Power MIG | Lincoln Electric SVM167-A guide

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POWER MIG® 215

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Lincoln Electric SVM167-A service manual Power MIG

Contents

Power MIG Safety Depends on You Safety California Proposition 65 Warnings Electric Shock can kill ARC Rays can burn Can be dangerous Welding and Cutting Sparks can cause fire or explosion Cylinder may explode if damagedIii 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 Safety Precautions Uncrating the Power MIGInstallation Location Output Polarity Connections GUN and Cable Installation AUXILIARY POWER RECEPTACLESShielding GAS Cylinder may explode if damaged Power MIG Operation SECTION OPERATIONB-2 Wear eye, ear and body protec- tion Operation Procedure for Changing Drive AND IDLE Roll Sets Wire Reel Loading READI-REELS, Spools or CoilsTo Start the Welder Feeding Wire Electrode Idle Roll Pressure SettingWire Drive Configuration Making a Weld Figure B.2b Avoiding Wire Feeding Problems Wire Feed Overload ProtectionFAN Control Input Line Voltage Variations Power MIG Accessories SECTION Accessories 3ACCESSORIESC-3 InstalledMaking a Weld with the Spool GUN Adapter KIT and Spool GUN Power MIG Maintenance SECTION Maintenance Liner Removal and Replace Ment Table D.1 GUN Handle Disassembly English Metric Description Size Figure D.2 Major Component Locations Power MIG Line Switch Theory of Operation SECTION Figure E.2 Input Power Circuit Theory of Operation Output Rectification Contactor and Control Board Figure E.3 Control Circuits Control BOARD, GUN Trigger and Wire Drive Motor Figure E.4 Optional Circuits Wirefeed Overload Protection Protective Devices and CircuitsThermal and Overload Protection Power MIG TROUBLESHOOTING AND REPAIR SECTION Troubleshooting and Repair How To Use Troubleshooting Guide PC Board Troubleshooting Procedures Perform the Main Transformer Perform the Output Contactor These capacitors is toxic Avoid contact with any portionYour body Function Problems Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Main Transformer Test Test DescriptionMaterials Needed Test Procedure ON/OFF Power Switch will be hot during these testsMain Transformer Test X10 Table F.1. Test Points Input Voltage Test Points Wire Drive Motor and Wire Speed Potentiometer Test Black White Test for Feedback Voltage to Control Board 1109 aVDC Power MIG Output Bridge Rectifier Test Negative Lead 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 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 Output Capacitors Replacement Figure F.14. Capacitor Bank Location Lead Mounting Bolts Nuts Lock washers 3 places Power MIG 41TROUBLESHOOTING and Repair F-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 215 208/220/230V POWEr miG Power MIG 215 208/220/230V for Codes 11099 SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG1 L12308 SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG2 ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS