Contactor Test | Lincoln Electric SVM157-A instruction

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F-22

TROUBLESHOOTING AND REPAIR

F-22

CONTACTOR TEST (Continued)

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TEST PROCEDURE

1.Remove the input power to the POWER MIG 200 machine.

2.Using the 5/16” Nutdriver, remove the tool tray.

3.Locate and remove leads 106B, 106C and 107A from the contactor coil terminals. See Figure F.7. See the Wiring Diagram.

4.Using the 7/16” wrench, remove one lead from the contactors large terminals. See Figure F.7. See the Wiring Diagram.

5.Carefully apply 12 VDC to the contactor coil leads. (small terminals)

CAUTION

Do not leave the 12 VDC applied to the contactor coil for a prolonged period of time (15 seconds maximum). Damage to contactor may result.

6.If the contactor does not activate when the 12VDC is applied, the contactor is faulty. Replace.

7.If the contactor activates when the 12VDC is applied, check the resistance between the two large terminals with the contactor activated. The resistance should be very low (0 to 1 ohm).

8.If the resistance is “high” or “open” between the two large terminals when the contactor is activated, the contactor is faulty. Replace.

9.If the contactor activates and the resistance between the terminals is low when the 12 VDC is applied, the contactor is good

NOTE: When the contactor is not activated, the resistance between the terminals should be very high (infinite). If the resistance is always low, the contacts are “stuck” and the contactor is faulty. Replace.

10.When the test is complete, replace leads 106B, 106C and 107A.

11.Replace the lead previously removed from one of the contactor large terminals.

12.Replace the tool tray.

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Figure F.7. Contactor Terminals and Leads

106B

106C

107A

Output

Contactor

POWER MIG 200

Image 56

Lincoln Electric SVM157-A service manual Contactor Test, Figure F.7. Contactor Terminals and Leads

Contents

Power MIG Safety Depends on You Safety California Proposition 65 Warnings Electric Shock can kill ARC Rays can burn Cylinder may explode if damaged Iii Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Power MIG 3INSTALLATIONA-3 Figure A.1 Dual Voltage Machine Input Connections Output Polarity Connections Figure A.2 Triple Voltage Machine Input Connections Cylinder may explode if damaged GUN and Cable InstallationShielding GAS Operation Section Operation Section B Operation Wear eye, ear and body protec- tion Wire Drive Roll Wire Size Conversion PartsProduct Description Recommended Processes and Equipment To Start the Welder Procedure for Changing Drive and Idle Roll SetsWire Reel Loading READI-REELS, Spools or Coils Feeding Wire Electrode Making a Weld Idle Roll Pressure Setting Avoiding Wire Feeding Problems Wire Feed Overload ProtectionFAN Control Input Line Voltage Variations Accessories Section Accessories Drive Roll KitsK363P READI-REEL Adapter Dual Cylinder Mounting KIT K1702-1 Installed Adapter KIT and Spool GUN Power MIG Maintenance Section Maintenance Cause poor wire feeding Liner Removal and REPLACE- MentThis screw should only be gently tightened Overtightening will split or collapse the liner GUN Handle Disassembly English Metric Description Size Maintenance Power MIG Line Switch Theory of Operation Section Theory of Operation Output Rectification Contactor and Control Board Motor Control Board Control BOARD, GUN Trigger and Wire Drive Motor Figure E.4 Optional Circuits Wirefeed Overload Protection Thermal and Overload Protection Power MIG Troubleshooting and Repair Section Troubleshooting and Repair Section F Troubleshooting and Repair How To Use Troubleshooting Guide 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 ON/OFF Power Switch will be hot during these tests Main Transformer Test X10 Table F.1. Test Points Input Voltage Test Points Wire Drive Motor and Tachometer Feedback Test Test Procedure Figure F.4. Plug J4 Disconnect the main AC input power to the machine Test for Supply Voltage to Tachometer Test for Feedback Voltage to Control Board VDC Output Bridge Rectifier Test Test Procedure Output Bridge Rectifier Test Contactor Test Contactor Test Figure F.7. Contactor Terminals and Leads Volts 10.0 Typical Output Voltage Waveform Machine Loaded MAX TAP G Volts 20.0 Normal Open Circuit Voltage Waveform MAX TAP G Machine Loaded to 180 Amps AT 16 VDC Scope Settings Volts 20.0 Control Board Replacement Description Control Board Replacement Procedure Wire Drive Motor Assembly Replacement Wire Drive Motor Assembly Replacement Wire Drive Bolt Gas Hose TOC Output Diode Bridge Rectifier Replacement Output Diode Bridge Rectifier Mounting Bracket Mounting Bolts Rectifier Power MIG Output Capacitors Replacement Output Capacitors Replacement Figure F.14. Capacitor Bank Location Lead Mounting Bolts Nuts & Lock washers Places Power MIG 41TROUBLESHOOTING and REPAIRF-41 Main Transformer Replacement Main Transformer Replacement See Figure F.17 Replacement Figure F.17. Leads X9, X10, 104B,104C, & H1B X2 X3 X4 X5 X6 X7 Lead Power MIG FAN BLADE/MOTOR Replacement FAN BLADE/MOTOR Replacement Perform the Output Capacitor Bank Removal Procedure Output Contactor Replacement Output Contactor Replacement Figure F.24 Mounting Bolts Retest After Repair Electrical Diagrams Table of Contents Electrical Diagrams Section Power MIG 200 208/230V Wiring Diagram Schematic Control PC Board PC Board ASSEMBLY-CONTROL G3851-1 SVM Error Reporting Form