Lincoln Electric SVM135-B manuals
Power Tools > Welder
When we buy new device such as Lincoln Electric SVM135-B we often through away most of the documentation but the warranty.
Very often issues with Lincoln Electric SVM135-B begin only after the warranty period ends and you may want to find how to repair it or just do some service work.
Even oftener it is hard to remember what does each function in Welder Lincoln Electric SVM135-B is responsible for and what options to choose for expected result.
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Lincoln Electric SVM135-B Service Manual
182 pages 3.21 Mb
PPoowweerr WWaavvee 445555//PPoowweerr FFeeeedd 1100SERVICE MANUAL SVM135-BFOR ENGINE powered equipment. 2 WARNINGELECTRIC AND MAGNETIC FIELDS may be dangerous 3 ARC RAYS can burn.ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. 4 FOR ELECTRICALLY powered equipment.CYLINDER may explode if damaged. WELDING SPARKS can cause fire or explosion. 5 PRCAUTIONS DE SRETPRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 6 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS 7 TABLE OF CONTENTS -INSTALLATION SECTION-8 TECHNICAL SPECIFICATIONS POWER FEED 10 WIRE DRIVE AND CONTROL BOXWIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC # TYPE LOW SPEED RATIO HIGH SPEED RATIO A-3RECOMMENDED INPUT WIRE AND FUSE SIZES PHYSICAL DIMENSIONS TEMPERATURE RANGES INPUT AT RATED OUTPUT - THREE PHASE ONLY 9 TECHNICAL SPECIFICATIONS POWER WAVE 45510 SAFETY PRECAUTIONSLOCATION AND MOUNTINGSTACKING ENVIRONMENT LIFTING FEEDER AND CONTROL BOX MOUNTING 11 A-5A-6 12 ELECTRICAL CONNECTIONSGROUNDING HIGH FREQUENCY INTERFERENCE PROTECTION INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS INPUT VOLTAGE RECONNECT A-7 13 CABLE CONNECTIONSCONTROL CABLE CONNECTIONS FLEXIBLE CONNECTION POSSIBILITIES 14 A-8CABLE CONNECTIONS ELECTRODE AND WORK LEADS ELECTRODE POSITIVE APPLICATIONS A-9 A-9 ELECTRODE AND WORK LEADS ELECTRODE NEGATIVE APPLICATIONS VOLTAGE SENSING AT THE WORK- PIECE 15 WIRE FEEDER SETUPWIRE DRIVE GEAR RATIO (HIGH OR LOW SPEED) 16 A-1017 A-11A-11 DIP SWITCH SETUP FIGURE A.3 S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-2 only) S2 DIP Switch Bank on Control Box Motherboard (For software version S24004-2 only) 18 A-12S1 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up) S2 DIP Switch Bank on Control Box Motherboard (For software version S24004-3 & up) 19 A-13A-13 S1 DIP Switch Bank on Control Box Motherboard (For software version S24456) S2 DIP Switch Bank on Control Box Motherboard (For