Lincoln Electric SVM 117-A service manual Main Transformer Test

Page 65

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F-12

 

TROUBLESHOOTING & REPAIR

 

 

 

 

 

 

F-12

 

 

 

 

 

 

 

 

 

 

 

MAIN TRANSFORMER TEST (CONTINUED)

 

 

 

 

 

 

 

4. Locate the following leads on Plug

 

a.

Turn the machine OFF between

 

 

J3:

 

 

 

 

 

 

 

each test.

 

 

 

 

 

 

 

 

 

G2332:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

b.

Carefully

insert the

meter

 

 

LEAD

 

PLUG

 

 

 

 

 

 

 

probes

into

the

 

back

of each

 

 

 

 

 

LOCATION

 

 

 

 

 

 

 

 

 

 

 

 

Molex Plug pin cavity to perform

 

 

 

 

 

 

 

 

 

 

 

 

 

#202

 

1J3

 

 

 

the test.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G2332:

 

 

 

 

 

 

 

 

 

 

#203

 

3J3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

#204 A

 

2J3

 

 

FROM

 

 

TO

 

EXPECTED

 

 

 

 

 

 

 

 

 

 

 

LEAD

 

 

LEAD

 

VOLTAGE

 

 

5. Connect main input power to the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

machine.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

#208

 

 

#209

 

 

60 VAC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6. Turn the Wire-Matic 250 ON/OFF

 

(16J6)

 

 

(7J6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POWER SWITCH to ON.

 

#208

 

 

#206

 

 

30 VAC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7. Make the following voltage tests at

 

(16J6)

 

 

(4J6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Plug J3.

 

 

 

 

 

 

#209

 

 

#206

 

 

30 VAC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

a. Turn the machine OFF between

 

(7J6)

 

 

(4J6)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

each test.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

c. If any of the voltages tested are

 

 

 

 

 

 

 

 

 

 

 

 

b. Carefully insert the meter

 

 

incorrect, check for loose or bro-

 

 

probes

into the back of each

 

 

ken leads between the test

 

 

Molex Plug pin cavity to perform

 

 

points and the main transformer.

 

 

the test.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

G2332:

 

 

 

 

 

 

d.

If ALL the voltages tested are

 

 

 

 

 

 

 

 

 

 

 

incorrect or missing, go to Step

 

FROM

 

TO

 

EXPECTED

 

 

 

 

 

 

 

12.

 

 

 

 

 

 

 

 

 

 

 

LEAD

 

LEAD

 

VOLTAGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12. Test for correct nameplate input volt-

 

#202

 

#203

 

30 VAC

 

 

 

 

age between the H1 lead at the

 

(1J3)

 

(3J3)

 

 

 

 

 

 

 

 

 

 

ON/OFF POWER SWITCH to H2 or

 

 

 

 

 

 

 

 

 

 

 

#202

 

#204 A

 

15 VAC

 

H3 (H5 if connected for 575 VAC) at

 

 

 

 

the reconnect panel. Voltage tested

 

(1J3)

 

(2J3)

 

 

 

 

 

 

 

 

 

 

will vary depending on Input Voltage

 

 

 

 

 

 

 

 

 

 

 

#203

 

#204 A

 

15 VAC

 

Connection. See wiring diagram for

 

 

 

 

test point locations.

 

 

 

 

 

 

 

(3J3)

 

(2J3)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

a.

If the voltage test is incorrect,

 

8. Turn OFF the machine

 

 

 

 

9. Locate the following leads on Plug

 

 

-

check for loose

or

broken

 

 

J6 on the G2332 Control PC Board.

 

 

leads between

the

reconnect

 

 

G2332:

 

 

 

 

 

 

 

panel and the ON/OFF POWER

 

 

 

 

 

 

 

 

 

 

 

SWITCH.

 

 

 

 

 

 

 

 

 

LEAD

 

PLUG

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LOCATION

 

 

 

- test the ON/OFF POWER

 

 

 

 

 

 

 

 

 

 

 

 

 

#206

 

 

4J6

 

 

 

SWITCH for proper operation.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

#208

 

16J6

 

 

b. If the correct nameplate voltage

 

 

#209

 

 

7J6

 

 

 

 

 

 

 

 

 

is being applied to the main

 

 

 

 

 

 

 

 

 

 

 

 

10. Turn ON the machine.

 

 

 

 

transformer and one or more of

 

11. Make the following voltage tests at

 

 

the

 

secondary

 

voltages

are

 

 

 

missing

or

are

 

incorrect,

the

 

 

 

 

 

 

 

 

 

 

 

 

Plug J6 on the G2332 Control PC

main transformer may be faulty.

Board.

Replace.

 

WIRE-MATIC 250

 

Page 64 Page 66
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Page 64 Page 66
Contents Safety Depends on You WIRE-MATICARC Welding can be hazardous SafetyCylinder may explode if damaged Iii Electric and MAG- Netic FieldsSûreté Pour Soudage a L’Arc Précautions DE SûretéWIRE-MATIC Table of Contents Table of Contents Installation Current Range Duty Cycle Amps Volts at Rated AmpsFuse Superlag Type 750C CopperSelect Proper Location Safety PrecautionsInput Connections StackingInput Power Connections and Ground Connections Fuse and Wire SizesConnect Shielding GAS Figure A.4 Input Air Supply Connections Reconnect ProcedureFigure A.5 Reconnect Diagram For 208/230/1/60 Machines Install the Work Clamp InstallationConnect Output Components GUN Liner and Contact Output Polarity ConnectionGUN and Cable Installation Wire Size Conversion PartsWIRE-MATIC Operation WELDING, Cutting Safety InstructionsGeneral Description Unit Features Design Features AdvantagesPower Source Features Recommended Processes and EquipmentMachine Capability Wire Feeder FeaturesLimitations Duty Cycle Amps VoltsFigure B.1 Operator Controls Controls and SettingsLoading the Wire Reel Using the Wire Drive RollProcedure for Changing Drive Roll To mount 10 to 30 lb. spools 8 and 12 diameter Proper Wire FeedingFeeding Electrode Starting the Welder Setting Idle Roll PressureOperating Steps Making a Weld WIRE-MATIC Accessories K607-1 Spool GUN Adapter KIT OPTIONS/ACCESSORIESInstalling the K607-1 Spool GUN Adapter KIT Spool GUN Module Board InstallationReturn Return to Section TOC Spool GUN Connection BOX InstallationSpool GUN Preparation Spool GUN ConnectionMaking the Weld Making a Weld with the Spool GUN Adapter K607-1 InstalledTimer KIT K585-1 Aluminum Wire Sizes Steel Wire Sizes Part NumberDrive Roll Kits To Make Spot Plug WeldsMaintenance Perform the following daily Routine and Periodic MaintenanceMaintenance Cable Cleaning Contact TIP and GAS Nozzle InstallationDrive Rolls and Guide Tubes GUN Tubes and Nozzles DROP-IN Reel Spindle and ClipsFigure D.2 Liner maintenance Liner Removal ReplacementTo open up the handle GUN Handle DisassemblyDescription English Size Metric Size WIRE-MATIC Theory of Operation Transformer Input Line Voltage and MainFeedback Control Output RectificationFigure E.4 Constant Voltage Output Constant Voltage OutputFeedback Wire Drive MotorThermal Protection Figure E.6 SCR Operation SCR OperationWIRE-MATIC Troubleshooting & Repair Recommended Course of Action HOW to USE Troubleshooting GuideBoard can be dam- aged by static electricity PC Board Troubleshooting ProceduresElectric Shock can kill Main Transformer Rectifier Assembly Test To Section TOC Perform the SCR Rectifier Perform the Wire Drive Motor Trolyte in these capacitors is Liquid elecPerform the Output Rectifier Materials Needed Main Transformer TestTest Description ON/OFF Power Switch will be hot during these tests Main Transformer Test Test ProcedureMain Transformer Test Static SCR Rectifier Assembly Test Leads Figure F.4 SCR 1 Test Points Active SCR Rectifier Assembly Test Leads SCR connections Figure F.7 SCR Tester CircuitWire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test Procedure Test for Feedback Voltage to the Control Board Test for Supply Voltage to TachometerNormal Open Circuit Voltage Waveform Scope SettingsTypical Output Voltage Waveform Machine Loaded Machine Loaded to 250 Amps AT 26 VDC Scope SettingsMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Materials Needed Control PC Board Removal and ReplacementRemoval and Replacement Procedure Removal and REPLACE- Ment Procedure Wire Drive Assembly Removal and Replacement Figure F.11 Wire Drive Assembly Removal Wire Drive Assembly Removal and Replacement ProcedureSCR Output Rectifier Removal & Replacement Disconnection Heat Sink Lead Right side heat sink See Figure F.14Capacitor Bank Removal and Replacement Components Bank Removal ReplacementMain Transformer Removal and Replacement Power Switch FAN Motor and FAN Removal and Replacement Figure F.16 Fan Motor and Fan Removal Components FAN Motor and FAN Removal and Replacement ProcedureTroubleshooting & Repair Open Circuit Voltage Wire Speed RangeInput Volts/Hertz 230/60 375WIRE-MATIC Table of Contents Electrical Diagrams Section WIRE-MATIC Electrical Diagrams Spool GUN Option Wiring Diagram 208/230 Code To Section Available from Lincoln Control PC Board G2332 Layout
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