Manuals / Lincoln Electric / Power Tools / Welding System

Lincoln Electric SVM170-A F-52TROUBLESHOOTING AND REPAIRF-52, Procedure, Return to Section TOC

Models: SVM170-A

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F-52TROUBLESHOOTING AND REPAIRF-52

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F-52TROUBLESHOOTING AND REPAIRF-52

MAIN TRANSFORMER AND OUTPUT CHOKE

REMOVAL AND REPLACEMENT (continued)

FIGURE F.17 — MAIN TRANSFORMER REMOVAL.

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LEAD

X1

OUTPUT

CHOKE POSITIVE

LEAD

OUTPUT

CHOKE

LEAD

NOTE: PLUG-IN LEADS ARE NOT SHOWN FOR CLARITY.

LEAD X4

LEADS

X2 AND X3

Section TOC

Master TOC

MAIN

TRANSFORMER

POWER

ENHANCEMENT

CHOKE

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PROCEDURE

1.Disconnect main input power to the machine.

2.Remove the case side panels using a 3/8 in. nutdriver.

3.Test that the capacitors are discharged using a volt ohmmeter. Polarity must be observed.

4.Remove lead X1 from the left side SCR heat sink assembly using a 1/2 in. sock- et wrench, extender and universal adapter. See Figure F.17.

5.Remove lead X4 from the right side heat sink assembly using a 1/2 in. sock- et wrench, extender and universal adapter.

6.Remove the two transformer secondary leads X2 and X3 (braided copper strap) from the negative capacitor bank buss bar using two 1/2 in. open end wrench- es.

7.Disconnect and label all transformer leads from the reconnect panel using a 3/8 in. open end wrench.

8.Disconnect and label all leads from the input power switch.

9.Remove the power switch.

10.Disconnect thermostat leads #320 and #320B from the SCR Rectifier.

POWER MIG 255C

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Lincoln Electric SVM170-A F-52TROUBLESHOOTING AND REPAIRF-52, Procedure, Return to Section TOC, Return to Master TOC