software version S24456) 21 A-15A-15 GUN AND CABLE ASSEMBLIES GMAW SHIELDING GAS 22 A-16STANDARD PANEL INSTALLATION 23 TABLE OF CONTENTS -OPERATION SECTION-SECTION B-1SECTION B-1 B-2 24 OPERATING INSTRUCTIONSSAFETY INSTRUCTIONS SYSTEM DESCRIPTIONRECOMMENDED EQUIPMENT B-3 B-3 DUTY CYCLE AND WELDING CAPABILITIES LIMITATIONS 25 CONTROLS AND SETTINGSPOWER WAVE CONTROLS AND STATUS LIGHTS 26 POWER FEED CONTROLS B-4 27 B-5DISPLAY CONTROL PANEL B-6Installation DIP Switch setup Installation DIP Switch setup BOARD LEVEL ADJUSTMENTS 28 WELD MODE DESCRIPTIONSCONSTANT VOLTAGE (CV/MIG) ARC GOUGING ELECTRODE ROUTING 29 WIRE SPINDLE PLACEMENTWIRE REEL LOADING - READI-REELS, SPOOLS OR COILS 30 B-8TO MOUNT A 50 TO 60 LB (22.7 TO 27.2 KG) COIL (USING K1504-1 COIL REEL) (FIGURE B.5): B-9 31 FEEDING ELECTRODE AND BRAKE ADJUSTMENTDRIVE ROLL KIT INSTALLATION (KP1505-[])Drive Roll Pressure Setting. DRIVE ROLL PRESSURE SETTING PROCEDURE FOR SETTING ANGLE OF FEEDPLATE 32 WIRE FEED OVERLOAD33 TABLE OF CONTENTS -ACCESSORIES SECTION-34 GENERAL35 POWER WAVE OPTIONS AND ACCESSORIESFACTORY INSTALLED FIELD INSTALLED WIRE FEEDER OPTIONS AND ACCESSORIESDRIVE ROLL AND GUIDE TUBE KITS 36 C-4INPUT CABLE ASSEMBLIES CABLE RECEPTACLES 37 C-538 C-6REEL ADAPTERS GUNS AND GUN ADAPTERS 39 C-7CONDUIT ADAPTERS 40 C-8DUAL PROCEDURE SWITCH OPTIONS GAS AND WATER KITS CHASSIS OPTIONS 41 C-9DESCRIPTION AND INSTALLATION OF OPTIONAL CONTROL BOX PANELS 42 C-1043 C-1144 C-1245 C-1346 C-1447 C-15CONTROL BOX PANELS -- SET UP CONTROLS DESCRIPTION CONTROL BOX -- PC BOARD ADJUSTMENTS C-16 C-16 CONTROL BOX -- SETTING OPERATING LIMITS CONTROL BOX -- USING OPERATING LIMITS 48 OPERATION WITH PREVIOUS SOFTWARE VERSION49 MAINTENANCESECTION D-1 TABLE OF CONTENTS -MAINTENANCE SECTION- 50 MAINTENANCE86 NOTES F-22 87 TEST PROCEDURES88 F-24INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 90 F-26SWITCH BOARD TEST 91 F-27SWITCH BOARD TEST Switch Board Removal and Replacement. 94 F-30OUTPUT RECTIFIER TESTOutput Rectifier Module Replacement Perform the Input Filter Capacitor Discharge Procedure. 96 F-32INPUT RECTIFIER TEST (continued) 97 F-33INPUT RECTIFIER TESTSwitch Board Test Input Contactor Test. Input Rectifier Removal and Replacement 100 F-36INPUT CONTACTOR TEST 102 F-38AUXILIARY TRANSFORMER NO. 2 TEST 104 F-40AUXILIARY TRANSFORMER NO. 1 TEST 105 F-41AUXILIARY TRANSFORMER NO. 1 TEST 108 F-44POWER BOARD TEST 109 F-45POWER BOARD TEST 112 F-48CURRENT TRANSDUCER TEST 113 F-49CURRENT TRANSDUCER TEST 116 F-52DRIVE MOTOR TESTGear Box and Drive Motor Removal and Replacement. 