Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM200-A FMD Controller and Helmet Removal and Replacement Procedure

Models: SVM200-A

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F-51

TROUBLESHOOTING AND REPAIR

F-51

FMD CONTROLLER AND HELMET

REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. 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 perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3878.

TEST DESCRIPTION

This procedure will aid the technician in the removal and replacement of the FMD Controller and Helmet.

NOTE: These devices are replaced and sold together.

MATERIALS NEEDED

3/8" Wrench

Hook & Loop Mounting Pads

Wiring Diagram

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VRTEX TM 360

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Lincoln Electric SVM200-A service manual FMD Controller and Helmet Removal and Replacement Procedure, Test Description

Contents

Vrtex AD1332-2Page ISAFETYi Safety Electric Shock can killWelding and Cutting Sparks can Cause fire or explosion Précautions DE Sûreté Safety Recycling Component Selective Treatment IdentificationMaster Table of Contents for ALL Sections Table of Contents Installation Section Input Power Single PhaseExplosion Shock HazardInstallation Vrtex 360 Virtual Reality Welding TrainerAD1332-1 Select Suitable Location Environmental AreaTilting High Frequency Interference PRO- TectionDesign Features Multiple System InstallationsGeneral Description Hardware OverviewFront upper Front lowerBolts Pin Collar Pins Swing ArmTable & Swing ARM SET-UP Cable Tie Grey Cable8INSTALLATIONA-8 Additional FeaturesMonitor VGAReturn to Section TOC Table of Contents Operation Section Operation Front of MachineVR GMAW/FCAW gun holder Hardware Specifics VR GMAW/FCAW GUNVR Smaw Device VR GMAW/FCAW GUNHelmet Functions Coupon DrawerHelmet Lenses CouponsPost W/PIN Inserted in #18 Coupon Insertion / Removal Swing ARM RotationTable Rotation Powering Up Your System Login ScreenLogin Screen Green Circular Button LocationLanguage Measurement UnitsMenu Joint Configuration Selection Joint Configuration Selection ScreenJoint Configuration Chart Mild Steel ScreenProcess Selection Screen Stand Set-Up ScreenOverview PIN Positions 18 a Gas Set-Up Screen Environment ScreenIncorrect Weld Settings Screen Push Buttons Travel Speed Visual CUEWelder’s View screen Instructor’s View screenTRAVEL/WORK Angle Instructors View Poor WeldLaser Screen Laser Screen Good Weld GRAPH, DEFECTS, DISCONTINUITIES, ETCSmaw Operation Discontinuity Indicator Bead Rend rUpdate Instructor Mode21OPERATIONB-21 WeldometerTMWeldometertm Tolerance Editor TolerancesTolerances Keyboard Screen USB EditTolerances Keyboard Screen Tolerances Process Selection Screen BackContinue Tolerances Equipment Settings Screen Tolerances Equipment Settings ScreenTolerances Value Modifying Tolerances Gas screenCoordinate Chart for Weld Placement Position Tolerances Pattern and Aim ScreenTolerances Welding Technique Parameters Pattern & AIM ScreenTolerances Whip and Travel Speed Screen Tolerances Weave ScreenWhip & Travel Speed Screen Tolerances Weave ScreenVrtex 360 Default Weld Process Settings Return to Section TOC Table of Contents Maintenance Section Maintenance Cleaning & Maintenance FMDMonitor Figure D.1 Major Component Location Return to Section TOC 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Figure E.2 General DescriptionInput Power & Distribution Figure E.3 Input Power & DistributionModule Signal Digital Display LED PC Board Return to Section TOC 1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting GuideTroubleshooting and Repair PC Board Troubleshooting ProceduresElectric Shock Problems Symptoms Possible Areas MisadjustmentsRecommended Course of Action POWER-UP Problems Troubleshooting and Repair Function Problems USB Interface Module TestUser Interface Digital IO Module TestSupply Test Perform the FMD Control Unit Perform the Interface Digital Module IO Test Procedure Perform the Interface DigitalCPU Removal PolhemusSee the Installation Section Studentsʼ reports are Not Studentsʼ reports can only Return to Section TOC VDC Supply Test Procedure Test DescriptionMaterials Needed 16TROUBLESHOOTING and REPAIRF-16 VDC Supply Test ProcedureTest Procedure Rocedure Removal Procedure17TROUBLESHOOTING and REPAIRF-17 Removal and Replacement ProcedureReturn to Section TOC 12/15 VDC Supply Test Procedure 20TROUBLESHOOTING and REPAIRF-20 12/15 VDC Supply Test ProcedureSupply Removal and Replacement Procedure Figure F.4 12/15 VDC