Contents

POWER MIG 255C SERVICE MANUALSafety Depends on You View Safety Info View Safety Info View Safety Info View Safety InfoSAFETY FOR ENGINE powered equipmentELECTRIC AND MAGNETIC FIELDS may be dangerous CALIFORNIA PROPOSITION 65 WARNINGSELECTRIC SHOCK can kill ARC RAYS can burnFUMES AND GASES can be dangerous SAFETYFOR ELECTRICALLY powered equipment WELDING SPARKS can cause fire or explosionCYLINDER may explode if damaged SAFETYPRÉCAUTIONS DE SÛRETÉ SAFETYReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCMASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN MENUINSTALLATION TABLE OF CONTENTSINSTALLATION SECTION SECTION ATECHNICAL SPECIFICATIONS - POWER MIG 255C INPUT - SINGLE PHASE ONLYPHYSICAL DIMENSIONS INSTALLATIONSAFETY PRECAUTIONS UNCRATING THE POWER MIG 255CINPUT POWER, GROUNDING AND CONNECTION DIAGRAMS LOCATIONINSTALLATION Return to Section TOCReturn to Master TOC FIGURE A.1 - DUAL VOLTAGE MACHINE INPUT CONNECTIONSINSTALLATION Return to Section TOCReturn to Master TOC FIGURE A.2 - TRIPLE VOLTAGE MACHINE INPUT CONNECTIONSGUN AND CABLE INSTALLATION AUXILIARY POWER RECEPTACLESSHIELDING GAS INSTALLATIONTABLE OF CONTENTS OPERATIONOPERATION SECTION SECTION BRead entire Operation section before operating the POWER MIG 255C Observe all safety information throughout this manualOPERATIONB-2 ELECTRIC SHOCK can killPRODUCT DESCRIPTION RECOMMENDED PROCESSES AND EQUIPMENTWELDING CAPABILITY LIMITATIONSWIRE SIZE CONVERSION PARTS WIRE DRIVE ROLLDESCRIPTION OF CONTROLS OPERATIONPROCEDURE FOR CHANGING WIRE REEL LOADING - READI REELS, SPOOLS OR COILSDRIVE AND IDLE ROLL SETS OPERATIONFEEDING WIRE ELECTRODE IDLE ROLL PRESSURE SETTINGWIRE DRIVE CONFIGURATION TO START THE WELDEROPERATION Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCSETTING RUN-IN SPEED ON STAN- DARD POWER MIG FEEDER FAST OR SLOW RUN-IN MODE SELECTIONINSTRUCTIONS TO ENTER SLOW RUN-IN INSTRUCTIONS TO ENTER FAST RUN-INAVOIDING WIRE FEEDING PROBLEMS WIRE FEED OVERLOAD PROTECTIONFAN CONTROL INPUT LINE VOLTAGE PROTECTIONB-10 WELDING THERMAL OVERLOAD PROTECTIONOVERCURRENT PROTECTION OPERATIONACCESSORIES ACCESSORIES SECTIONSECTION C TABLE OF CONTENTSTIMER KIT INSTALLATION Optional K1701-1 DRIVE ROLL KITSALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES MAGNUM GUN CONNECTION KITOPERATING INSTRUCTIONS FOR TIMER KIT CONNECTING THE SPOOL GUN TO THE POWER MIG 255CSPOOL GUN ACCESSORIESMAKING A WELD WITH THE PRINCE XL SPOOL GUN MAKING A WELD WITH THE MAGNUM SG SPOOL GUNFIGURE C.1 ACCESSORIESACCESSORIES SG Spool Gun Wire Feed SpeedReturn to Section TOC 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 TOCMAINTENANCE MAINTENANCE SECTIONSECTION D TABLE OF CONTENTSGENERAL MAINTENANCE GUN CABLE CLEANINGCONTACT TIP AND GAS NOZZLE INSTALLATION LINER REMOVAL AND REPLACEMENTLINER REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM 250L GUN HANDLE DISASSEMBLYMAINTENANCE Return to Master TOCMAINTENANCED-4 TABLE D.2 ACCESSORIES AND EXPENDABLE REPLACEReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCTHEORY OF OPERATION THEORY OF OPERATION SECTIONSECTION E TABLE OF CONTENTSINPUT LINE VOLTAGE AND MAIN TRANSFORMERDiagram are the subject of discussion POWER MIG 255COUTPUT RECTIFICATION AND FEEDBACK CONTROLDiagram are the subject of discussion POWER MIG 255CCONSTANT VOLTAGE OUTPUT Diagram are the subject of discussionPOWER MIG 255C THEORY OF OPERATIONWIRE DRIVE MOTOR AND FEEDBACKDiagram are the subject of discussion POWER MIG 255CWIRE FEED OVERLOAD PROTECTION THERMAL AND OVERLOAD PROTECTIONTHEORY OF OPERATION OVERCURRENT PROTECTIONSCR OPERATION THEORY OF OPERATIONReturn to Section Return to MasterReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR TROUBLESHOOTING AND REPAIR SECTIONTABLE OF CONTENTS Return to Master TOC Return to Master TOC Return to Master TOCF-2TROUBLESHOOTING AND REPAIRF-2 HOW TO USE TROUBLESHOOTING GUIDEReturn to Section TOC Return to Master TOCTROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURESReturn to Section Return to Section TOC TOC Return to Master Return to Master TOC TOCTROUBLESHOOTING GUIDE PROBLEMSSYMPTOMS MISADJUSTMENTSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSFUNCTION PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSWIRE FEEDING PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSWELDING PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSF-10 TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSTEST PROCEDURES F-11MAIN TRANSFORMER TEST TEST DESCRIPTIONTEST PROCEDURE F-12MAIN TRANSFORMER TEST continued TROUBLESHOOTING AND REPAIRF-13 TROUBLESHOOTING AND REPAIRF-13 MAIN TRANSFORMER TEST continuedF-14 TROUBLESHOOTING AND REPAIRF-14 MAIN TRANSFORMER TEST