Lincoln Electric SVM157-A service manual

Contents

Main POWER MIG200 SERVICE MANUAL SVM157-A POWER MIG 200 FOR ENGINE powered equipment. WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous ii ARC RAYS can burn. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. iii WELDING SPARKS can cause fire or explosion. iv PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR vv MASTER TABLE OF CONTENTS FOR ALL SECTIONS - INSTALLATION SECTION- Section ASection A INSTALLATION TECHNICAL SPECIFICATIONS POWER MIG 200 INSTALLATION A-3 SAFETY PRECAUTIONS UNCRATING THE POWER MIG 200 LOCATION INSTALLATION A-4 INSTALLATION A-5 OUTPUT POLARITY CONNECTIONS INSTALLATION A-6 GUN AND CABLE INSTALLATION SHIELDING GAS - OPERATION SECTION - Section BSection B Page OPERATION PRODUCT DESCRIPTION RECOMMENDED PROCESSES AND EQUIPMENT WELDING CAPABILITY LIMITATIONS OPERATION PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS WIRE REEL LOADING - READI-REELS, SPOOLS OR COILS To Mount a 30 Lb. (14 kg) Readi-Reel Package (Using the Molded Plastic K363-P Readi-Reel Adapter:) To Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300 mm Diameter) or 14Lb.(6 Kg) Innershield Coils: OPERATION FEEDING WIRE ELECTRODE IDLE ROLL PRESSURE SETTING MAKING A WELD OPERATION AVOIDING WIRE FEEDING PROBLEMS TABLE B.1. FAN CONTROL INPUT LINE VOLTAGE VARIATIONS Page ACCESSORIES DRIVE ROLL KITS 3/64" (1.2 mm) ALUMINUM FEEDING KIT (K1703-1) K363P READI-REEL ADAPTER DUAL CYLINDER MOUNTING KIT (K1702-1) ACCESSORIES MAKING A WELD WITH THE SPOOL GUN ADAPTER KIT AND SPOOL GUN INSTALLED Page - MAINTENANCE SECTION - Section DSection D MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. (READ THE SAFETY PRECAUTIONS IN THE FRONT OF THIS MANUAL BEFORE WORKING ON THIS MACHINE.) GENERAL MAINTENANCE MAINTENANCE LINER REMOVALAND REPLACE- MENT MAINTENANCE GUN HANDLE DISASSEMBLY Page Page - THEORY OF OPERATION SECTION - Section ESection E THEORY OF OPERATION INPUT LINE VOLTAGE, MAIN TRANSFORMER, VOLTAGE SELECTOR SWITCH AND BAFFLE MOUNTED DIODE BRIDGE + - - THEORY OF OPERATION OUTPUT RECTIFICATION, CONTACTOR AND CONTROL BOARD THEORY OF OPERATION CONTROL BOARD, GUN TRIGGER AND WIRE DRIVE MOTOR THEORY OF OPERATION PROTECTIVE DEVICES AND CIRCUITS THERMAL AND OVERLOAD PROTECTION WIREFEED OVERLOAD PROTECTION Page - TROUBLESHOOTING AND REPAIR SECTION - Section FSection F F-2 How To Use Troubleshooting Guide F-3 PC BOARD TROUBLESHOOTING PROCEDURES F-4 F-5F-5 F-6 F-7F-7 F-8F-8 F-9F-9 F-10F-10 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST (continued) X6 X7 X8 X1 Page Page TROUBLESHOOTING AND REPAIR J11 TEST PROCEDURE TROUBLESHOOTING AND REPAIR TEST FOR SUPPLY VOLTAGE TO TACHOMETER TROUBLESHOOTING AND REPAIR TEST FOR FEEDBACK VOLTAGE TO CONTROL BOARD J11 Black Black Arm White Arm TROUBLESHOOTING AND REPAIR OUTPUT BRIDGE RECTIFIER TEST TROUBLESHOOTING AND REPAIR OUTPUT BRIDGE RECTIFIER TEST (continued) Figure F.6. Rectifier Test Points Front Negative Lead TROUBLESHOOTING AND REPAIR CONTACTOR TEST TROUBLESHOOTING AND REPAIR CONTACTOR TEST (Continued) Figure F.7. Contactor Terminals and Leads 10.0 V 5 ms TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP G) MACHINE LOADED TO 200 AMPS AT 22 VDC TROUBLESHOOTING AND REPAIR 20.0 V 1.0 ms NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAPG) TROUBLESHOOTING AND REPAIR 20.0 V 5 ms ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED (MAX TAP G) ONE OUTPUT DIODE NOT FUNCTIONING MACHINE LOADED TO 180 AMPS AT 16 VDC TROUBLESHOOTING AND REPAIR 20.0 V 5 ms ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAPG) TROUBLESHOOTING AND REPAIR CONTROL BOARD REPLACEMENT TROUBLESHOOTING AND REPAIR CONTROL BOARD REPLACEMENT (continued) DEPRESS LOCKING TAB ON MOUNTING PIN F-29 WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT F-30 Wire Drive F-30 Gas Hose 9/16" Bolt 5/16" Sheet Metal Screws TROUBLESHOOTING AND REPAIR F-33 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT F-34 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED) OUTPUT DIODE BRIDGE RECTIFIER Page Page OUTPUT CAPACITORS REPLACEMENT F-38 OUTPUT CAPACITORS REPLACEMENT (Continued) LOWER RIGHT CASE WRAPAROUND COVER CAPACITOR BANK ASSEMBLY Page Page F-41 MAIN TRANSFORMER REPLACEMENT F-42 MAIN TRANSFORMER REPLACEMENT (Continued) Main Transformer 1/2" Mounting Bolts F-43 X10 X9 MAIN TRANSFORMER REPLACEMENT (Continued) REPLACEMENT 104B 104C H1B Front Lead 118 Page F-47 FAN BLADE/MOTOR REPLACEMENT F-48 } FAN BLADE/MOTOR REPLACEMENT (Continued) REAR 5/16" Bolts } OUTPUT CONTACTOR REPLACEMENT F-50 106C 107A OUTPUT CONTACTOR REPLACEMENT (Continued) 106B Output Contactor Page F-52 RETEST AFTER REPAIR ELECTRICAL DIAGRAMS ELECTRICAL DIAGRAMS WIRING DIAGRAM - Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC (NON-LEAD SIDE OF CONNECTOR) POWER MIG 200 (208/230V) L11424 CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P.C. BOARD) - + Page ELECTRICAL DIAGRAMS PC BOARD ASSEMBLY-CONTROL Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC 3.10 .20 SVM ERROR REPORTING FORM