Lincoln Electric POWER MIG SVM157-A Service Manual Download | Manualshive

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TROUBLESHOOTING AND REPAIR

Observe Safety Guidelines

detailed in the beginning of this manual.

Troubleshooting Guide –

See Wiring Diagrams for location of specified

components and for troubleshooting of specific circuits.

F-9

F-9

POWER MIG 200

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the
Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353

CAUTION

WELDING PROBLEMS

PROBLEMS
(SYMPTOMS)

POSSIBLE AREAS OF
MISADJUSTMENT(S)

RECOMMENDED
COURSE OF ACTION

Poor arc striking with electrode
sticking or blasting off.

The arc is unstable and or “hunting”

1. Make sure the settings for wire

feed speed and voltage are cor-
rect for the process being used.

2. Make certain the gas shielding is

correct for the process being
used.

3. Make sure the machine’s recon-

nect panel is configured properly
for the input voltage being
applied.

1. Check for a worn or melted con-

tact tip.

2. Check for loose or faulty connec-

tions on the work and gun cables.

3. Make sure the electrode polarity

is correct for the welding process
being used.

4. Check for rusted or dirty electrode

wire.

5. Make sure the machine’s settings

and shielding gas are correct for
the process being used .

1. The output capacitors may be faulty.

Check for loose connections at the
capacitors. Also check for leaky
capacitors. Replace if necessary.

WARNING: The liquid electrolyte in
these capacitors is toxic. Avoid con-
tact with any portion of your body.

2. Perform the Output Diode Rectifier

Test.

1. Check for loose or faulty connections

at the output terminals, choke, output
capacitors, output selector switch,
output contactor, and all heavy cur-
rent carrying leads. See the wiring
diagram.

2. Check the output selector switch for

proper operation and good connec-
tions.

3. The output capacitors may be faulty.

Check for loose connections at the
capacitors. Also check for leaky
capacitors. Replace if necessary.

WARNING: The liquid electrolyte in
these capacitors is toxic. Avoid con-
tact with any portion of your body.

4. Perform the Output Bridge Rectifier

Test.

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Summary of Contents for POWER MIG SVM157-A

Page 1: ...roper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 10564 10584 RETURN TO MAIN MENU World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries ...

Page 2: ...IOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free c...

Page 3: ...nd the work or metal to be welded to a good electrical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the t...

Page 4: ...ng area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to preven...

Page 5: ...t à proximité au soudage à l aide d écrans appropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pantalons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans latera...

Page 6: ...CTIONS Page Safety i iv Installation Section A Operation Section B Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams Section G Parts Manual P372 P202 H 2 RETURN TO MAIN MENU ...

Page 7: ... MIG 200 A 3 Location A 3 Input Power Grounding and Connection Diagrams A 3 Dual Voltage Machine Input Connections A 4 Triple Voltage Machine Input Connections A 5 Output Polarity Connections A 5 Gun and Cable Installation A 6 Shielding Gas A 6 Section A Section A Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 8: ... 33 10 6 mm2 8 10 mm2 NOTE Use 10 AWG Grounding Wire TECHNICAL SPECIFICATIONS POWER MIG 200 INPUT SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES Height Width Depth Weight 31 79 in 18 88 in 38 78 in 210 Ibs 808 mm 480 mm 985 mm 95 kg PHYSICAL DIMENSIONS Wire Speed 50 700 IPM 1 27 17 8 m minute WIRE SPEED RANGE Standard Voltage Frequency Input Current 150 Amp Rated Outpu...

Page 9: ...n air into the louvers in the back and out the front A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air pas sages and cause overheating ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring All input power must be electrically dis connected before proceeding...

Page 10: ... have a quali fied electrician connect a receptacle Customer Supplied or cable to the input power lines and the system ground per the U S National Electrical Code and any applicable local codes See Technical Specifications at the beginning of this chapter for proper wire sizes For long runs over 100 feet larger copper wires should be used Fuse the two hot lines with super lag type fuses as shown i...

Page 11: ...PER GROUNDING CONNECT TO HOT WIRES OF A THREE WIRE SINGLE PHASE SYSTEM OR TO ONE PHASE OF A TWO OR THREE PHASE SYSTEM OUTPUT POLARITY CONNECTIONS The welder as shipped from the factory is connected for electrode positive polarity This is the normal polarity for GMA welding If negative polarity is required interchange the con nection of the two cables located in the wire drive com partment near the...

Page 12: ...g and Cutting published by the American Welding Society 2 Remove the cylinder cap Inspect the cylinder valves and regulator for damaged threads dirt dust oil or grease Remove dust and dirt with a clean cloth DO NOT ATTACH THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive 3 Stand to one side...

Page 13: ...rsion Parts B 3 Procedure for Changing Drive and Idle Roll Sets B 4 Wire Reel Loading B 4 To Start the Welder B 4 Feeding Wire Electrode B 5 Idle Roll Pressure Setting B 5 Making a Weld B 5 Avoiding Wire Feeding Problems B 6 Fan Control B 6 Input Line Voltage Variations B 6 Wirefeed Overload Protection B 6 Welding Thermal Overload Protection B 6 Section B Section B Return to Master TOC Return to M...

Page 14: ...rous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on closed containers ARC RAYS can burn eyes and skin Wear eye ear and body protec tion Observe all safety information throughout this manual WARNING Return to Section TOC Return to Section TOC Return to Section TOC Retur...

Page 15: ...se of GMAW processes requires a supply of shielding gas WELDING CAPABILITY The POWER MIG 200 is rated at 200 amps 22 volts at a 30 duty cycle based on a ten minute cycle time It is capable of higher duty cycles at lower output cur rents The tapped transformer design makes it well suited for use with most portable or in plant generating systems LIMITATIONS The output voltage current of the POWER MI...

Page 16: ...Rotate the spindle and adapter so the retaining spring is at the 12 o clock position 6 Position the Readi Reel so that it will rotate in a direction when feed ing so as to be de reeled from top of the coil 7 Set one of the Readi Reel inside cage wires on the slot in the retain ing spring tab 8 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the groov...

Page 17: ...drive roll the idle roll pressure is too great Back the adjustment knob out 1 2 turn run new wire through gun and repeat above steps 3 If the only result was drive roll slippage loosen the adjustment knob on the conductor plate and pull the gun cable forward about 6 15 cm There should be a slight waviness in the expose wire If there is not waviness the pressure is too low Tighten the adjustment kn...

Page 18: ...be less than normal for a given tap setting If your input line is low you may want to select a high er voltage tap than given on the recommended proce dure chart WIRE FEED OVERLOAD PROTECTION The POWER MIG has solid state overload protection of the wire drive motor If the motor becomes over loaded the protection circuitry turns off the wire feed speed and gas solenoid Check for proper size tip lin...

Page 19: ... 1 C 2 K363P Readi Reel Adapter C 2 Dual Cylinder Mounting Kit C 2 Alternative Magnum GMAW Gun and Cable Assemblies C 2 Magnum Gun Connection Kit C 2 Spool Gun and Adapter Kit C 2 Making a Weld with the Spool Gun Adapter Kit C 3 Section C Section C Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 20: ... 2 mm KP1696 045S Cored 035 0 9 mm KP1697 035C 045 1 2 mm KP1697 045C Aluminum 3 64 1 2 mm KP1695 3 64A ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES The following Magnum 250L gun and cable assemblies are separately available for use with the POWER MIG 200 Each is rated 200 amps 60 duty cycle and is equipped with the integrated connector twist lock trig ger connector fixed nozzle and insulator ...

Page 21: ...spool gun selector switch to the Spool Gun Position and pulling SPOOL GUN Trigger Disables built in feeder gun operation and machine gas solenoid valve Enables spool gun operation and spool gun gas solenoid valve Closing spool gun trigger starts spool gun weld ing and makes both electrodes electrically HOT 3 Operation with POWER MIG 200 Turn the POWER MIG 200 input power ON Adjusting the voltage t...

Page 22: ...NOTES C 4 C 4 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 23: ...tact Tip and Gas Nozzle Installation D 2 Gun Tubes and Nozzles D 2 Gun Cable Cleaning D 2 Liner Removal and Replacement D 3 Gun Handle Disassembly D 4 Accessories and replacement parts for Magnum 250L Gun Cable Assemblies D 4 Major Component Location D 5 Section D Section D Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 24: ...T TIP AND GAS NOZZLE INSTALLATION 1 Choose the correct size contact tip for the electrode being used wire size is stenciled on the side of the contact tip and screw it snugly into the gas diffuser 2 Screw the appropriate fixed gas nozzle fully onto the diffuser Either the standard 50 12 7 mm flush nozzle or other optional flush or recessed spray arc nozzle sizes may be used See Table D 2 in this s...

Page 25: ...liner cut off length requirement Liners are shipped with the jacket of the liner extended the proper amount 1 Remove the gas nozzle and nozzle insulator if used to locate the set screw in the gas diffuser which is used to hold the old liner in place Loosen the set screw with a 5 64 2 0 mm Allen wrench 2 Remove the gas diffuser from the gun tube 3 Lay the gun and cable out straight on a flat surfac...

Page 26: ...For 15 4 5 m or M16087 2 025 030 0 6 0 8 mm shorter Cable M16087 1 035 045 0 9 1 2 mm M17714 1 3 64 1 2 mm Alum wire Alum wire CONTACT TIPS Standard Duty S19391 6 025 0 6 mm S19391 7 030 0 8 mm S19391 1 035 0 9 mm S19391 2 045 1 2 mm Heavy Duty S19392 1 035 0 9 mm S19292 2 045 1 2 mm Tapered S19393 5 025 0 6 mm S19393 6 030 0 8 mm S19393 1 035 0 9 mm S19393 2 045 1 2 mm Tab For Aluminum S18697 46 ...

Page 27: ...Panel Assembly 3 Center Assembly 4 Wire Drive Assembly 5 Base Power Component Assembly 6 Covers Assembly Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 28: ...NOTES D 6 D 6 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 29: ...E 5 Thermal Overload Protection E 5 Wirefeed Overload Protection E 5 Section E Section E Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E 1 THEORY OF OPERATION BLOCK DIAGRAM LINE SWITCH RECONNECT PANEL FAN MOTOR RECTIFIER DIODE BRIDGE CONTROL BOARD GAS SOLENOID WIRE SPEED CONTROL WIRE DRIVE MOTOR TACH FEEDBACK GUN TRIGGER OUTPUT DIODE BRIDGE NEGATIVE TER...

Page 30: ...witch the user can preset the desired voltage output from a minimum setting A to a maximum voltage setting G In addition the main transformer houses a 28VAC winding This 28VAC is rectified at the baffle mounted diode bridge and the resultant DC voltage is used to power the electronics on the control board the output contactor and the gas solenoid NOTE Unshaded areas of block logic diagrams are the...

Page 31: ...ge output is applied to the output terminals of the machine FIGURE E 3 CONTROL CIRCUITS NOTE Unshaded areas of block logic diagrams are the subject of discussion Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC LINE SWITCH RECONNECT PANEL FAN MOTOR RECTIFIER DIODE BRIDGE CONTR...

Page 32: ...rigger circuitry If either of these thermostats would open the trigger circuit would be interrupted and the machine s output would be disabled FIGURE E 4 OPTIONAL CIRCUITS NOTE Unshaded areas of block logic diagrams are the subject of discussion Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Ret...

Page 33: ... left on and the reset should occur within a 15 minute period If the fan is not turning or the air intake louver are obstructed then the input power must be removed and the fan problem or air obstruction must be corrected WIREFEED OVERLOAD PROTECTION The POWER MIG 200 has solid state overload protection of the wire drive motor If the motor becomes overloaded the protection circuitry turns off the ...

Page 34: ...NOTES E 6 E 6 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 35: ... F 27 Wire Drive Motor Assembly Replacement F 29 Output Diode Bridge Rectifier Replacement F 33 Output Capacitors Replacement F 37 Main Transformer Replacement F 41 Fan Blade Motor Replacement F 47 Output Contactor Replacement F 49 Retest After Repair F 52 Section F Section F WARNING ELECTRIC SHOCK can kill Never work on the inside of the machine without removing the input power You can receive a ...

Page 36: ...ding problems and function problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled RECO...

Page 37: ... can t be installed immediately put it back in the static shielding bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis 4 Test the machine to determine if the failure symptom h...

Page 38: ...un trigger is activated The cooling fan is not running 1 Make certain the input power switch S1 is in the ON position 2 Check the input voltage at the machine The input voltage must match the rating plate and the reconnect panel 3 Check for blown or missing fuses in the input lines 1 Check the input power switch S1 It may be faulty 2 Check for broken or missing wires at the reconnect panel 3 Perfo...

Page 39: ...er 1 Make sure the gun cable and work cables are connected properly and in good condition 2 Make sure the output selector switch is in a good condition position and not between posi tions 1 Check the output selector switch for proper operation and good connections 2 Perform the Output Contactor Test 3 Perform the Output Bridge Rectifier Test 4 Perform the Main Transformer Test 5 Check the heavy cu...

Page 40: ...r leaky capacitors Replace if necessary WARNING The liquid electrolyte in these capacitors is toxic Avoid contact with any portion of your body 3 The output selector switch may be faulty Check for good con tact and continuity zero ohms through the switch See the Wiring Diagram 4 Perform the Output Contactor Test 5 Perform the Output Bridge Rectifier Test 6 Perform the Main Transformer Test F 6 TRO...

Page 41: ...NOT installed make certain the jumper plug is installed in J5 See the wiring diagram 3 Check the gas source and hoses for kinks or leaks 1 Check for a mechanical restric tion in the wire feed path The gun may be clogged 2 Make sure the drive rolls and guide plates are clean and are the correct size 3 Check the spindle for ease of rotation 1 Check plug J1 on the control board for loose or faulty co...

Page 42: ... the wire feed path 3 The gun liner may be clogged Check or replace 4 If the drive rolls are not turning when the gun trigger is activated contact your local Lincoln Electric Authorized Field Service Facility 1 The wire speed control potentiometer may be faulty Check or replace Normal potentiometer resistance is 10K ohms 2 Perform the Wire Drive Motor and Tachometer Feedback Test 3 The control boa...

Page 43: ...rk and gun cables 3 Make sure the electrode polarity is correct for the welding process being used 4 Check for rusted or dirty electrode wire 5 Make sure the machine s settings and shielding gas are correct for the process being used 1 The output capacitors may be faulty Check for loose connections at the capacitors Also check for leaky capacitors Replace if necessary WARNING The liquid electrolyt...

Page 44: ...act tip seizes in the gas dif fuser 1 Make sure the welding proce dures and electrode polarity are correct for the process being used 2 Make certain the shielding gas is correct and the flow is proper 3 Make sure the weld joint is not contaminated 1 The tip is being over heated due to excessive current and or high duty cycle 2 A light application of high temper ature anti seize lubricant may be ap...

Page 45: ...ult 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 technical troublesh...

Page 46: ...0 ON OFF Power Switch to the ON position 9 Carefully make the following voltage tests See Table F 1 10 Turn Off the machine 11 If any of the voltages are incorrect or missing check for loose or broken connections between the main transformer and the test points TROUBLESHOOTING AND REPAIR F 12 F 12 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC...

Page 47: ...AIN TRANSFORMER TEST continued FIGURE F 2 LEAD X1 FIGURE F 3 LEAD X9 X10 X1 X9 X10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 48: ... 12 If ALL the voltages tested are incorrect or missing test for correct nameplate input voltage between the H1 lead at the ON OFF POWER SWITCH to H2 or H3 at the reconnect panel Voltage tested will vary depending on input voltage con nection See wiring diagram for test point locations A If the input voltage test is incorrect check for loose or broken leads between the reconnect panel and the ON O...

Page 49: ...e 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 technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the wire drive motor and voltage feedb...

Page 50: ...R FEEDBACK TEST continued FIGURE F 4 PLUG J4 Black Tach J11 Black Arm White Arm Blue Tach Red Tach TEST PROCEDURE NOTE POLARITY MUST BE OBSERVED FOR THESE TESTS Test for correct wire drive motor armature voltage 1 Disconnect main input power to the machine 2 Open the side panels and remove the tool tray using a 5 16 nutdriver 3 Locate plug J4 on the wiring harness See Wiring Diagram 4 Locate the b...

Page 51: ... the following voltage tests a Turn the machine OFF between each test b Carefully insert the meter probes into the lead side of plug J4 6 If the 5 6 VDC is present check the leads to the tachometer circuit 7 If the leads are okay and 5 6 VDC is pre sent the correct voltage is being received from the control PC board Continue with the supply voltage to tachometer test 8 If the 5 6 VDC is not presen...

Page 52: ... Turn the machine ON and pull the gun trigger to conduct the voltage test 5 If the 3 0 to 4 0 VDC is present the tachometer circuit is sending the correct feedback signal to the control PC board Check the leads and plug J5 See the Wiring Diagram 6 If the 3 0 to 4 0 VDC is NOT present or NOT correct the control PC board is not receiving the proper feedback voltage from the tachometer circuit 7 If t...

Page 53: ...arranty 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 technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD WARNING This procedure t...

Page 54: ... output rectifier bridge assembly Be sure there is no electrical contact between the rectifier and the lead See Figure F 6 NOTE Do not disassemble the rectifier assembly 4 Test for shorted or leaky diodes by checking from the anodes to the cathodes of the diode heatsink plates The readings should be high resistance in one polarity and low resistance in the opposite polarity 5 If any of the diodes ...

Page 55: ... 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 technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD WARNING Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC R...

Page 56: ...large terminals with the contactor activated The resistance should be very low 0 to 1 ohm 8 If the resistance is high or open between the two large terminals when the contactor is activated the contactor is faulty Replace 9 If the contactor activates and the resistance between the terminals is low when the 12 VDC is applied the contactor is good NOTE When the contactor is not activated the resista...

Page 57: ...orizontal division represents 5 milliseconds in time The machine was loaded with a resistance grid bank NOTE Scope probes connected at machine output terminals probe to electrode probe to work Volts Div 10V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal SCOPE SETTINGS MACHINE LOADED TO 200 AMPS AT 22 VDC Return to Section TOC Return to Section TOC Return to Section TOC Return to Sectio...

Page 58: ...T VOLTAGE WAVEFORM MAX TAP G 20 0 V 1 0 ms 0 Volts This is a typical DC output voltage wave form generated from a properly operat ing machine Note that each vertical division represents 20 volts and that each horizontal division represents 1 0 milliseconds in time NOTE Scope probes connected at machine output terminals probe to electrode probe to work Volts Div 20V Div Horizontal Sweep 1 0 ms Div ...

Page 59: ...put diode Each vertical division repre sents 20 volts and each horizontal divi sion represents 5 milliseconds in time The machine was loaded with a resis tance grid bank NOTE Scope probes connected at machine output terminals probe to electrode probe to work Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal SCOPE SETTINGS MACHINE LOADED TO 180 AMPS AT 16 VDC Return to Sectio...

Page 60: ...X TAP G 20 0 V 5 ms 0 Volts This is NOT a typical DC output voltage waveform The output capacitors are not functioning Note the lack of filter ing in the output waveform The output capacitor bank was disconnected Each vertical division represents 20 volts and each horizontal division represents 5 milliseconds in time NOTE Scope probes connected at machine output terminals probe to electrode probe ...

Page 61: ... 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 ...

Page 62: ...river remove the three screws securing the tool tray 3 Locate the control board 4 Disconnect all associated plugs and leads connected to the control board 5 Depress the retaining pins on the sides of the four nylon mounts to release the control board See Figure F 8 6 Carefully remove the control board 7 Mount the new board to the nylon mounting pins 8 Reconnect any plugs or leads previously remove...

Page 63: ...ecautions 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 technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD WARNING DESCRIPTION The following procedure will aid the technician in removing the wire drive and tachometer for re...

Page 64: ...ly not the machine 5 Using a 5 16 nutdriver remove the three mounting screws next to the wire drive assembly See Figure F 10 6 Using a 5 16 nutdriver remove the two screws on the case front assembly See Figure F 11 7 Carefully maneuver the wire drive assem bly out the side of the machine to gain access to plug J4 See Wiring Diagram 8 Disconnect plug J4 WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT Continu...

Page 65: ...F 10 WIRE DRIVE HOSE LEAD LOCATION FIGURE F 11 MOUNTING SCREW LOCATIONS Gas Hose 9 16 Bolt 5 16 Sheet Metal Screws 5 16 Monuting Screws Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 66: ...Return to Master TOC 1 Place the new wire drive assembly into its proper position 2 Connect plug J4 3 Maneuver assembly back into its original position 4 Replace all mounting screws previously removed 5 Using a 3 4 nut driver replace the thick black lead previously removed 6 Reconnect the gas hose to the wire drive assembly 7 Close case wrap around cover WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT Conti...

Page 67: ...tes 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 technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD WARNING DESCRIPTION The following procedure will aid the technician in removing the output diode bridge re...

Page 68: ... mounting bracket out of the left side of the machine 7 Using a 1 2 nutdriver remove the three bolts mounting the bracket to the rectifier The rectifi er is now ready for repair or replacement See Figure F 13 8 Mount the new rectifier to the mounting bracket using the three 1 2 bolts 9 Carefully manipulate the rectifier and mounting bracket as a one back into the machine to its proper location 10 ...

Page 69: ... Mounting Bracket Mounting Bolts 1 2 Rectifier Mounting Bolts Mounting Bracket FIGURE F 13 OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 70: ...F 36 NOTES F 36 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 71: ...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 technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD WARNING DESCRIPTION The following procedure will aid the technician in removing the output capaci...

Page 72: ...e mounting bolts See Figure F 15 5 Remove the capacitor bank assembly from the machine 6 Place the new capacitor bank into its proper location inside the machine 7 Replace the three 3 8 nuts and lock washers previously removed 8 Using a 1 2 wrench reconnect the five labeled leads and associated washers previously removed 9 Replace the lower right side case wraparound cover previously removed FIGUR...

Page 73: ...ENT Continued FIGURE F 15 MOUNTING SCREW BOLT LOCATIONS 3 8 Nuts Lock washers 3 places Lead Mounting Bolts Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 74: ...F 40 NOTES F 40 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 75: ...s 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 technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD WARNING DESCRIPTION The following procedure will aid the technician in removing the main transformer for repair or replaceme...

Page 76: ...ssembly Note washer position upon removal See Figure F 18 7 Using a 1 2 nutdriver label and remove lead X1 from the output diode bridge rectifi er 8 Using a 5 16 Nutdriver open the rear access panel See Figure F 20 9 Disconnect lead 118 from the rear access panel See Figure F 21 10 Feed lead 118 toward the inside of the machine 11 Cut any necessary cable ties 12 Remove any necessary wiring harness...

Page 77: ...sly opened 5 Reconnect lead X1 to the output diode bridge rectifier 6 Reconnect leads X8 X7 X6 X5 X4 X3 X2 previously removed from the switch assembly 7 Reconnect lead H1B and the other associat ed lead connected to the same terminal These leads are connected to the ON OFF switch 8 Replace any necessary cable ties and wiring harnesses 9 Reconnect leads X9 X10 104B 104C See Wiring Diagram 10 Using ...

Page 78: ...MENT Continued FIGURE F 18 LEADS SWITCH LEADS FIGURE F 19 LEAD 121 118 X8 X7 X6 X5 X4 X3 X2 Front 121 118 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 79: ... 16 Nut REAR ACCESS PANEL FIGURE F 20 REAR ACCESS PANEL FIGURE F 21 REAR ACCESS PANEL CLOSE UP 230V 208V 4 L1 L2 Lead 118 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 80: ...F 46 NOTES F 46 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 81: ...s 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 technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD WARNING DESCRIPTION The following procedure will aid the technician in removing the fan blade and fan motor for repair or re...

Page 82: ...ly manuver the fan motor and fan blade out of the right side of the machine 8 Replace the fan motor and fan blade if nec essary 9 Tighten the fan blade mounting band 10 Carefully manuver the fan assembly into its original position 11 Replace the two 11 32 fan motor mounting nuts and lockwashers 12 Replace the four 5 16 fan assembly mount ing screws in the rear of the machine NOTE Make sure the fan...

Page 83: ...afety 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 technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD WARNING DESCRIPTION The following procedure will aid the technician in removing the output contact...

Page 84: ... wrench remove the three mounting bolts from the output contactor Note washer positions for replacement See Figure F 24 7 Replace output contactor 8 Using a 7 16 wrench mount the new output contactor in its proper location 9 Reconnect leads 106B 106C 107A to their proper terminals See Wiring Diagram 10 Reconnect the two thick black leads previ ously removed from the top of the output contactor 11 ...

Page 85: ...ACTOR REPLACEMENT Continued 7 16 Mounting Bolts FIGURE F 24 OUTPUT CONTACTOR MOUNTING BOLTS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 86: ...C Return to Master TOC Return to Master TOC Return to Master TOC F 52 TROUBLESHOOTING AND REPAIR F 52 POWER MIG 200 RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS OPEN CIRCUIT VOLTAGE WIRE SPEED RANGE Input Volts Herts 230 60 Maximum Idle Amps 2 0 Maximum Idle Watts 150 35 40 VDC 50 700 IPM 1 27 17 8 m minute ...

Page 87: ...1 TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION ELECTRICAL DIAGRAMS SECTION G WIRING DIAGRAM G 2 CONTROL PC BOARD SCHEMATIC G 3 CONTROL PC BOARD ASSEMBLY G 4 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 88: ...1 L2 6 3 L1 4 5 J2 X4 C1 H2 G PANEL RECONNECT S1 SWITCH LINE H1 208V L2 B SPEED WIRE FEED H3 GEARBOX MOTOR WORK TO R1 H3 H4 324 325 W CODE NATIONAL ELECTRICAL TO GROUND PER FOR SPOOL GUN OPTION J3 1 2 J3 1 4 3 2 J5 110A 111A 1 4 3 2 JUMPER PLUG INSTALLED FOR NON SPOOL GUN OPERATION PA GAS SOLENOID 107A 106C 106B 106C 116B 105A 105B 113A 1 4 3 2 1 4 3 2 6 5 T A C H 115A R B U R B U J4 9 PA J4 TRIGG...

Page 89: ...C Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 3 SCHEMATIC CONTROL PC BOARD G 3 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

Page 90: ...0V SOT 23 MM Q15 Q16 Q17 Q19 Q8 Q10 Q12 Q18 4 S25050 2SMT TRANSISTOR SMS PNP SOT23 0 5A 40V MM R1 R55 2 S25000 2801SMT RESISTOR SMD METAL FILM 1 10W 2 80K 1 R2 1 S25000 3162SMT RESISTOR SMD METAL FILM 1 10W 31 6K 1 R3 R7 R126 3 S25001 2671SMT RESISTOR SMD 2 67K 1 4W 1206 1 TR R4 1 S25001 24R9SMT RESISTOR SMD 24 9OHMS 1 4W 1206 1 TR R5 R33 R36 R120 4 S25000 5621SMT RESISTOR SMD METAL FILM 1 10W 5 6...

Page 91: ...__________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ _____________________________________________________________...

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