continuedF-15 RECTIFIER DIODE BRIDGE TESTTROUBLESHOOTING AND REPAIR F-15F-16TROUBLESHOOTING AND REPAIRF-16 RECTIFIER DIODE BRIDGE TESTING continuedTEST PROCEDURE Return to Section TOC Return to Section TOCF-17 TROUBLESHOOTING AND REPAIRRECTIFIER DIODE BRIDGE TESTING continued F-17F-18 F-18Return to Section TOC Return to Section TOCSTATIC SCR RECTIFIER ASSEMBLY TEST F-19TROUBLESHOOTING AND REPAIR F-19STATIC SCR RECTIFIER ASSEMBLY TEST continued F-20TROUBLESHOOTING AND REPAIR TEST PROCEDUREF-21 TROUBLESHOOTING AND REPAIRSTATIC SCR RECTIFIER ASSEMBLY TEST continued F-21F-22 F-22Return to Section TOC Return to Section TOCACTIVE SCR RECTIFIER ASSEMBLY TEST F-23TROUBLESHOOTING AND REPAIR F-23ACTIVE SCR RECTIFIER ASSEMBLY TEST continued F-24TROUBLESHOOTING AND REPAIR TEST PROCEDUREF-25 TROUBLESHOOTING AND REPAIRACTIVE SCR RECTIFIER ASSEMBLY TEST continued F-25F-26 TROUBLESHOOTING AND REPAIRACTIVE SCR RECTIFIER ASSEMBLY TEST continued F-26WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST F-27TROUBLESHOOTING AND REPAIR F-27WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continued F-28TROUBLESHOOTING AND REPAIR TEST PROCEDUREF-29 TEST FOR SUPPLY VOLTAGE TO TACHOMETERTROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continuedF-30 TEST FOR FEEDBACK VOLTAGE TO CONTROL BOARDTROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continuedNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM F-31TROUBLESHOOTING AND REPAIR F-31TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED F-32TROUBLESHOOTING AND REPAIR F-32F-33 TROUBLESHOOTING AND REPAIRF-33 Return to Section TOC Return to Section TOC Return to Section TOCABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING F-34TROUBLESHOOTING AND REPAIR F-34TYPICAL SCR GATE VOLTAGE WAVEFORM F-35TROUBLESHOOTING AND REPAIR F-35F-36 F-36Return to Section TOC Return to Section TOCCOMPONENT REPLACEMENT PROCEDURES CONTROL PC BOARD REMOVAL AND REPLACEMENTF-37 DESCRIPTIONCONTROL PC BOARD REMOVAL AND REPLACEMENT continued REMOVAL AND REPLACEMENTPROCEDURE F-38CONTROL PC BOARD REMOVAL AND REPLACEMENT continued F-39TROUBLESHOOTING AND REPAIR F-39F-40 F-40Return to Section TOC Return to Section TOCWIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT F-41TROUBLESHOOTING AND REPAIR F-41WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT continued F-42TROUBLESHOOTING AND REPAIR F-42F-43 TROUBLESHOOTING AND REPAIRWIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT continued PROCEDUREF-44 F-44Return to Section TOC Return to Section TOCSCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT F-45TROUBLESHOOTING AND REPAIR F-45SCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT continued F-46TROUBLESHOOTING AND REPAIR PROCEDUREF-47 TROUBLESHOOTING AND REPAIRSCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT continued F-47F-48 F-48Return to Section TOC Return to Section TOCCAPACITOR BANK REMOVAL AND REPLACEMENT F-49TROUBLESHOOTING AND REPAIR F-49CAPACITOR BANK REMOVAL AND REPLACEMENT continued F-50TROUBLESHOOTING AND REPAIR PROCEDUREMAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT F-51TROUBLESHOOTING AND REPAIR F-51F-52TROUBLESHOOTING AND REPAIRF-52 MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT continuedPROCEDURE Return to Section TOCF-53 TROUBLESHOOTING AND REPAIRMAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT continued F-53F-54 F-54Return to Section TOC Return to Section TOCFAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT F-55TROUBLESHOOTING AND REPAIR F-55FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT continued F-56TROUBLESHOOTING AND REPAIR PROCEDUREWIRE SPEED RANGE RETEST AFTER REPAIRF-57 OPEN CIRCUIT VOLTAGEReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODE 11192 L12464Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCWIRING DIAGRAM - ENTIRE MACHINE CODE 11218 L12506 ELECTRICAL DIAGRAMSReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCSCHEMATIC - ENTIRE MACHINE - G4752 ELECTRICAL DIAGRAMSReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCSCHEMATIC - CONTROL PC BOARD - G4823-2D1 SHEET ELECTRICAL DIAGRAMSReturn to Section TOC Return to Master TOCELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD - G4823-2D1 SHEETReturn to Section TOC Return to Master TOCELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD - G4823-2D1 SHEETReturn to Section TOC Return to Master TOCPC BOARD ASSEMBLY - CONTROL - G4824-2D1 ELECTRICAL DIAGRAMSto Section TOC to Master TOCSCHEMATIC - DISPLAY PC BOARD L10951 ELECTRICAL DIAGRAMSReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCPC BOARD ASSEMBLY - DISPLAY - L10952 G-10ELECTRICAL DIAGRAMS G-10SVM ERROR REPORTING FORM