118 F-54TACH FEEDBACK TEST 120 F-56VOLTAGE SENSE PC BOARD TEST 122 F-58DUAL ENCODER PC BOARD TEST 124 F-60CONTROL CABLE CONTINUITY TEST 125 COMPONENT REPLACEMENT PROCEDURES126 F-62GAS SOLENOID REMOVAL AND REPLACEMENT INSTALLATION 128 F-64WIRE FEEDER CONTROL BOARD REMOVAL AND REPLACEMENT INSTALLATIONPC Board Troubleshooting Procedures 130 F-66TACH (HALL EFFECT) ASSEMBLY REMOVAL AND REPLACEMENT 132 F-68GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT 133 F-69GEAR BOX AND DRIVE MOTOR REMOVAL AND REPLACEMENT 136 F-72SWITCH BOARD AND FILTER CAPACITOR REMOVAL 137 F-73SWITCH BOARD AND FILTER CAPACITOR REMOVAL 138 F-74METER ACCURACY CHECK PROCEDURE TO REPAIR IF METERS ARE OUT OF RANGE POWER WAVE 455 / PF-10 METER ACCURACY CHECK MATERIAL NEEDED 140 F-76CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT REMOVAL PROCEDURE 141 F-77CONTROL OR POWER BOARD REMOVAL AND REPLACEMENT INSTALLATION PROCEDURE 144 F-80AUXILIARY TRANSFORMER NO. 1 REMOVAL AND 145 F-81AUXILIARY TRANSFORMER NO. 1 REMOVAL AND 148 F-84MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT 149 F-85MAIN INPUT CONTACTOR REMOVAL AND REPLACEMENT REPLACEMENT PROCEDURE 152 F-88INPUT RECTIFIER REMOVAL AND REPLACEMENT 154 F-90OUTPUT RECTIFIER AND MODULE REMOVAL AND REPLACEMENT RECTIFIER ASSEMBLY 155 F-91OUTPUT RECTIFIER AND MODULE REMOVAL AND REPLACEMENT RECTIFIER ASSEMBLY RECTIFIER MODULE REMOVAL AND REPLACEMENT TROUBLESHOOTING AND REPAIR FLOWCHART - POWER SOURCE ERROR INTERPRETATION GUIDE (For Codes 10555 and Below) 157 Power Source Error Interpretation Guide(Semi Automatic PW-455, PW455/STT)Key: PS = Power Source UI = User Interface (Control Box) FH = Feed Head F-93 158 TROUBLESHOOTING AND REPAIR FLOWCHART - PERFORMANCE TROUBLESHOOTING GUIDE(For Codes 10555 and Below) Performance Troubleshooting Guide(Semi Automatic PW-455, PW455/STT)Key: PS = Power Source UI = User Interface (Control Box) FH = Feed Head F-94 TROUBLESHOOTING AND REPAIR FLOWCHART - FUNCTIONAL TROUBLESHOOTING GUIDE (For Codes 10555 and Below) 159 Functional Troubleshooting Guide(Semi Automatic PW-455, PW455/STT)Key: PS = Power Source UI = User Interface (Control Box) FH = FeedHead F-95 G-1 160 TABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION-162 G-2Power Wave 455 Wiring Diagram - Code 103726A CIRCUIT RECEPTACLE SWITCH BOARD #1 SWITCH BOARD #2 FRONT OF MACHINEELECTRODE POWER BD RECTIFIER INPUT RECTIFIER LEFT SIDE AUXILIARY TRANSFORMER WN.C. OUTPUT RECT 110V RECEPTACLE CB2 S4 RIGHT SIDE OF MACHINERIGHT SIDE INPUT BOARD POWER BOARD P90 CURRENT TRANSDUCER