Lincoln Electric MOBIFLEX 200-M Service Manual
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Lincoln Electric MOBIFLEX 200-M Service Manual

Lincoln Electric MOBIFLEX 200-M Service Manual

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MOBIFLEX
200-M
For use with machines having Code Numbers:
K1653-1, K1653-2 and K1653-3
SERVICE MANUAL
SVM254
| Issue D ate 15-Mar
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

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Summary of Contents for Lincoln Electric MOBIFLEX 200-M

  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. ® MOBIFLEX 200-M For use with machines having Code Numbers: K1653-1, K1653-2 and K1653-3 SERVICE MANUAL SVM254 | Issue D ate 15-Mar...
  • Page 2 Service and repair should be performed by only exhaust at the arc, or both, to keep Lincoln Electric Factory Trained Personnel. Unauthorized the fumes and gases from your breathing zone and the general area. repairs performed on this equipment may result in danger...
  • Page 3 American Welding Society, P.O. Box 351040, Miami, Florida 33135 MAGNETIC FIELDS MAY or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 BE DANGEROUS St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 MOBIFLEX 200-M SAFETY ® ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover electrically “hot” when the welder is on. Do plates to protect your eyes from sparks and the rays of the arc not touch these “hot”...
  • Page 5 MOBIFLEX 200-M SAFETY ® WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. and properly operating regulators designed for If this is not possible, cover them to prevent the gas and pressure used.
  • Page 6 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding equipment, in metallic conduit or equivalent. Shielding should be Equipment. It is for use with other Lincoln Electric equipment. It is electrically continuous throughout its length. The shielding should be designed for industrial and professional use.
  • Page 7 MOBIFLEX 200-M SAFETY ® Ventilation As a rule of thumb, for many mild steel electrode, if the air is visibly clear and you are comfortable, then the ventilation is generally There are many methods which can be selected by the user to adequate for your work.
  • Page 8 Limit) is 3.0 milligrams per cubic meter. OSHA PEL is a ceiling Know Act of 1986 and of 40CFR 370 and 372. Safety Data Sheet (MSDS) with product or on the Lincoln Electric TLV value for iron oxide is 5 milligrams per cubic meter.
  • Page 9 MOBIFLEX 200-M NOTES ® viii...
  • Page 10 MOBIFLEX 200-M TABLE OF CONTENTS ® MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety ....................................ii-viii Installation, Operation, Accessories, Maintenance ................See Instruction Manual Theory of Operation ..............................Section E Troubleshooting and Repair ............................Section F Electrical Diagrams ..............................Section G...
  • Page 11 MOBIFLEX 200-M THEORY OF OPERATION ® TABLE OF CONTENTS - THEORY OF OPERATION SECTION - Theory Of Operation ......................Section E Input Power And Motor Protection Switch .........E-2 Transformer, Contactor And Optional Auto Start / Stop Arc Sensor .
  • Page 12 This input power is applied to the motor protection (On/Off switch). When the motor protection switch is open (OFF position), no current will flow and the Mobiflex 200-M will shut down. When the motor protection switch is closed (ON position), input power will be sent through an internal thermal overload relay and then to the transformer and the contactor.
  • Page 13 MOBIFLEX 200-M THEORY OF OPERATION ® Figure E.3 - Transformer, contactor and optional auto start/stop arc sensor (OPTIONAL) LAMP REMOTE AUTO START/STOP SWITCH ARC SENSOR 24VAC 24VAC 24VAC INPUT 115VAC MOTOR POWER 115VAC TRANSFORMER 115VAC CONTACTOR FAN MOTOR PROTECTION 115V SWITCH 60HZ 115VAC...
  • Page 14 MOBIFLEX 200-M THEORY OF OPERATION ® Figure E.4 - Motor (OPTIONAL) LAMP REMOTE AUTO START/STOP SWITCH ARC SENSOR 24VAC 24VAC 24VAC INPUT 115VAC MOTOR POWER 115VAC TRANSFORMER 115VAC CONTACTOR FAN MOTOR PROTECTION 115V SWITCH 60HZ 115VAC MOTOR The single phase 3300 RPM motor is powered by 115VAC. When activated by the contactor this motor turns the blower paddles to create the 735 CFM (cubic feet per minute) air flow.

