Troubleshooting and Repair Section | Lincoln Electric SVM157-A

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Section F	TABLE OF CONTENTS	Section F
	- TROUBLESHOOTING AND REPAIR SECTION -

Troubleshooting and Repair	Section F
How to Use Troubleshooting Guide	F-2
PC Board Troubleshooting Procedures	F-3
Troubleshooting Guide	F-4
Test Procedures	F-11
Main Transformer Test	F-11
Wire Drive Motor and Tachometer Feedback Test	F-15
Output Bridge Rectifier Test	F-19
Contactor Test	F-21
Voltage Waveforms	F-23
Component Replacement Procedures	F-27
Control Board Replacement	F-27
Wire Drive Motor Assembly Replacement	F-29
Output Diode Bridge Rectifier Replacement	F-33
Output Capacitors Replacement	F-37
Main Transformer Replacement	F-41
Fan Blade/Motor Replacement	F-47
Output Contactor Replacement	F-49
Retest After Repair	F-52

WARNING

ELECTRIC SHOCK can kill.

•Never work on the inside of the machine without removing the input power. You can receive a life threatening electrical shock if you fail to do this. Only qualified technicians should perform installation, maintenance, and troubleshooting work on the machine.

POWER MIG 200

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Lincoln Electric SVM157-A service manual Troubleshooting and Repair Section F

Contents

Safety Depends on You Power MIG California Proposition 65 Warnings Safety ARC Rays can burn Electric Shock can kill Iii Cylinder may explode if damaged Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Master Table of Contents for ALL Sections Installation Section Table of Contents Technical Specifications Power MIG Installation 3INSTALLATIONA-3 Figure A.1 Dual Voltage Machine Input Connections Figure A.2 Triple Voltage Machine Input Connections Output Polarity Connections Cylinder may explode if damaged GUN and Cable InstallationShielding GAS Operation Section B Operation Section Wear eye, ear and body protec- tion Operation Recommended Processes and Equipment Wire Drive RollWire Size Conversion Parts Product Description To Start the Welder Procedure for Changing Drive and Idle Roll SetsWire Reel Loading READI-REELS, Spools or Coils Idle Roll Pressure Setting Feeding Wire Electrode Making a Weld Input Line Voltage Variations Avoiding Wire Feeding ProblemsWire Feed Overload Protection FAN Control Accessories Section Dual Cylinder Mounting KIT K1702-1 AccessoriesDrive Roll Kits K363P READI-REEL Adapter Adapter KIT and Spool GUN Installed Power MIG Maintenance Section Maintenance Overtightening will split or collapse the liner Cause poor wire feedingLiner Removal and REPLACE- Ment This screw should only be gently tightened English Metric Description Size GUN Handle Disassembly Maintenance Power MIG Theory of Operation Section Line Switch Theory of Operation Motor Control Board Output Rectification Contactor and Control Board Figure E.4 Optional Circuits Control BOARD, GUN Trigger and Wire Drive Motor Thermal and Overload Protection Wirefeed Overload Protection Power MIG Troubleshooting and Repair Section F Troubleshooting and Repair Section How To Use Troubleshooting Guide Troubleshooting and Repair PC Board Troubleshooting Procedures Perform the Main Transformer Perform the Output Contactor Your body These capacitors is toxicAvoid contact with any portion Function Problems Tachometer Feedback Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Materials Needed Main Transformer TestTest Description Main Transformer Test ON/OFF Power Switch will be hot during these tests X10 Input Voltage Test Points Table F.1. Test Points Wire Drive Motor and Tachometer Feedback Test Figure F.4. Plug J4 Test Procedure Test for Supply Voltage to Tachometer Disconnect the main AC input power to the machine VDC Test for Feedback Voltage to Control Board Output Bridge Rectifier Test Output Bridge Rectifier Test Test Procedure Contactor Test Figure F.7. Contactor Terminals and Leads Contactor Test Typical Output Voltage Waveform Machine Loaded MAX TAP G Volts 10.0 Normal Open Circuit Voltage Waveform MAX TAP G Volts 20.0 Machine Loaded to 180 Amps AT 16 VDC Scope Settings Volts 20.0 Description Control Board Replacement Procedure Control Board Replacement Wire Drive Motor Assembly Replacement Wire Drive Wire Drive Motor Assembly Replacement Bolt Gas Hose TOC Output Diode Bridge Rectifier Replacement Output Diode Bridge Rectifier Mounting Bracket Mounting Bolts Rectifier Power MIG Output Capacitors Replacement Figure F.14. Capacitor Bank Location Output Capacitors Replacement Lead Mounting Bolts Nuts & Lock washers Places Power MIG Main Transformer Replacement 41TROUBLESHOOTING and REPAIRF-41 See Figure F.17 Main Transformer Replacement Figure F.17. Leads X9, X10, 104B,104C, & H1B Replacement X2 X3 X4 X5 X6 X7 Lead Power MIG FAN BLADE/MOTOR Replacement Perform the Output Capacitor Bank Removal Procedure FAN BLADE/MOTOR Replacement Output Contactor Replacement Figure F.24 Output Contactor Replacement Mounting Bolts Retest After Repair Table of Contents Electrical Diagrams Section Electrical Diagrams Wiring Diagram Power MIG 200 208/230V Schematic Control PC Board G3851-1 PC Board ASSEMBLY-CONTROL SVM Error Reporting Form