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Lincoln Electric SVM160-B service manual Table of Contents Installation Section

Models: SVM160-B

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A-1A-1

TABLE OF CONTENTS

- INSTALLATION SECTION -

INSTALLATION	Section A
Technical Specifications	A-2
Safety Precautions	A-3
Input Supply Connection Diagram	A-4
Gun and Cable Installation	A-5

POWER MIG 300

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Lincoln Electric SVM160-B service manual Table of Contents Installation Section

Contents

Power MIG California Proposition 65 Warnings SafetyARC Rays can burn Electric Shock can killFumes and Gases can be dangerous Cylinder may explode if damaged Welding Sparks can cause fire or explosionIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Power MIG InstallationLocation Safety PrecautionsUncrating the Power MIG Input POWER, Grounding and Connection DiagramsInstallation Liner Installation and Trimming Instruction see Figure A.3 GUN and Cable InstallationInstallation Table of Contents Operation Section Definitions of Welding Modes OperationCommon Welding Abbrevia TionsOther features Controls and SettingsProduct Description Operations 5OPERATIONB-5 Setting and Configuring the Power MIG 300 for WeldingPreflow / Postflow Weld ModeStart Procedure MULTI-PROCESS Panel FunctionsTable B.2-ARC Control Settings by Process Spot Wire Drive RollCrater BurnbackWire Reel Loading READI-REELS, Spools or Coils Procedure for Changing Drive and Idle Roll SetsIdle Roll Pressure Setting Feeding Wire ElectrodeAvoiding Wire Feeding Problems Pulse Welding GMAW-P Special Welding Processes Available on the Power MIGBenefits of Pulse on Pulse from Lincoln Electric PULSE-ON-PULSE GMAW-PPRecommended Welding Procedures for Power Mode Table B.4 Power ModePower MIG 1C-1 Dual Cylinder Mounting KIT K1702-1 AccessoriesDrive Roll Kits K363P READI-REEL AdapterRemember do not change the WFS at the spool gun Non-Synergic Weld Modes ModePUSH-PULL Feeding Connection Adapter KIT K2154-1 Synergic Weld ModesPower MIG Table of Contents Maintenance Maintenance See Figure D.1 Liner Removal and ReplacementTable of Contents Theory of Operation Section General Description Theory of OperationWeld Control Board Input Voltage and Main TRANS- FormerReturn to Section Section TOC Input RECTIFIER, Chopper Assembly and FeedbackDiode Control Rectifier Power BoardWeld Control Board Figure E.6 Wire Drive Motor and FeedbackFigure E.7 Wire Drive Motor and Feedback Wire Drive Motor and Feed BackThermal Protection Over Current Protection Wire Feeder Overload PRO- TectionInsulated Gate Bipolar Transistor Igbt Operation Sec Pulse Width ModulationFigure E.10 Chopper Technology FundamentalsTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board Troubleshooting Procedures Observe Safety Guidelines Troubleshooting GuideDetailed in the beginning of this manual Output Problems Troubleshooting Guide Function Problems Wire Feeding Problems Welding Problems Welding Problems Corrective Action Materials Needed Chopper Board Capacitor Discharge ProcedureProcedure Chopper Board Capacitor Discharge ProcedureCapacitors Terminals Test Description Main Transformer TestRectifier Main Transformer TestChopper Board Test 437+1J99 431-4J99 Test ProcedureChopper Board Test Resistance TestExpected Voltage PWM Signal TestDescription Control Rectifier Test472B Control Rectifier TestTest Description Output Rectifier Assembly TestB B Wire Drive Motor and Tachometer Feedback Test J83 J84 Wire Drive Motor and Tachometer Feedback TestTest for Supply Voltage to Tachometer and Feedback Voltage For Codes Above Encoder PC Board TestEncoder PC Board Test J85If you do not read 15VDC on the first reading of encoder Description Current Transducer TestFigure F.10 Current Transducer Test500 450 400 350 300 250 200 150 100 Description Power MIG 300 Scrolling Dashes TestTest Procedures Power MIG 300 Scrolling Dashes TestCodes 10562 and below Scope SettingsCodes 10952 and UP Machine Loaded to 250 Amps AT 26 VDC Typical Output Voltage Waveform Machine LoadedDescription Motor & Gear BOX Assembly Removal ReplacementRemoval and Replacement Motor & Gear BOX AssemblyRemoval Procedure For Codes below Replacement ProcedureFigure F.12 For Codes AboveDescription Output Rectifier Removal and ReplacementOutput Rectifier Perform the Chopper Board Capacitor Discharge ProcedureReplacement Procedure Description Chopper Board Assembly Removal ReplacementReplacement Chopper Board Assembly RemovalReplacement Procedure Description Main Transformer and Output Choke Removal ReplacementMain Transformer and Output Choke Removal Case Front Assembly RemovalPreparation Lead Disconnection Main Transformer and Choke Assembly RemovalFigure F.15 Under Panel Back Side TENDescription FAN Motor Assembly Removal and ReplacementFigure F.16 FAN Motor Assembly Removal Voltage & Current Calibration Procedure Calibration Check Code Voltage & Current Calibration ProcedureVoltage Calibration Current Calibration Procedure Calibration Check Codes 10952 and UP Troubleshooting & Repair Input Volts/Hertz Wire Speed RangeRetest After Repair Input Idle Watts and AmpsTable of Contents Electrical Diagrams Section Electrical DiagramsDigital Power Supply Board Wiring Diagram Power MIG 300 Code 10562 onlyBoard Connection Detail Wiring Diagram Power MIG 300 Code 10952 onlyMSP III Board Wiring Diagram Power MIG 300 Code 10958 and 11000 onlyFeeder Board Wiring Diagram Power MIG 300 Code 11097 and 11098 onlyG4315 Schematic Complete Machine Code 10958 and 11000 onlyG4512 Schematic Complete Machine Code 11097 and 11098 onlySchematic Digital Control PC Board #1 Code 10562 Schematic Digital Control PC Board #2 Code 10562 Schematic Digital Control PC Board #3 Code 10562 Schematic Digital Control PC Board #4 Code 10562 Machine Control Power Supply Schematic Power Supply Printed Circuit Board Code 10562Schematic Chopper Board Code 10562 Schematic MSP3 PC Board Code 10562 Ground Side PC Board Assembly MSP3 Panel Code 10562Schematic Feeder PC Board Board Code 10562 11098 Sheet Electrical Diagrams Schematic Spool GUN PC Board Code 10562 11098 Sheet Electrical Diagrams Schematic Encoder PC Board Code 10562 only 50 B R PC Board Assembly Encoder PC Board Code 10562 onlySchematic Display PC Board Code 10562 PC Board Assembly Display PC Board Code 10562 SVM Error Reporting Form Power MIG