SW1 POWER S2 SENSE CB1 VOLTAGE RECEPTACLE S3 RS232 CONNECTOR FAN RECONNECT PANEL AUXILIARY TRANSFORMER #1 #2ELECTRICAL SYMBOLS PER E1537 MAIN CHOKE L1 RECONNECT SWITCH VCR1 THIS AREA VIEWED FROM REAR OF MACHINE (TOP) REAR OF MACHINECB3 MAIN TRANSFORMER CONTROL BOARD WORK S1 WIRE FEEDER CB4 LEFT SIDE OF MACHINE G-2 163 G-3Power Wave 455 Wiring Diagram - Code 10555RIGHT SIDE OF MACHINE L2 WORK POWER BOARD WV 3-19-99D RECTIFIER RECONNECT PANEL AUXILIARY TRANSFORMER #2 ++ G-3S4 (TOP) FRONT OF MACHINE110V RECEPTACLE OUTPUT RECT MAIN TRANSFORMER LEFT SIDE MAIN CHOKE L1 AUXILIARY TRANSFORMER #1 SWITCH BOARD #1 CB3 S3 RS232 CONNECTOR REAR OF MACHINEELECTRODE SW1 POWER S1 WIRE FEEDER RECEPTACLE FAN CB4 6A CIRCUIT S2 VOLTAGE SENSE RECEPTACLE LEFT SIDE OF MACHINECONTROL BOARDRECONNECT SWITCH THIS AREA VIEWED FROM REAR OF MACHINE P91 CURRENT TRANSDUCER CB1 INPUT BOARD L7 RIGHT SIDE SWITCH BOARD #2ELECTRICAL SYMBOLS PER E1537 CB2 SOLID STATE RELAY 164 G-4Power Wave 455 Wiring Diagram - Code 10553 G-4LEFT SIDE OF MACHINEFRONT OF MACHINE REAR OF MACHINE 165 G-5Power Feed 10 Control Box Wiring DiagramBOARD 9-11-98D L10586MOTHER ENCODER P.C. BOARD DUAL LOWER OPTION N.E. UPPER OPTION N.E.USER DISPLAY P.C. BOARD INTERFACE NOTES: N.E. THE OPTION INSTALLED MAY NOT HAVE ALL OF THE SHOWN WIRES. SEE THE OPTION'S WIRING DIAGRAM FOR ADDITIONAL INFORMATION. G-5 166 G-6Power Feed 10 Wire Drive Wiring Diagram 167 G-7POWER FEED 10 MACHINE SCHEMATICJ9 OPTIONAL VOLTAGE SENSE SELECT PCB J9 OPTIONAL J6 INPUT GUN GUN CONTROLS WIRE DRIVE CONTROL PCB FEEDER CONTROLS WIRE COLOR CODE B = BLACK U = BLUE R = RED W = WHITEJ6 INPUT J6 OPTIONAL DISPLAY P.C. BOARD DUAL ENCODER P.C. BOARD 18LOWER OPTION PANELS. SOME OPTIONS DO NOT HAVE ALL WIRES SHOWN. UPPER OPTION PANELS. SOME OPTIONS DO NOT HAVE ALL WIRES SHOWN. DUAL PROCEDURE PANEL KIT DUAL PROCEDURE / MENORY PANEL KIT CV/GOUGE PANEL (STD) "M" PANEL KIT "MSTT" PANEL KIT "MX2" PANEL KIT "MSP2" PANEL KIT CONTROL BOX USER INTERFACE PCB INTERNAL HARNESS AND CONNECTOR USED ONLY IF UNIT CONFIGURED AS A BENCH FEEDER. 8-14-98F G3602 168 G-8POWER WAVE 455 MACHINE SCHEMATIC - CODE 10372Enhanced DiagramSWITCH BOARD#2 (RIGHT) GTHE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. THE LINCOLN ELECTRIC CO. G MACHINE SCHEMATIC ELECTRICAL SYMBOLS PER E1537 INPUT BOARD POWER BOARD CONTROL BOARD AUX. RECONNECT CR1 S5 RS232 CONNECTOR S1 WIRE FEEDER RECEPTACLE INPUT RECTIFIER RECONNECT SWITCHNOTES : N.A. PC BOARD COMPONENTS SHOWN FOR REFERENCE ONLY. ALL COMPONENTS ARE NOT SHOWN. RECEPTACLE S2 VOLTAGE