  • Page 15: Table Of Contents

    MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR SECTION - Troubleshooting and Repair ....................Section F How to Use Troubleshooting Guide ..........F-2 PC Board Troubleshooting Procedures .

  • Page 16: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE 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 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 17: Pc Board Troubleshooting Procedures

    MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® PC BOARD TROUBLESHOOTING PROCEDURES 4. Test the machine to determine if the failure symptom has been WARNING corrected by the replacement PC board. NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

  • Page 18: Troubleshooting Guide

    1. Clean excess dirt from fan. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Automation Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3878.

  • Page 19: Case Cover Removal And Replacement Procedure

    CASE COVER 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.
  • Page 20 REMOVAL PROCEDURE 1. Remove the input power to the Mobiflex 200-M machine. 2. Secure the Mobiflex 200-M in place by pressing down on the large front tab on the right (when facing the machine) front wheel. This will lock the wheel in place and keep the machine from moving while performing tests and procedures.
  • Page 21 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.2 – Ground strap location MOUNTING SCREW GROUND STRAP Figure F.3 – Control panel removal MOUNTING SCREWS (4) CONTROL PANEL...
  • Page 22 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position the control panel onto the Mobiflex 200-M machine. 2. Connect the hose to the bottom of the filter indicator. 3. Using needle nose pliers, connect the ground lead that is attached to the control panel, to the ground bar in front of the transformer.

  • Page 23: Contactor Test

    CONTACTOR TEST 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.
  • Page 24 11. Using a slotted screwdriver, connect the leads to terminals A1 and PROCEDURE A2 of the contactor. See Wiring Diagram. 1. Remove the input power to the Mobiflex 200-M machine. 12. Perform the Case Cover Replacement Procedure. 2. Perform the Case Cover Removal Procedure.
  • Page 25 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® CONTACTOR TEST (continued) Figure F.5 – Contactor lead locations F-11...
  • Page 26 MOBIFLEX 200-M NOTES ® F-12...

  • Page 27: Transformer Test

    TRANSFORMER TEST 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.
  • Page 28 10. Using a volt/ohmmeter, verify that 24VAC is being generated at PROCEDURE the secondary terminals of the transformer. See Figure F.8. See 1. Remove the input power to the Mobiflex 200-M machine. Wiring Diagram. 2. Perform the Case Cover Removal Procedure.
  • Page 29 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® TRANSFORMER TEST (continued) Figure F.7 – Transformer lead locations BROWN WHITE BROWN BLUE Figure F.8 – Transformer terminals PRIMARY SECONDARY TERMINALS TERMINALS F-15...
  • Page 30 MOBIFLEX 200-M NOTES ® F-16...

  • Page 31: Motor Protection Switch Test

    MOTOR PROTECTION SWITCH TEST 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.
  • Page 32 2/T1 4/T2 6/T3 PROCEDURE 1. Remove the input power to the Mobiflex 200-M machine. 2. Perform the Case Cover Removal Procedure. 3. Locate the motor protection switch on the control panel. See Figure F.9. 4. Using a volt/ohmmeter, perform the resistance test in Table F.1.
  • Page 33 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® MOTOR PROTECTION SWITCH TEST (continued) Figure F.10 – Motor protection switch lead locations 1/L1 3/L2 5/L3 2/T1 4/T2 6/T3 Table F.1 – Motor protection switch resistance tests TEST POINTS TEST POINTS EXPECTED READING CONDITION NO RESISTANCE POWER OFF, ON SWITCH (ZERO OHMS)
  • Page 34 MOBIFLEX 200-M NOTES ® F-20...

  • Page 35: Motor Test

    MOTOR TEST 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.
  • Page 36 6/T3 MOTOR LEADS PROCEDURE 1. Remove the input power to the Mobiflex 200-M machine. 2. Perform the Case Cover Removal Procedure. 3. Using a slotted screwdriver, label and disconnect the motor leads from terminals 4T2 and 6T3 of the contactor. See Figure F.11.

