Manuals / Lincoln Electric / Power Tools / Welding System

Lincoln Electric SVM170-A F-23, Active Scr Rectifier Assembly Test, Troubleshooting And Repair

Models: SVM170-A

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F-23

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F-23

TROUBLESHOOTING AND REPAIR

F-23

ACTIVE SCR RECTIFIER ASSEMBLY TEST

WARNING

Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory war- ranty. 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 per- form the test/repairs safely, contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

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TEST DESCRIPTION

The Active SCR Rectifier Assembly Test will determine if the device is able to be gated ON and conduct current from anode to cathode.

The Static SCR Rectifier Assembly Test must be performed before proceeding with the Active SCR Test.

MATERIALS NEEDED

3/8 in. Nutdriver 5/16 in. Nutdriver

An SCR Tester as specified in this procedure

POWER MIG 255C wiring diagrams (See Electrical Diagrams Section of this Manual) SCR Heat Sink Assembly Drawings

A volt-ohmmeter

POWER MIG 255C

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Lincoln Electric SVM170-A F-23, Active Scr Rectifier Assembly Test, Troubleshooting And Repair, Test Description

Contents

View Safety Info View Safety Info View Safety Info View Safety Info POWER MIG 255CSERVICE MANUAL Safety Depends on YouCALIFORNIA PROPOSITION 65 WARNINGS SAFETYFOR ENGINE powered equipment ELECTRIC AND MAGNETIC FIELDS may be dangerousSAFETY ELECTRIC SHOCK can killARC RAYS can burn FUMES AND GASES can be dangerousSAFETY FOR ELECTRICALLY powered equipmentWELDING SPARKS can cause fire or explosion CYLINDER may explode if damagedReturn to Master TOC PRÉCAUTIONS DE SÛRETÉSAFETY Return to Master TOC Return to Master TOC Return to Master TOCRETURN TO MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONSSECTION A INSTALLATIONTABLE OF CONTENTS INSTALLATION SECTIONINSTALLATION TECHNICAL SPECIFICATIONS - POWER MIG 255CINPUT - SINGLE PHASE ONLY PHYSICAL DIMENSIONSLOCATION SAFETY PRECAUTIONSUNCRATING THE POWER MIG 255C INPUT POWER, GROUNDING AND CONNECTION DIAGRAMSFIGURE A.1 - DUAL VOLTAGE MACHINE INPUT CONNECTIONS INSTALLATIONReturn to Section TOC Return to Master TOCFIGURE A.2 - TRIPLE VOLTAGE MACHINE INPUT CONNECTIONS INSTALLATIONReturn to Section TOC Return to Master TOCINSTALLATION GUN AND CABLE INSTALLATIONAUXILIARY POWER RECEPTACLES SHIELDING GASSECTION B TABLE OF CONTENTSOPERATION OPERATION SECTIONELECTRIC SHOCK can kill Read entire Operation section before operating the POWER MIG 255CObserve all safety information throughout this manual OPERATIONB-2LIMITATIONS PRODUCT DESCRIPTIONRECOMMENDED PROCESSES AND EQUIPMENT WELDING CAPABILITYOPERATION WIRE SIZE CONVERSION PARTSWIRE DRIVE ROLL DESCRIPTION OF CONTROLSOPERATION PROCEDURE FOR CHANGINGWIRE REEL LOADING - READI REELS, SPOOLS OR COILS DRIVE AND IDLE ROLL SETSTO START THE WELDER FEEDING WIRE ELECTRODEIDLE ROLL PRESSURE SETTING WIRE DRIVE CONFIGURATIONReturn to Section TOC OPERATIONReturn to Master TOC Return to Section TOC Return to Section TOC Return to Section TOCINSTRUCTIONS TO ENTER FAST RUN-IN SETTING RUN-IN SPEED ON STAN- DARD POWER MIG FEEDERFAST OR SLOW RUN-IN MODE SELECTION INSTRUCTIONS TO ENTER SLOW RUN-ININPUT LINE VOLTAGE PROTECTION AVOIDING WIRE FEEDING PROBLEMSWIRE FEED OVERLOAD PROTECTION FAN CONTROLOPERATION B-10WELDING THERMAL OVERLOAD PROTECTION OVERCURRENT PROTECTIONTABLE OF CONTENTS ACCESSORIESACCESSORIES SECTION SECTION CMAGNUM GUN CONNECTION KIT TIMER KIT INSTALLATION Optional K1701-1DRIVE ROLL KITS ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIESACCESSORIES OPERATING INSTRUCTIONS FOR TIMER KITCONNECTING THE SPOOL GUN TO THE POWER MIG 255C SPOOL GUNACCESSORIES MAKING A WELD WITH THE PRINCE XL SPOOL GUNMAKING A WELD WITH THE MAGNUM SG SPOOL GUN FIGURE C.1Return to Section TOC ACCESSORIESSG Spool Gun Wire Feed Speed Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTABLE OF CONTENTS MAINTENANCEMAINTENANCE SECTION SECTION DLINER REMOVAL AND REPLACEMENT GENERAL MAINTENANCEGUN CABLE CLEANING CONTACT TIP AND GAS NOZZLE INSTALLATIONReturn to Master TOC LINER REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM 250LGUN HANDLE DISASSEMBLY MAINTENANCEReturn to Section TOC MAINTENANCED-4TABLE D.2 ACCESSORIES AND EXPENDABLE REPLACE Return to Section TOC Return to Section TOC Return to Section TOCTABLE OF CONTENTS THEORY OF OPERATIONTHEORY OF OPERATION SECTION SECTION EPOWER MIG 255C INPUT LINE VOLTAGEAND MAIN TRANSFORMER Diagram are the subject of discussionPOWER MIG 255C OUTPUT RECTIFICATION ANDFEEDBACK CONTROL Diagram are the subject of discussionTHEORY OF OPERATION CONSTANT VOLTAGE OUTPUTDiagram are the subject of discussion POWER MIG 255CPOWER MIG 255C WIRE DRIVE MOTORAND FEEDBACK Diagram are the subject of discussionOVERCURRENT PROTECTION WIRE FEED OVERLOAD PROTECTIONTHERMAL AND OVERLOAD PROTECTION THEORY OF OPERATIONReturn to Master SCR OPERATIONTHEORY OF OPERATION Return to SectionReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR SECTION TABLE OF CONTENTSReturn to Master TOC F-2TROUBLESHOOTING AND REPAIRF-2HOW TO USE TROUBLESHOOTING GUIDE Return to Section TOCReturn to Master Return to Master TOC TOC TROUBLESHOOTING & REPAIRPC BOARD TROUBLESHOOTING PROCEDURES Return to Section Return to Section TOC TOCMISADJUSTMENTS TROUBLESHOOTING GUIDEPROBLEMS SYMPTOMSMISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSMISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSSYMPTOMS FUNCTION PROBLEMSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS WIRE FEEDING PROBLEMSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS WELDING PROBLEMSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS F-10TROUBLESHOOTING AND REPAIR PROBLEMSTEST DESCRIPTION TEST PROCEDURESF-11 MAIN TRANSFORMER TESTTROUBLESHOOTING AND REPAIR TEST PROCEDUREF-12 MAIN TRANSFORMER TEST continuedMAIN TRANSFORMER TEST continued F-13TROUBLESHOOTING AND REPAIR F-13MAIN TRANSFORMER TEST continued F-14TROUBLESHOOTING AND REPAIR F-14F-15 F-15RECTIFIER DIODE BRIDGE TEST TROUBLESHOOTING AND REPAIRReturn to Section TOC Return to Section TOC F-16TROUBLESHOOTING AND REPAIRF-16RECTIFIER DIODE BRIDGE TESTING continued TEST PROCEDUREF-17 F-17TROUBLESHOOTING AND REPAIR RECTIFIER DIODE BRIDGE TESTING continuedReturn to Section TOC F-18F-18 Return to Section TOCF-19 STATIC SCR RECTIFIER ASSEMBLY TESTF-19 TROUBLESHOOTING AND REPAIRTEST PROCEDURE STATIC SCR RECTIFIER ASSEMBLY TEST continuedF-20 TROUBLESHOOTING AND REPAIRF-21 F-21TROUBLESHOOTING AND REPAIR STATIC SCR RECTIFIER ASSEMBLY TEST continuedReturn to Section TOC F-22F-22 Return to Section TOCF-23 ACTIVE SCR RECTIFIER ASSEMBLY TESTF-23 TROUBLESHOOTING AND REPAIRTEST PROCEDURE ACTIVE SCR RECTIFIER ASSEMBLY TEST continuedF-24 TROUBLESHOOTING AND REPAIRF-25 F-25TROUBLESHOOTING AND REPAIR ACTIVE SCR RECTIFIER ASSEMBLY TEST continuedF-26 F-26TROUBLESHOOTING AND REPAIR ACTIVE SCR RECTIFIER ASSEMBLY TEST continuedF-27 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TESTF-27 TROUBLESHOOTING AND REPAIRTEST PROCEDURE WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continuedF-28 TROUBLESHOOTING AND REPAIRWIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continued