SENSE SWITCH BOARD #1 (LEFT) G-8 169 G-9G+ L2 INVERTER WELDERS 3181-1 SWITCH BOARD#2 (RIGHT) POWER WAVE 455 MACHINE SCHEMATIC - CODE 105553181-1 S1 WIRE FEEDER RECEPTACLE S5 RS232 CONNECTOR INPUT BOARD SWITCH LEAD FILTER SWITCH BOARD #1 (LEFT)CR1 INPUT LINE FILTER INPUT RECTIFIER POWER BOARDELECTRICAL SYMBOLS PER E1537 MACHINE SCHEMATIC CONTROL BOARDS2 VOLTAGE SENSE RECEPTACLE GTHE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. EMSTHE LINCOLN ELECTRIC CO. THE LINCOLN ELECTRIC CO. 170 G-10POWER BOARD SWITCH BOARD#2 (RIGHT) G POWER WAVE 455 MACHINE SCHEMATIC - CODE 10553N.C. N.B. GTHE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. EMSTHE LINCOLN ELECTRIC CO. THE LINCOLN ELECTRIC CO. S5 RS232 CONNECTOR S2 VOLTAGE SENSE RECEPTACLE INPUT BOARD SWITCH BOARD #1 (LEFT)INPUT RECTIFIER S1 WIRE FEEDER RECEPTACLE CONTROL BOARD 174 G-14KJ comF Control eR15 CAN PRIMARY SWITCHING CIRCUIT SWITCH_GND GLABELS NONE LC "BK" Test Points FeederCTRL AMPH. WIRE FEEDER CAN +5Ve RS 232 +40Vf +5Vc e CTRL WIRE FEEDER POWER comF TESTVa c +5Ve POWER WAVE 455 POWER PC BOARD SCHEMATICR54 R55 R41 PWM Wire +40Vwf50 GND a +5Va +15Va comF c -15Va INVERTER POWER SUPPLIES USE VOLTAGE BRD TRANS "WT" To GCLEVELAND, OHIO U.S.A. 2-21-97 THE LINCOLN ELECTRIC CO.NOTES : GENERAL INFORMATION 3026 +15Va TESTVa +5Va -15Va a +5Vc Board To 65 Vdc +/- 20%46VAC Rect.& Filtered INVERTER WELDERS SCHEMATIC, POWER PCB 175 G-15+13V FROM CONTROL BOARD COIL CONNECT PRE-CHARGE CONTROL VAC CONTACTOR CONTROL CR1 17921 MLABELS CLEVELAND, OHIO U.S.A. THE LINCOLN ELECTRIC CO. UNUSED PINS FILENAME: M17921_3DA POWER WAVE 455 INPUT PC BOARD SCHEMATICSINGLE PHASE DETECT NOTES : CENTER LEG TO OUTSIDE LEG OF INPUT R23 R20 R21 R13 R17 R16 R15 R14 R12 R18 R5 MGENERAL INFORMATION CR2 PRE-CHARGE CONNECTIONS CONTACTOR OUTPUT Input CONTACTOR MINVERTER WELDERS SCHEMATIC, INPUT PCBXB-RW 11-14-97 2-27-98L 12-4-98A 176 G-16SHT. SWITCH SCHEMATIC 9904 NOTE: 203,206 BOLT ON WITH FILTER CAPSFILENAME: L9904-4EA THE LINCOLN ELECTRIC CO. 19 PRIMARY CAPACITOR 11/12 OR 15/16 POWER WAVE 455 SWITCH PC BOARD SCHEMATIC - CODE 10372 & 10555TRANSFORMER PRIMARY OVERVOLTAGE PROTECTION RECONNECT FILTER 20 13/14 OR 17/18 TRANSFORMER RECONNECTBLEEDERTYPE SUBJECT GENERAL INFORMATION NONE CLEVELAND, OHIO U.S.A. TO CONTROL BD. (VOLTAGE PROTECTION) (Pre-charge Shut-off) PWM LLABELS TO CONTROL BD. (VOLTAGE PROTECTION) (Trigger Loop) L 177 G-17XA LC/JLV 20 (Pre-charge Shut-off) 13/14 OR 17/18 TRANSFORMERCLEVELAND, OHIO U.S.A. THE LINCOLN ELECTRIC CO. FILENAME: L10666_1AA NOTE: 203,206 