Supply Lead LocationReturn to Section TOC Face Mounted Display FMD Control Unit Test Face Mounted Display FMD Control Unit Test Figure F.5 FMD LocationControl Unit Removal and Replacement Case Cover ReplacementMonitor Pedestal Replacement Procedure Perform the FMDReturn to Section TOC Interface Digital Module I/O Test Procedure 28TROUBLESHOOTING and REPAIRF-28 Interface Digital Module I/O Test ProcedureMonitor and Pedestal Removal 29TROUBLESHOOTING and REPAIRF-29 Figure F.8 Interface Digital Module I/O RearReturn to Section TOC USB Interface Module Test Procedure 32TROUBLESHOOTING and REPAIRF-32 USB Interface Module Test Procedure33TROUBLESHOOTING and REPAIRF-33 Figure F.10 USB Interface Module Green LED RearReturn to Section TOC Polhemus Interface Module Test Procedure 36TROUBLESHOOTING and REPAIRF-36 Polhemus Interface Module Test Procedure37TROUBLESHOOTING and REPAIRF-37 Perform the Polhemus Interface ModuleMonitor Pedestal Return to Section TOC Monitor and Pedestal Removal and Replacement Procedure Power Cord Removal Procedure 1. Remove input powerPhillips Screws Replacement Procedure See Retest After RepairReturn to Section TOC Case Cover Removal and Replacement Procedure Case Cover Removal and Replacement Procedure Monitor and Pedestal Removal ProcedureRight Case Side Removal Left Case Side RemovalPerform the Monitor and Pedestal Replacement Procedure Figure F.16 Drawer Release TabsReturn to Section TOC Polhemus Module Removal and Replacement Procedure Polhemus Module Removal and Replacement ProcedureRemoval Procedure Perform the Case Cover Removal Proc dureFront Return to Section TOC FMD Controller and Helmet Removal and Replacement Procedure Removal and Replacement Procedure FMD Controller and HelmetFigure F.20 Access Plate Monitor and PedestalReturn to Section TOC Relay PC Board Removal and Replacement Procedure 56TROUBLESHOOTING and REPAIRF-56 Relay PC Board Removal and Replacement Procedure57TROUBLESHOOTING and REPAIRF-57 Placement ProcedureReturn to Section TOC 5VDC Supply Module Removal and Replacement Procedure Figure F.23 5 Volt Supply Location See Figure F.24Figure F.24 5 Volt Supply Lead Locations Return to Section TOC 12/15VDC Supply Module Removal and Replacement Procedure Figure F.25 12/15 Volt Supply Module Location See Figure F.26+ + Return to Section TOC On Button Removal and Replacement Procedure On Button Removal and Replacement Procedure Figure F.27 on Button LocationFigure F.28 on Switch Leads Perform the Case Cover ReplacementReturn to Section TOC Test Description Interface Module Digital I/O Figure F.29 Interface Module Digital I/O LocationSlide Switch Ribbon CableUSB Screw Figure F.31 Shortcut to START-UP SIM Screen Shot Interface Module USB Removal and Replacement Procedure Interface Module USB Figure F.33 Interface Module USB Location16-PIN Terminal StripInterface Module Digital USB USB 0……………….See Figure F.36Figure F.36 Measurements & Automation Return to Section TOC Display Board Removal and Replacement Procedure Display Board Figure F.37 Display LED Board LocationFigure F.38 Display LED Board Plug Location See the Retest After RepairReturn to Section TOC Motor Control Board Removal and Replacement Procedure Materials Needed 5mm WrenchRocedure Ver Removal Procedure Motor Control BoardCase Cover Replacement Rocedure Monitor Pedestal Placement ProcedureReturn to Section TOC VR Smaw Stick Device Removal and Replacement Procedure VR Smaw Stick Device Figure F.41 VR Smaw Device LocationFigure F.42 Strain Relief Return to Section TOC VR GMAW/FCAW MIG Device Removal and Replacement Procedure Materials Needed 3/8 wrenchVR GMAW/FCAW MIG Device Figure F.43 VR GMAW/FCAW Device LocationFigure F.44 Strain Relief Return to Section TOC VGA Splitter Removal and Replacement Procedure VGA Splitter Removal and Replacement Procedure Figure F.45 VGA Splitter LocationVGA Plug VGA100 Table Swing ARM Removal and Replacement Procedure Figure F.47 SOURCE’ Cable Connected to Polhemus Module Figure F.48Figure F.48 Case Back Rear 104 CPU Removal and Replacement Procedure 106TROUBLESHOOTING and REPAIRF-106 CPU Removal and Replacement Procedure107TROUBLESHOOTING and REPAIRF-107 Case Cover Replacement Procedure108TROUBLESHOOTING and REPAIRF-108 Strain ReliefScrews 109TROUBLESHOOTING and REPAIRF-109 Figure F.52 CPU Plug LocationsProcess Settings Retest After RepairThis manual.Operation Section Table of Contents Diagram Section Electrical Diagrams Schematic Entire Machine G3244-565Schematic Relay PC Board M22295-1D0 PC Board Assembly Relay PC BD M22296-1 M22296