F-29TEST FOR SUPPLY VOLTAGE TO TACHOMETER TROUBLESHOOTING AND REPAIRWIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continued F-30TEST FOR FEEDBACK VOLTAGE TO CONTROL BOARD TROUBLESHOOTING AND REPAIRF-31 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORMF-31 TROUBLESHOOTING AND REPAIRF-32 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADEDF-32 TROUBLESHOOTING AND REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC F-33TROUBLESHOOTING AND REPAIR F-33F-34 ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONINGF-34 TROUBLESHOOTING AND REPAIRF-35 TYPICAL SCR GATE VOLTAGE WAVEFORMF-35 TROUBLESHOOTING AND REPAIRReturn to Section TOC F-36F-36 Return to Section TOCDESCRIPTION COMPONENT REPLACEMENT PROCEDURESCONTROL PC BOARD REMOVAL AND REPLACEMENT F-37F-38 CONTROL PC BOARD REMOVAL AND REPLACEMENT continuedREMOVAL AND REPLACEMENT PROCEDUREF-39 CONTROL PC BOARD REMOVAL AND REPLACEMENT continuedF-39 TROUBLESHOOTING AND REPAIRReturn to Section TOC F-40F-40 Return to Section TOCF-41 WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENTF-41 TROUBLESHOOTING AND REPAIRF-42 WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT continuedF-42 TROUBLESHOOTING AND REPAIRPROCEDURE F-43TROUBLESHOOTING AND REPAIR WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT continuedReturn to Section TOC F-44F-44 Return to Section TOCF-45 SCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENTF-45 TROUBLESHOOTING AND REPAIRPROCEDURE SCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT continuedF-46 TROUBLESHOOTING AND REPAIRF-47 F-47TROUBLESHOOTING AND REPAIR SCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT continuedReturn to Section TOC F-48F-48 Return to Section TOCF-49 CAPACITOR BANK REMOVAL AND REPLACEMENTF-49 TROUBLESHOOTING AND REPAIRPROCEDURE CAPACITOR BANK REMOVAL AND REPLACEMENT continuedF-50 TROUBLESHOOTING AND REPAIRF-51 MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENTF-51 TROUBLESHOOTING AND REPAIRReturn to Section TOC F-52TROUBLESHOOTING AND REPAIRF-52MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT continued PROCEDUREF-53 F-53TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT continuedReturn to Section TOC F-54F-54 Return to Section TOCF-55 FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENTF-55 TROUBLESHOOTING AND REPAIRPROCEDURE FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT continuedF-56 TROUBLESHOOTING AND REPAIROPEN CIRCUIT VOLTAGE WIRE SPEED RANGERETEST AFTER REPAIR F-57Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Master TOC TABLE OF CONTENTSELECTRICAL DIAGRAMS SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC ELECTRICAL DIAGRAMSWIRING DIAGRAM - ENTIRE MACHINE - CODE 11192 L12464 Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC WIRING DIAGRAM - ENTIRE MACHINE CODE 11218 L12506ELECTRICAL DIAGRAMS Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC SCHEMATIC - ENTIRE MACHINE - G4752ELECTRICAL DIAGRAMS Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC SCHEMATIC - CONTROL PC BOARD - G4823-2D1 SHEETELECTRICAL DIAGRAMS Return to Section TOCReturn to Master TOC ELECTRICAL DIAGRAMSSCHEMATIC - CONTROL PC BOARD - G4823-2D1 SHEET Return to Section TOCReturn to Master TOC ELECTRICAL DIAGRAMSSCHEMATIC - CONTROL PC BOARD - G4823-2D1 SHEET Return to Section TOCto Master TOC PC BOARD ASSEMBLY - CONTROL - G4824-2D1ELECTRICAL DIAGRAMS to Section TOCReturn to Section TOC SCHEMATIC - DISPLAY PC BOARD L10951ELECTRICAL DIAGRAMS Return to Section TOC Return to Section TOC Return to Section TOCG-10 PC BOARD ASSEMBLY - DISPLAY - L10952G-10 ELECTRICAL DIAGRAMSSVM ERROR REPORTING FORM