BOLT ON WITH FILTER CAPS POWER WAVE 455 SWITCH PC BOARD SCHEMATIC - CODE 10553RECONNECT OVERVOLTAGE PROTECTION TO CONTROL BD. (VOLTAGE PROTECTION) (Trigger Loop) CAPACITOR PWM LDRIVE GATE T1 B A 10666 LLABELS TRANSFORMER PRIMARY FILTER 11/12 OR 15/16 PRIMARY RECONNECT TO CONTROL BD. (VOLTAGE PROTECTION) 19INVERTER WELDERS SCHEMATIC, SWITCH PCB 178 G-1810-17-97A J5THE LINCOLN ELECTRIC CO.FILENAME: G3142_1BAR85 R83 1.50K R79 1.3K R82 6.19K R66 100K R36 PROC. B POT SUPPLY POT WIPER PROC. A OPTION 0 0 CAN LOW A15 A14R72 R59 R8 R7 R71 3142 MOTHER BD. SCHEMATIC J5 G4 STEP CONFIG. ( LSB ) ( MSB ) RUN IN MODE GROUP ID R57 10.0K -2 -1 -2 -1 POWER BUS B ENCODER 2 A DIP SWITCH 1R5 R37 R46 R40 R11 R13 R22 2.21K 26.7K R23 1.82K R90 POWER FEED 10 MOTHER CONTROL PC BOARD SCHEMATICR15 R20 R19 R21 R18 R17 R96 R24 R12 R10 X26 GENCODER SUPPLY BURNBACK A ENCODER 1 B TRIMMER DIP SWITCH 2R44 R42 R39 R43 R41 GROUP ID WFS DISPLAY S1MODE IPM / MPM ( EURO / US ) CLEVELAND, OHIO U.S.A. MOLEX CONNECTORS S2J4 J1,J2R48 R51 -6 -5 -7 -8 -4 MODE 1 MODE 3 POT COMMON DATA BUS MEMORY/DP SWITCHING 1 11 A13 HIGH DECODE INFO 11 1 DISPLAY STD OPTION LOWER POWER SUPPLYR91 NOTES : GENERAL INFORMATION XB BS 179 G-19BS DATA BUS GCONTROL P.C. BOARD SCHEMATIC 3144 uCOMPUTERSHUT DOWN A13C26.7K R22 1.82K R54 R89 6.81K R81 B 4 STEPR71 R75 1.50K 6.19K 5.11K R72 8.25K FILENAME: G3144_1BA THE LINCOLN ELECTRIC CO. J1X MEM X( LSB ) GROUP ID SPARE GROUP ID R76 POWER FEED 10 CONTROL PC BOARD SCHEMATICR88 332 R74 POWER BUS S1 J4 J5 J3 J2POLARITY ELECTRODE SENSE NONE CLEVELAND, OHIO U.S.A.R68 150K R69 R92 R15 R66 R70 R65 R13 R11 GAS PURGE COLD INCHR3 R5 R9 R2 R86 A BR78 R25 R51 332 R53 681 R58 R43 X3 DECODE INFO A14A15475 R31 X2R44 100 R47 R45 R46 R35 100 R36 R77 475 R33 R19 10K R87 10K R17 DUAL PROC. B TRIGGER G M TACH. 180 G-20XA NOTES : LR7 R6 CTT CLEVELAND, OHIO U.S.A. THE LINCOLN ELECTRIC CO.SCALE 2/5/96 LABELS GENERAL INFORMATION FILENAME: L10276_1AB POWER FEED 10 DISPLAY PC BOARD SCHEMATICSUP'S'D'G. SHT. 10276 LEQUIP. SUBJECT NONECHK. R5 LATCH 500 512 SCK VOLTS TRIM SCHEMATIC, STANDARD DISPLAY PCB POWER DRIVE WIRE FEEDER 181 G-21NONE 3-11-96 SJRF THE LINCOLN ELECTRIC CO. POWER FEED 10 ENCODER PC BOARD SCHEMATICS22920USER INTERFACE DUAL ENCDR PCB SCHEM. CLEVELAND, OHIO U.S.A. FILENAME: S22920_2BB 182 G-22SNONE CLEVELAND, OHIO U.S.A. THE LINCOLN ELECTRIC CO. 23918 POWER FEED 10 VOLTAGE SENSE PC BOARD SCHEMATICFILENAME: S23918_3CA STO HEAD P.C.B. FRAME BRASS BLOCK SWG VOLTAGE SENSE SELECT SCHEMATIC
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