Output Contactor Replacement | Lincoln Electric SVM167-A instruction

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F-50	TROUBLESHOOTING AND REPAIR	F-50

OUTPUT CONTACTOR REPLACEMENT (Continued)

PROCEDURE

1.	Using a 5/16” nutdriver, remove the three		7.	Replace output contactor.
	screws securing the tool tray.
			8.	Using a 7/16” wrench, mount the new output
2.	Locate	the output contactor. See Figure		contactor in its proper location.
	F.23.
			9.	Reconnect leads 106B, 106C, & 107A to
3.	Using a 7/16” wrench, label and remove the			their proper terminals. See Wiring Diagram.
	two thick black leads at the top of the output
	contactor. Note lead and washer placement		10. Reconnect the two thick black leads previ-
	for reassembly.			ously removed from the top of the output
				contactor.
4.	Remove lead 107A and note lead place-
	ment.	See Figure F.23.	11. Replace the tool tray using a 5/16” nutdriv-
				er.

5.Remove leads 106B and 106C. See Figure F.23.

6.Using a 7/16” wrench, remove the three mounting bolts from the output contactor. Note washer positions for replacement. See

Figure F.24.

FIGURE F.23. - OUTPUT CONTACTOR LEADS

106B

106C

107A

Output

Contactor

POWER MIG® 215

Image 86

Lincoln Electric SVM167-A service manual Output Contactor Replacement, Figure F.24

Contents

Power MIG Safety Depends on You Safety California Proposition 65 Warnings Electric Shock can kill ARC Rays can burn Can be dangerous Iii Welding and Cutting Sparks can cause fire or explosionCylinder may explode if damaged 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 Installation Safety PrecautionsUncrating the Power MIG Location Output Polarity Connections Shielding GAS GUN and Cable InstallationAUXILIARY POWER RECEPTACLES Cylinder may explode if damaged Power MIG Operation SECTION OPERATIONB-2 Wear eye, ear and body protec- tion Operation To Start the Welder Procedure for Changing Drive AND IDLE Roll SetsWire Reel Loading READI-REELS, Spools or Coils Wire Drive Configuration Feeding Wire ElectrodeIdle Roll Pressure Setting Making a Weld Figure B.2b FAN Control Avoiding Wire Feeding ProblemsWire Feed Overload Protection Input Line Voltage Variations Power MIG Accessories SECTION Accessories Making a Weld with the Spool GUN 3ACCESSORIESC-3Installed 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 Thermal and Overload Protection Wirefeed Overload ProtectionProtective Devices and Circuits 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 Your body These capacitors is toxicAvoid contact with any portion Function Problems Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Materials Needed Main Transformer TestTest Description Main Transformer Test Test ProcedureON/OFF Power Switch will be hot during these tests X10 Table F.1. Test Points Input Voltage Test Points Wire Drive Motor and Wire Speed Potentiometer Test Black White VDC Test for Feedback Voltage to Control Board1109 a 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