Lincoln Electric SVM144-B service manual Troubleshooting and Repair

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F-14

TROUBLESHOOTING AND REPAIR

F-14

 

 

 

MAIN TRANSFORMER TEST (continued)

 

 

14. Locate the following leads on plug J9

c. If any of the voltages tested are

 

on the M19248 snubber PC board and

incorrect, check for loose or broken

 

on plug J5 on the G3521 control PC

leads between the test points and

 

board. See Figure F.1.

the main transformer.

 

 

G3521:

 

 

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PLUG

 

LEAD

LOCATION

 

 

 

 

206

3J5

 

 

 

M19248:

 

 

 

 

 

 

PLUG

 

LEAD

LOCATION

 

 

 

 

208S

2J9

 

209S

6J9

 

 

 

15.Turn the machine ON.

16.Make the following voltage tests at plug J9 on the M19248 snubber PC board and at plug J5 on the G3521 control PC board.

a.Turn the machine OFF between each test.

b.Carefully insert the meter probes into the back of each Molex plug pin cavity to perform the test.

FROM

TO

EXPECTED

LEAD

LEAD

VOLTAGE

 

 

 

208S

209S

56VAC

(2J9 on

(6J9 on

 

M19248)

M19248)

 

208S

206

28VAC

(2J9 on

(3J5 on

 

M19248)

G3521)

 

209S

206

28VAC

(6J9 on

(3J5 on

 

M19248)

G3521)

 

 

 

 

d.If ALL the voltages tested are incor- rect or missing, go to step 16.

17.Test for correct nameplate input voltage between the H1 lead at the ON/OFF POWER SWITCH to H2 or H3 (H5 if connected for 575 VAC) at the reconnect panel. Voltage tested will vary depending on input voltage connection. See wiring diagram for test point locations.

a.If the voltage test is incorrect,

-check for loose or broken leads between the reconnect panel and the ON/OFF POWER SWITCH.

-test the ON/OFF POWER SWITCH for proper operation.

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

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POWER MIG 255

Image 52
Contents Power MIG Safety Electric Shock can kill Safety Welding Sparks can cause fire or explosionPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionInstallation Technical Specifications Power MIGUncrating the Power MIG Safety PrecautionsLocation Power MIG Figure A.2 Triple Voltage Machine Input Connections GUN and Cable Installation Shielding GASOperation Section Section BOPERATIONB-2 Fumes and Gases can be dangerousOperation Product DescriptionWelding Capability LimitationsDescription of Controls Procedure for Changing Drive and Idle Roll Sets Wire Reel Loading READI-REELS, SPOOLS, or CoilsFeeding Wire Electrode Setting RUN-IN Speed on STAN- Dard Power MIG FeederIdle Roll Pressure Setting To Start the WelderAvoiding Wire Feeding Problems Making a WeldFAN Control Input Line Voltage ProtectionAccessories Section Section CAccessories Drive Roll KitsK363P READI-REEL Adapter Dual Cylinder Mounting KIT K1702-1Operating Instructions For Timer KIT Making a Weld with the Spool GUN, Spool GUN Installed Spool GUN Adapter KITMaintenance Section Section DRoutine and Periodic Maintenance MaintenanceGUN Tubes and Nozzles Figure D.1 Component Locations Contact TIP and GAS Nozzle Installation Liner Removal Replacement5MAINTENANCED-5 To open up the handleTable D.2 Description English Size Metric SizeTheory of Operation Section Section EInput Line Voltage Theory of OperationMain Transformer Output Rectification Feedback ControlConstant Voltage Output Figure E.4 Constant Voltage OutputWire Drive Motor FeedbackThermal and Overload Protection Wire Feed Overload ProtectionOvercurrent Protection SCR Operation Figure E.6 SCR OperationPower MIG Troubleshooting & Repair Section Section FTroubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures WorkstationsOutput Problems SCR Rectifier Rectifier Function Problems Wire Feeding Problems Welding Problems Welding Problems Main Transformer Test Test DescriptionTest Procedure Main Transformer TestFigure F.1 Troubleshooting and Repair Test Description Rectifier Diode Bridge TestMaterials Needed Rectifier Diode Bridge Testing 208R 206 28 VAC 209R Power MIG Static SCR Rectifier Assembly Test Static SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Power MIG Active SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Figure F.7 Location Leads X2 Open switch SW-1 Wire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test for Supply Voltage to Tachometer 515B 206B 15 VDC 5J1 1J1Test for Feedback Voltage to Control Board 555 206B To 3.5 VDC 6J1 1J1Normal Open Circuit Voltage Waveform VoltsMachine Loaded to 250 Amps AT 26 VDC Scope Settings Typical Output Voltage Waveform Machine LoadedMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Power MIG Control PC Board Removal and Replacement Procedure DescriptionRemoval and Replacement Procedure Control PC BoardFigure F.11 Control Board Mounting Power MIG 41TROUBLESHOOTING & REPAIRF-41 Wire Drive Assembly Removal and Replacement ProcedureWire Drive Assembly Removal and Replacement ProcedureTOC Power MIG SCR Output Rectifier Removal and Replacement Procedure SCR Output Rectifier Removal and Replacement Figure F.15 Right Heat Sink Lead Disconnection Power MIG Capacitor Bank Removal and Replacement Procedure Capacitor Bank Removal and Replacement Troubleshooting & Repair Removal and Replacement Main Transformer and Output ChokeTOC Power MIG FAN Motor Assembly Removal and Replacement Procedure FAN Motor Assembly Removal and Replacement Troubleshooting and Repair Wire Speed RangeRetest After Repair Open Circuit VoltagePower MIG Electrical Diagrams Section Power MIG 255 208/230V Wiring Diagram Entire Machine Code 10563 L10979Power MIG 255 230/460/575V Wiring Diagram Entire Machine Code 10583 L10980Power MIG 255 230/460/575 Wiring Diagram Entire Machine Code 10986 L11980Power MIG 255 208/230 Wiring Diagram Entire Machine Code 10990 L11979Control PC Board Schematic G3520-1D1 Control PC Board Assembly G3521-1 3521Display PC Board Schematic L10951 PowermigDisplay PC Board Assembly L10952-1 Lincoln Electric COSnubber PC Board Schematic S24374 24374 SSnubber PC Board Assembly M19248-1 00 ~.04SVM Error Reporting Form