Troubleshooting & Repair | Lincoln Electric SVM 117-A specs

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TROUBLESHOOTING & REPAIR

TABLE OF CONTENTS

- TROUBLESHOOTING & REPAIR SECTION -

TROUBLESHOOTING & REPAIR SECTION	Section F
How to use Troubleshooting Guide	F-1
PC Board Troubleshooting Procedures	F-2
Troubleshooting Guide	F-3
Test Procedures
Main Transformer Test	F-10
Static Output Rectifier Bridge Test	F-13
Active SCR Rectifier Assembly Test	F-16
Wire Drive Motor and Tachometer Feedback Test	F-19
Oscilloscope Waveforms	F-22
Normal Open Circuit Voltage Waveform	F-22
Typical Output Voltage Waveform - Machine Loaded	F-23
Abnormal Output Voltage Waveform - Machine Loaded One Output SCR Not Functioning .....F-24
Abnormal Open Circuit Voltage Output Capacitor Bank Not Functioning	F-25
Typical SCR Gate Voltage Waveform	F-26
Replacement Procedures
Control PC Board Removal and Replacement	F-27
Wire Drive Assembly Removal and Replacement	F-29
SCR Output Rectifier Removal and Replacement	F-31
Capacitor Bank Removal and Replacement	F-33
Main Transformer Removal and Replacement	F-35
Fan Motor and Fan Removal and Replacement	F-37
Retest After Repair	F-40

WIRE-MATIC 250

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Lincoln Electric SVM 117-A service manual Troubleshooting & Repair

Contents

Safety Depends on You WIRE-MATIC ARC Welding can be hazardous Safety Cylinder may explode if damaged Iii Electric and MAG- Netic Fields Sûreté Pour Soudage a L’Arc Précautions DE Sûreté WIRE-MATIC Table of Contents Table of Contents Installation Current Range Duty Cycle Amps Volts at Rated AmpsFuse Superlag Type 750C Copper Select Proper Location Safety PrecautionsInput Connections Stacking Input Power Connections and Ground Connections Fuse and Wire Sizes Connect Shielding GAS Figure A.4 Input Air Supply Connections Reconnect Procedure Figure A.5 Reconnect Diagram For 208/230/1/60 Machines Install the Work Clamp InstallationConnect Output Components GUN Liner and Contact Output Polarity Connection GUN and Cable Installation Wire Size Conversion Parts WIRE-MATIC Operation WELDING, Cutting Safety InstructionsGeneral Description Unit Features Design Features AdvantagesPower Source Features Recommended Processes and Equipment Machine Capability Wire Feeder FeaturesLimitations Duty Cycle Amps Volts Figure B.1 Operator Controls Controls and Settings Loading the Wire Reel Using the Wire Drive RollProcedure for Changing Drive Roll To mount 10 to 30 lb. spools 8 and 12 diameter Proper Wire FeedingFeeding Electrode Starting the Welder Setting Idle Roll PressureOperating Steps Making a Weld WIRE-MATIC Accessories K607-1 Spool GUN Adapter KIT OPTIONS/ACCESSORIESInstalling the K607-1 Spool GUN Adapter KIT Spool GUN Module Board Installation Return Return to Section TOC Spool GUN Connection BOX Installation Spool GUN Preparation Spool GUN Connection Making the Weld Making a Weld with the Spool GUN Adapter K607-1 Installed Timer KIT K585-1 Aluminum Wire Sizes Steel Wire Sizes Part NumberDrive Roll Kits To Make Spot Plug Welds Maintenance Perform the following daily Routine and Periodic Maintenance Maintenance Cable Cleaning Contact TIP and GAS Nozzle InstallationDrive Rolls and Guide Tubes GUN Tubes and Nozzles DROP-IN Reel Spindle and Clips Figure D.2 Liner maintenance Liner Removal Replacement To open up the handle GUN Handle Disassembly Description English Size Metric Size WIRE-MATIC Theory of Operation Transformer Input Line Voltage and Main Feedback Control Output Rectification Figure E.4 Constant Voltage Output Constant Voltage Output Feedback Wire Drive Motor Thermal Protection Figure E.6 SCR Operation SCR Operation WIRE-MATIC Troubleshooting & Repair Recommended Course of Action HOW to USE Troubleshooting Guide Board can be dam- aged by static electricity PC Board Troubleshooting ProceduresElectric Shock can kill Main Transformer Rectifier Assembly Test To Section TOC Perform the SCR Rectifier Perform the Wire Drive Motor Trolyte in these capacitors is Liquid elec Perform the Output Rectifier Materials Needed Main Transformer TestTest Description ON/OFF Power Switch will be hot during these tests Main Transformer Test Test Procedure Main Transformer Test Static SCR Rectifier Assembly Test Leads Figure F.4 SCR 1 Test Points Active SCR Rectifier Assembly Test Leads SCR connections Figure F.7 SCR Tester Circuit Wire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test Procedure Test for Feedback Voltage to the Control Board Test for Supply Voltage to Tachometer Normal Open Circuit Voltage Waveform Scope Settings Typical Output Voltage Waveform Machine Loaded Machine Loaded to 250 Amps AT 26 VDC Scope Settings Machine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Materials Needed Control PC Board Removal and ReplacementRemoval and Replacement Procedure Removal and REPLACE- Ment Procedure Wire Drive Assembly Removal and Replacement Figure F.11 Wire Drive Assembly Removal Wire Drive Assembly Removal and Replacement Procedure SCR Output Rectifier Removal & Replacement Disconnection Heat Sink Lead Right side heat sink See Figure F.14 Capacitor Bank Removal and Replacement Components Bank Removal Replacement Main Transformer Removal and Replacement Power Switch FAN Motor and FAN Removal and Replacement Figure F.16 Fan Motor and Fan Removal Components FAN Motor and FAN Removal and Replacement Procedure Troubleshooting & Repair Open Circuit Voltage Wire Speed RangeInput Volts/Hertz 230/60 375 WIRE-MATIC Table of Contents Electrical Diagrams Section WIRE-MATIC Electrical Diagrams Spool GUN Option Wiring Diagram 208/230 Code To Section Available from Lincoln Control PC Board G2332 Layout