Board Figure E.3 Control CircuitsControl BOARD, GUN Trigger and Wire Drive Motor Figure E.4 Optional CircuitsWirefeed Overload Protection Protective Devices and CircuitsThermal and Overload Protection Power MIG TROUBLESHOOTING AND REPAIR SECTION Troubleshooting 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 Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Main Transformer Test Test DescriptionMaterials Needed Test Procedure ON/OFF Power Switch will be hot during these testsMain Transformer Test X10 Table F.1. Test Points Input Voltage Test PointsWire Drive Motor and Wire Speed Potentiometer Test Black WhiteTest for Feedback Voltage to Control Board 1109 aVDC Power MIG Output Bridge Rectifier Test Negative Lead 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 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 Output Capacitors Replacement Figure F.14. Capacitor Bank LocationLead Mounting Bolts Nuts Lock washers 3 places Power MIG 41TROUBLESHOOTING and Repair F-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 215 208/220/230V POWEr miGPower MIG 215 208/220/230V for Codes 11099 SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG1 L12308SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG2 ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS