1. Manuals
  2. Brands
  3. Lincoln Electric Manuals
  4. Welding System
  5. SVM189-B
  6. Service manual

Lincoln Electric SVM189-B Service Manual

Lincoln electric welder user manual
Hide thumbs
Table of Contents

Advertisement

Quick Links

SVM189-B
RETURN TO MAIN MENU
January, 2011
COMPACT WIRE WELDERS
For use with machines having Code Numbers: 11173 Thru 11506
and
11646 Thru 11650
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper 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.

SERVICE MANUAL

Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888=935=3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Advertisement

Table of Contents
loading

Related Manuals for Lincoln Electric SVM189-B

Summary of Contents for Lincoln Electric SVM189-B

  • Page 1: Service Manual

    SVM189-B RETURN TO MAIN MENU January, 2011 COMPACT WIRE WELDERS For use with machines having Code Numbers: 11173 Thru 11506 11646 Thru 11650 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However,...

  • Page 2: California Proposition 65 Warnings

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding 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 adjcent areas.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN MENU Page Safety ................i-iv Installation .
  • Page 7 TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Machines in This Manual .
  • Page 8 TECHNICAL SPECIFICATIONS 180 Amp units Standard Voltage/Frequency 230 V 60 Hz 208 V 60 Hz Voltage/Duty Cycle 230 V 208 V Welding Current Range 30-180 Amps RECOMMENDED INPUT CABLE AND FUSE SIZES Input Voltage/Frequency Fuse or Breaker Size 230 V 60 Hz 40 Amp Super Lag Height...

  • Page 9: Technical Specifications

    258 mm 454 mm SELECT SUITABLE LOCATION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the...

  • Page 10: Identify And Locate Components

    IDENTIFY AND LOCATE COMPONENTS NOTE: Not all components are in every model. Check the Operator’s Manual for items included with a specific machine. • Wire Feeder Welder. • Work Cable & Clamp. • Handshield • Magnum 100L Welding Gun. • 3 .035” (0.9mm) Contact Tips (1 installed on the welding gun).

  • Page 11: Table Of Contents

    TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Product Description &...
  • Page 12 Read entire operation section before oper- ating the Compact Wire Welder. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. • Always wear dry insulating gloves.

  • Page 13: Operation

    CONTROLS AND SETTINGS See Figure B.1 1. POWER SWITCH – Turns power on and off to the machine. 2. ARC VOLTAGE CONTROL – This knob sets the output voltage of the machine. Along with wire feed speed (WFS) this control sets a weld procedure. Refer to the procedure decal on the inside wire drive compartment door to set a correct welding proce- dure based on type of material and thickness being...
  • Page 14 See Figure B.3 8. WELDING GUN CONNECTOR BUSHING & THUMBSCREW – Provides electrical power to the welding gun. The thumbscrew holds the welding gun into the connector block. (Front of Machine, Side Door and Wire Drive Cover have been removed for clarity of Items 8 and 9).

  • Page 15: Drive Roll & Wire Guides

    See Figure B.5a 11a. WIRE DRIVE & COMPONENTS (MOLDED DRIVE HOUSING) – Feeds wire from the wire spool through the drive and through the welding gun to the weld. a. Drive Roll – Drives the wire through the drive system. The drive roll has a groove to match the specific wire type and diameter.

  • Page 16: Items Needed For Flux Core Welding

    SETTING UP AND MAKING A FLUX-CORED WELD A. ITEMS NEEDED FOR FLUX CORED WELDING 1. 035”(0.9mm) Contact Tip 2. .025”-.035”(0.6mm-0.9mm) wire guide INNER WIRE GUIDE .025-.035 (.6-.9mm) 3. Knurled Drive Roll 4. .035”(0.9mm) NR-211MP Flux-Cored Wire 5. Black Flux Cored gun nozzle 6.

  • Page 17: Connect Leads & Cables

    B. CONNECT LEADS AND CABLES ON THE MACHINE (See Figure B.7) 1. Open the case side door 2. Slide the connector end of the gun and cable through the hole in the machine front and into the gun connector bushing on the wire drive. 3.
  • Page 18 (See Figure B.9) 9. Feed the wire through the wire drive inlet along the inner wire guide groove and into the wire drive outlet on the gun side. 10. Close the top drive roll pressure arm and secure by pivoting the tension adjustor back to the up position. 11.

  • Page 19: Items Needed For Mig Welding

    SETTING UP AND MAKING A MIG WELD A. ITEMS NEEDED FOR MIG WELDING 1. 025”(0.6mm) Contact Tip 2. 025”-035”(0.6mm-0.9mm) Inner wire guide (140 180 amp machines) INNER WIRE GUIDE .025-.035 3. .025”(0.6mm) Drive Roll 4. .025”(0.6mm) SuperArc L-56 Solid MIG Wire 5.

  • Page 20: Shielding Gas

    Keep cylinder upright and chained to support • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder away from welding or other live electrical circuits.

  • Page 21: Connect Leads & Cables

    B-11 C. CONNECT LEADS AND CABLES ON THE MACHINE (See Figure B.14) 1. Open the case side door. 2. Slide the connector end of the gun and cable through the hole of the machine front and into the gun connector bushing on the wire drive. 3.
  • Page 22 B-12 (See Figure B.16) 9. Feed the wire through the wire drive inlet along the inner wire guide groove and into the wire drive out- let on the gun side. 10. Close the top drive roll pressure arm and secure by pivoting the tension adjustor back to the up posi- tion.
  • Page 23 B-13 SETTING UP AND MAKING AN ALUMINUM WELD USING THE OPTIONAL SPOOL GUN 1. Follow the MIG welding steps in the previous sec- tion. 2. Connect a bottle of 100% Argon shielding Gas per previous section. 3. Disconnect Magnum 100L Gun. 4.
  • Page 24 NOTES B-14 B-14 COMPACT WIRE WELDERS...
  • Page 25 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Accessories .

  • Page 26: Accessories

    K2525-1 - Spot Timer Kit Timer kit, when turned on, allows you to set a fixed weld time so that when the gun trigger is pulled the machine will weld for a fixed time period up to 10 sec- onds. Ideal for making consistent spot welds when welding on thin sheet metal K2528-1 - 045 Innershield Kit (For 230V models) Includes everything needed to weld with .045”(1.1mm)
  • Page 27 K520—Utility Cart Heavy duty cart stores and transports welder, 150 cubic foot shielding gas cylinder, welding cables and accessories. Includes stable platforms for welder and gas bottle platform, lower tray for added storage capacity and adjustable height handle. For mounting welding machines to K520 carts that do not have slotted mounting holes, Drill 9/32”...
  • Page 28 K2275-1 - Welding Cart Lightweight cart stores and transports welder, 80 cubic foot shielding gas cylinder, welding cables and acces- sories. Includes an angled top shelf for easy access to controls, lower tray for added storage capacity, a stur- dy fixed handle and convenient cable wrap hanger.
  • Page 29 TECHNICAL SPECIFICATIONS - MAGNUM 100SG SPOOL GUN K2532-1 MODEL WELDING PROCESS WIRE ALLOYS WIRE SIZES (DIAMETERS) SPOOL SIZE RATED WELDING CURRENT AND DUTY CYCLE OVERALL WEIGHT CABLE LENGTH OVERALL SIZE (BOUNDING BOX) METHOD OF GUIDANCE METHOD OF COOLING UNPACKING THE SPOOL GUN The spool gun is factory-assembled and tested, and then packed in its own cushioned carrying case.

  • Page 30: Locating Spool Gun Components

    SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. • Turn the input power OFF at the welding power source before instal- lation or changing drive rolls and/or guides. • Do not touch electrically live parts. • When inching with the gun trigger, electrode and drive mechanism are "hot"...
  • Page 31 ASSEMBLY OF ITEMS INSIDE THE MAGNUM SPOOL GUN Machine Connections 1. Liner Assembly feeds all specified wire. 2. Drive Roll: This Drive Roll feeds all specified wires. 3. Idle Roll Assembly: Non-adjustable tension setting for all specified wires 4. Incoming Wire Guide: Highly wear-resistant. 5.
  • Page 32 SAFETY PRECAUTIONS WELDING MACHINES ------------------------------------------------------------------------ SPOOL GUN • Metal parts remain at welding voltage for sever- al seconds after trigger is released. Read warn- ing label on gun. • This product shall not be used in precipitation, or in wet or damp locations. ------------------------------------------------------------------- RECOMMENDED WELDING MACHINES The MAGNUM 100XL Spool Gun can be installed in all...
  • Page 33 SPOOL GUN / WIRE DRIVE SELECTOR SWITCH INSTALLATION 1. Install the M21182 electrical adapter harness that came with the spool gun per the following instruc- tions. WARNING ELECTRIC SHOCK CAN KILL. 2. Disconnect input power from the machine. ------------------------------------------------------------------------ OPEN THE MACHINE 3.

  • Page 34: Electrical Connections

    C-10 ELECTRICAL CONNECTIONS 544A (Male) 543A (Female) J7 (10-pin) J8 (6-pin) P7 (10-pin) 8. Adapter harness. All 6 connections shown are used, and each one is unique. (Proceed as follows) 9.A. Remove P3 (10-pin) from board J3 (10-pin). 9.B. Connect P3 (10-pin) to harness J7 (10-pin). ACCESSORIES Toggle Switch 10.
  • Page 35 C-11 11.D. Find assembled pair of machine terminals (leads 543A & 544A) and disconnect. Go to step 13. IF MACHINE DOES HAVE OPTIONAL SPOT TIMER. (12.A. thru 12.D.) 12.A. Remove P5 (6-pin) from spot timer harness J9 (6-pin). 12.B. Connect P5 (6-pin) to adapter harness J8 (6- pin).

  • Page 36: Mounting The Switch

    C-12 MOUNTING THE SWITCH 15. Remove the plug button from the panel hole. 16. Plug button is no longer needed. Discard. 17, Remove mounting nut from switch. Keep mount- ing nut for installation. 18. Install switch into panel hole. Ensure washer tab ACCESSORIES is fully seated into smaller hole.

  • Page 37: Preparation

    C-13 ROUTINE WELDING MACHINE PREPARATION 1. Disconnect input power to the machine. ------------------------------------------------------------------------ 2. Machine polarity setting: Set to DC electrode posi- tive polarity per the machine’s Instruction Manual. 3. Gas selection and flow rate: Connect 100% welding grade argon gas supply to the machine’s gas sole- noid valve.
  • Page 38 C-14 LOADING ALUMINUM WIRE 1. Remove gas cone and contact tip. Remove spool cover by unscrewing captive locking knob. FIGURE C.5 2. Remove locking knob from spindle bolt by unscrew- ing it. FIGURE C.6 3. Select wire alloy and diameter needed. Alloy 4043 and 0.035 wire size shown.
  • Page 39 C-15 7. Guide straightened wire through inlet wire guide and toward drive roll groove. FIGURE C.11 8. While holding open the idle roll, slide end of wire through drive roll’s groove and toward gun tube liner. FIGURE C.12 9. Slide the wire into the liner until it extends approxi- mately 1 inch beyond the end of the gas diffuser.

  • Page 40: Welding Machine

    C-16 12. Cut off excess wire 1 to 2 inches from gas diffuser. Install properly-sized contact tip slightly past hand- tight. Install gas cone and hand-tighten. FIGURE C.17 13. Reinstall spool cover. 1: tuck cover’s tab in place at arrow and hold with thumb. 2: swing cover closed. 3: finger-tighten locking knob.
  • Page 41 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .

  • Page 42: Routine Maintenance

    If so, blow dirt out of the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build-up on inter- nal parts.

  • Page 43: Gun And Cable

    GUN AND CABLE MAINTENANCE FOR MAGNUM™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor.

  • Page 44: Changing Liner

    Set Screw Brass Cable Connector Liner Assembly (Liner bushing to be sealed tight against brass cable connector) FIGURE D.2 Liner trim length CHANGING LINER NOTICE: The variation in cable lengths prevents the interchangeability of liners. Once a liner has been cut for a particular gun, it should not be installed in anoth- er gun unless it can meet the liner cutoff length require- ment.
  • Page 45 MAINTENANCE MAJOR COMPONENT LOCATIONS 1. Case Front, Back and Bottom Assembly 2. Power Module Assembly 3. Center Panel Assembly 4. Wire Drive Assembly 5. Wraparound & Door Assembly COMPACT WIRE WELDERS...
  • Page 46 MAINTENANCE MAJOR COMPONENT LOCATIONS 1. Case Front Assembly 2. Wire Drive Assembly 3. Center Panel Assembly 4. Power Module and Base Assembly 5. Wraparound & Door Assembly COMPACT WIRE WELDERS...
  • Page 47 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .

  • Page 48: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 — GENERAL DESCRIPTION VOLTAGE CONTROL CIRCUIT LINE BREAKER SWITCH INPUT RECEPTACLE GENERAL DESCRIPTION The Compact Wire Welders that are covered by this manual are Constant Voltage (CV) DC welders that can be used for MIG or Flux-Core process . The 120 VAC machines are rated for 90 amps, 19.5 volts, at 20% duty cycle.
  • Page 49 The fan motor is rated for the same AC Voltage as the welder and should run whenever the machine is Power Switch is turned ON. WIRE...

  • Page 50: Output Control

    THEORY OF OPERATION VOLTAGE CONTROL CIRCUIT LINE BREAKER SWITCH INPUT RECEPTACLE OUTPUT CONTROL, RECTIFICATION & VOLTAGE FEEDBACK The AC voltage that is applied to the main transformer primary is controlled at the control board by two SCRs (Silicon Controlled Rectifiers). The SCRs are controlled by a pulse signal developed on the control board.
  • Page 51 THEORY OF OPERATION FIGURE E.5 — TRIGGER, GAS SOLENOID & WIRE DRIVE VOLTAGE CONTROL CIRCUIT LINE BREAKER SWITCH INPUT RECEPTACLE TRIGGER, GAS SOLENOID AND WIRE DRIVE Closure of the trigger circuit (pulling the gun trigger) signals the control board to start several functions. A DC is applied to the gas solenoid (if present) to allow shielding gas to flow if required.

  • Page 52: Scr Operation

    THEORY OF OPERATION SCR OPERATION A silicon controlled rectifier (SCR) is a three terminal device used to control large currents to a load. An SCR acts very much like a switch. When it is turned on, there is current flow from anode to cathode. In the ON state, the SCR acts like a closed switch.
  • Page 53 THEORY OF OPERATION THERMAL PROTECTION The Compact Wire Welders have a rated output duty cycle as defined in the Technical Specification page. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools to a reasonable operating temperature.
  • Page 54 NOTES COMPACT WIRE WELDERS...
  • Page 55 TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 56: How To Use Troubleshooting Guide

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and 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.

  • Page 57: Pc Board Troubleshooting Procedures

    - 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 prop- er failure analysis.
  • Page 58 Fan does run. 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 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 59 ( 33 vdc maximum) - weld output. 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 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 60 No wire speed control. 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 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 61 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 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 62 Spool Gun trigger is pulled. 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 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 63 When using the Spool Gun. 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 1-888-935-3877. POSSIBLE AREAS OF...
  • Page 64 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 1-888-935-3877. POSSIBLE AREAS OF...

  • Page 65: Case Cover Removal And Replacement

    CASE COVER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only 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.
  • Page 66 TROUBLESHOOTING & REPAIR F-12 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) 3/4” 5/16 Hex Head Screws Screws (2 Places) PROCEDURE 1. Disconnect power to the machine. 2. Remove the two(2) 5/16 hex-head screws from the top of the door and remove the door 3.

  • Page 67: Gas Solenoid Test

    TROUBLESHOOTING & REPAIR F-13 Service and repair should be performed by only 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.
  • Page 68 TROUBLESHOOTING & REPAIR F-14 GAS SOLENOID TEST (CONTINUED) FIGURE F.2 – GAS SOLENOID LOCATION & LEADS PROCEDURE 1. Remove input power to the machine. 2. Perform the Case Cover Removal Procedure. 3. Locate the gas solenoid and lead connections. Do not disconnect the leads.
  • Page 69 TROUBLESHOOTING & REPAIR F-15 Service and repair should be performed by only 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.
  • Page 70 TROUBLESHOOTING & REPAIR F-16 WIRE DRIVE MOTOR TEST (CONTINUED) MOT- 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. Perform the Case Cover Removal Procedure. 3.

  • Page 71: Main Transformer Test

    F-17 MAIN TRANSFORMER TEST Service and repair should be performed by only 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.
  • Page 72 TROUBLESHOOTING & REPAIR F-18 MAIN TRANSFORMER TEST (CONTINUED) 1. Remove the input power to the machine. 2. Perform the Case Cover Removal Procedure. 3. Locate H1 and H2 on the control board terminal strips. See Wiring Diagram. 4. Place the voltage control to maximum. 5.
  • Page 73 TROUBLESHOOTING & REPAIR F-19 F-19 MAIN TRANSFORMER TEST (CONTINUED) FIGURE F.4. – X1 & X2 LOCATION Secondary Lead (Secondary Lead on opposite side not shown) COMPACT WIRE WELDERS...
  • Page 74 NOTES F-20 F-20 COMPACT WIRE WELDERS...

  • Page 75: Fan Motor Test

    TROUBLESHOOTING & REPAIR F-21 Service and repair should be performed by only 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.
  • Page 76 TROUBLESHOOTING & REPAIR F-22 FAN MOTOR TEST (CONTINUED) 1. Remove the input power to the machine. 2. Perform the Case Cover Removal Procedure. 3. Locate the fan terminals on the Control board on terminal strip 1 and terminal strip 2. See Wiring Diagram.

  • Page 77: Typical Output Voltage Waveform - Machine Loaded

    TROUBLESHOOTING & REPAIR F-23 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED 10Volts This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 78: Abnormal Open Circuit Voltage Waveform

    TROUBLESHOOTING & REPAIR F-24 ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 10Volts This is NOT the typical voltage wave- form. The output capacitor was dis- connected from the circuit. Note the increased ripple in the waveform. This condition simulates the faulty output filter capacitor.

  • Page 79: Control Board Removal And Replacement

    F-25 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE Service and repair should be performed by only 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.
  • Page 80 TROUBLESHOOTING & REPAIR F-26 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.6 – CONTROL BOARD LOCATION Control Board 1. Remove the input power to the machine. WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment.
  • Page 81 TROUBLESHOOTING & REPAIR F-27 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.7 – SCREW/NUT LOCATION(S) Nameplate Control Knob 5/64” Allen Set Screw (CONTINUED) Phillips Screws COMPACT WIRE WELDERS F-27...
  • Page 82 NOTES F-28 F-28 COMPACT WIRE WELDERS...

  • Page 83: Power Module Removal And Replacement

    POWER MODULE REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only 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.
  • Page 84 TROUBLESHOOTING & REPAIR F-30 POWER MODULE REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.8 – CASEBACK MOUNTING SCREWS 2 Phillips Screws 1. Disconnect main input power to the machine. 2. Perform the Case Cover Removal Procedure. WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment.
  • Page 85 TROUBLESHOOTING & REPAIR F-31 F-31 POWER MODULE REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.9 – CENTER PANEL SCREW REMOVAL Cent er Panel Pol ar i t y Panel Cent er Panel Scr ew s Out put St uds COMPACT WIRE WELDERS...
  • Page 86 NOTES F-32 F-32 COMPACT WIRE WELDERS...

  • Page 87: Rectifier, Transformer, Choke Assembly & Capacitor Removal And Replacement

    RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE Service and repair should be performed by only 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.
  • Page 88 TROUBLESHOOTING & REPAIR F-34 RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) 3/ 8” Bol t ed Lead ( oppos i t e s i de not s how n) 1. Remove the input power to the machine. 2.
  • Page 89 TROUBLESHOOTING & REPAIR F-35 RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) Dow Cor ni ng 340 ( Appl y t o ar ea, oppos i t e s i de not s how n) ) 8. When re-installing the capacitor, make sure that the polarity is NOT reversed.
  • Page 90 TROUBLESHOOTING & REPAIR F-36 RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.12 – DOW CORNING APPLICATION AREAS Lock W as her Pl ai n W as her TRANSFORMER AND CHOKE 11. With the Power Module removed from the machine, remove the top chassis on the Module.
  • Page 91 TROUBLESHOOTING & REPAIR F-37 F-37 RECTIFIER, TRANSFORMER, CHOKE ASSEMBLY & CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.13 – DOOR REMOVAL Transformer COMPACT WIRE WELDERS...
  • Page 92 NOTES F-38 F-38 COMPACT WIRE WELDERS...
  • Page 93 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only 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.
  • Page 94 TROUBLESHOOTING & REPAIR F-40 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.14 – CASEFRONT KNOB REMOVAL Nameplate Control Knob 5/64” Allen Set Screw 1. Remove the input power to the machine. 2. Perform the Case Cover Removal Procedure. WARNING ELECTRIC SHOCK can kill.
  • Page 95 TROUBLESHOOTING & REPAIR F-41 F-41 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) FIGURE F.15 – WIRE DRIVE MOTOR 3 Phillips Mounting Screws COMPACT WIRE WELDERS...
  • Page 96 NOTES F-42 F-42 COMPACT WIRE WELDERS...
  • Page 97 F-43 FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE Service and repair should be performed by only 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.
  • Page 98 TROUBLESHOOTING & REPAIR F-44 FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.16 – CENTER PANEL/FAN MOUNTING SCREW LOCATION 1. Remove the input power to the machine. 2. Perform the Case Cover Removal Procedure. WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment.
  • Page 99 TROUBLESHOOTING & REPAIR F-45 FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.17 – CENTER PANEL MOUNTING SCREWS 6. Remove the appropriate wiring and gas hose from the top of the Power Module Chassis. Pliers may be necessary. 7. Remove the flathead mounting screws from the center panel.
  • Page 100 TROUBLESHOOTING & REPAIR F-46 FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE 8. Depress the locking tabs and remove the top Power Module Chassis. See Figure F.18. 9. Label and disconnect any necessary leads attached to the Fan. 10. Remove the fan from the machine. (CONTINUED) FIGURE F.18 –...
  • Page 101 TROUBLESHOOTING & REPAIR F-47 RETEST AFTER REPAIR (125 AMP UNITS) INPUT IDLE AMPS & WATTS Input Volts/Hertz 120/60 RETEST AFTER REPAIR (140 AMP UNITS) INPUT IDLE AMPS & WATTS Input Volts/Hertz 120/60 Maximum Idle Amps 3.00 OPEN CIRCUIT VOLTAGE 9-33 VDC WIRE SPEED RANGE 50-500 in./min.
  • Page 102 TROUBLESHOOTING & REPAIR F-48 F-48 RETEST AFTER REPAIR (180 AMP UNITS) INPUT IDLE AMPS & WATTS Input Volts/Hertz Maximum Idle Amps Maximum Idle Watts 230/60 2.50 OPEN CIRCUIT VOLTAGE 9-33 VDC WIRE SPEED RANGE 50-500 in./min. (1.3-12.7 m/min) COMPACT WIRE WELDERS...
  • Page 103 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram - (M20410) .

  • Page 104: Electrical Diagrams

    WiriNG DiaGram - cOmplETE machiNE - (m20410) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ElEcTrical DiaGramS WIRING DIAGRAM WARNING...
  • Page 105 WiriNG DiaGram - SpOOl GuN iNTErfacE OpTiON - (m20410-1) HIGH VOLTAGE NOTES: NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ElEcTrical DiaGramS SPOOL GUN INTERFACE - WIRING DIAGRAM WARNING...
  • Page 106 WiriNG DiaGram - cOmplETE machiNE - cODE 11444 ONly - (m20410-2) WARNING HIGH VOLTAGE can kill NOTES: N.A. BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT N.B. WORK AND GUN CONNECTIONS SHOWN FOR GMAW WELDING. N.C. CAVITY NUMBERING SEQUENCE VIEWED FROM INSERTION SIDE N.F.
  • Page 107 WiriNG DiaGram -cOmplETE machiNE - cODE 11442 ONly - (m20410-3) WARNING HIGH VOLTAGE can kill ELECTRICAL CODES. (GREEN/YELLOW LEAD) NOTES: N.A. BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT N.B. WORK AND GUN CONNECTIONS SHOWN FOR GMAW WELDING. N.C. CAVITY NUMBERING SEQUENCE VIEWED FROM INSERTION SIDE N.D.
  • Page 108 SchEmaTic - cOmplETE machiNE m21240 M21240 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: Two versions of INPUTS 180A units: 208/230v retail and industrial Different cord and plug for both voltages (NEMA) 6-50 plug, 20 amps normal (use 40 super lag) 125A and 140A units: 120v retail and industrial (NEMA) 5-15 plug, 20 amps TopRear Air flow is back to front...
  • Page 109 SchEmaTic - machiNES WiTh vOlTaGE cONTrOl SWiTch - (G4741-1) +15V Vmiave 4.32K Wire Feed 1.82K Speed 100K +15V 33074A 4.32K 0.1uF 1.5K 68.1 AC_HOT 400V 26.7K 400V 400V BOARD TRANSFORMER 26.7K 115 / 230 SELECTION 400V 400V AC COM INPUT AC COM TO FAN WINDING...
  • Page 110 SchEmaTic - machiNES WiTh cONTiNuOuS vOlTaGE cONTrOl (G4822-1) +15V 3.74K 7.5K Vmiave 100K 4.32K Wire Feed Speed 100K 4.32K 0.1uF 33074A 100K 100K AC_HOT 400V 400V 26.7K 400V BOARD TRANSFORMER 26.7K 115 / 230 SELECTION 400V AC COM INPUT AC COM TO FAN WINDING AC COM...
  • Page 111 SchEmaTic - filTEr pc bOarD aSSEmbly - (S24206-2) PROPRIETARY & CONFIDENTIAL: SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGE- ABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER.

This manual is also suitable for:

Pro-mig 140tPro-mig 180tPower mig 140tPower-mig 140cPower mig 180tPro-core 125t ... Show all

Table of Contents