41TROUBLESHOOTING and REPAIRF-41 | Lincoln Electric SVM157-A

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F-41TROUBLESHOOTING AND REPAIRF-41

MAIN TRANSFORMER REPLACEMENT

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed. Call 1-800-833- 9353(WELD).

DESCRIPTION

The following procedure will aid the technician in removing the main transformer for repair or replacement.

MATERIALS NEEDED

3/8” Nutdriver

7/16” Nutdriver

1/2” Nutdriver

5/16” Nutdriver

Flathead Screwdriver

This procedure takes approximately 80 minutes to perform.

POWER MIG 200

Image 75

Lincoln Electric SVM157-A service manual 41TROUBLESHOOTING and REPAIRF-41, Main Transformer Replacement

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 GUN and Cable Installation Shielding GASCylinder may explode if damaged 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 Procedure for Changing Drive and Idle Roll Sets Wire Reel Loading READI-REELS, Spools or CoilsTo Start the Welder 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 These capacitors is toxic Avoid contact with any portionYour body Function Problems Tachometer Feedback Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Main Transformer Test Test DescriptionMaterials Needed 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