  • Page 37: Motor Capacitor Test

    MOTOR CAPACITOR TEST 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.
  • Page 38 MOUNTING SCREW (4) PROCEDURE 1. Remove the input power to the Mobiflex 200-M machine. 2. Perform the Motor And Fan Removal Procedure, to separate the motor and fan assembly from the machine. 3. Using a Phillips screwdriver, remove the four screws securing the motor capacitor cover.
  • Page 39 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® MOTOR CAPACITOR TEST (continued) Figure F.13 – Motor capacitor lead location MOTOR CAPACITOR CAPACITOR LEAD F-25...
  • Page 40 MOBIFLEX 200-M NOTES ® F-26...

  • Page 41: Extraction Arm Removal And Replacement Procedure

    EXTRACTION ARM 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.
  • Page 42 1. Remove the input power to the Mobiflex 200-M. the machine. See Figure F.15. 2. Secure the Mobiflex 200-M in place by pressing down on the large 11. With the help of an assistant carefully lift the extraction arm up front tab on the right (when facing the machine) front wheel.
  • Page 43 MOUNTING BOLT (2) REPLACEMENT PROCEDURE 1. Secure the Mobiflex 200-M in place by pressing down on the large front tab on the right (when facing the machine) front wheel. This will lock the wheel in place and keep the machine from moving while replacing the extraction arm.
  • Page 44 MOBIFLEX 200-M NOTES ® F-30...

  • Page 45: Front Wheel Removal And Replacement Procedure

    FRONT WHEEL 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.
  • Page 46 FRONT WHEEL ASSEMBLY MOUNTING NUT (4) REMOVAL PROCEDURE 1. Remove the input power to the Mobiflex 200-M machine. 2. Perform the Extraction Arm Removal Procedure. 3. Carefully turn the machine on its side to gain access to the front wheels.
  • Page 47 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® FRONT WHEEL REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. With the machine on its side, position the new wheel onto the mounting posts. 2. Using a 13mm nutdriver, attach the four nuts securing the front wheel to the machine.
  • Page 48 MOBIFLEX 200-M NOTES ® F-34...

  • Page 49: Contactor Removal And Replacement Procedure

    CONTACTOR 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.
  • Page 50 (continued) Figure F.17 – Contactor lead locations REMOVAL PROCEDURE 1. Remove the input power to the Mobiflex 200-M machine. 2. Perform the Case Cover Removal Procedure. 3. Using a slotted screwdriver, label and disconnect the six leads from contactor terminals 3L2, 4T2, 5L3, 6T3, A1 and A2. See Figure F.17.
  • Page 51 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® CONTACTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Carefully position new contactor in front of DIN rail. 2. Place the bottom tabs of the contactor on the DIN rail and rock the contactor upward onto the DIN rail until it snaps onto the DIN rail. 3.
  • Page 52 MOBIFLEX 200-M NOTES ® F-38...

  • Page 53: Transformer Removal And Replacement Procedure

    TRANSFORMER 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.
  • Page 54 WHITE BROWN BLUE REMOVAL PROCEDURE 1. Remove the input power to the Mobiflex 200-M machine. 2. Perform the Case Cover Removal Procedure. 3. Label and disconnect all leads from the transformer. See Figure F.18. See Wiring Diagram. 4. Using needle nose pliers, label and disconnect the two ground leads from the ground bar in front of the transformer.
  • Page 55 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.19 – Transformer mounting screws MOUNTING SCREWS (4) REPLACEMENT PROCEDURE 1. Carefully position new transformer onto machine. 2. Using a Phillips screwdriver, attach the four screws securing the transformer to the machine.
  • Page 56 MOBIFLEX 200-M NOTES ® F-42...

  • Page 57: Terminal Block Removal And Replacement Procedure

    TERMINAL BLOCK 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.
  • Page 58 BROWN WHITE GREEN REMOVAL PROCEDURE 1. Remove the input power to the Mobiflex 200-M machine. 2. Perform the Case Cover Removal Procedure. 3. Label all leads connected to the terminal block. See Figure F.20. See Wiring Diagram. 4. Using a small slotted screwdriver, push in on front opening that corresponds to the lead being removed and pull lead out of the top opening of the terminal block.
  • Page 59 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® TERMINAL BLOCK REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.21 – Terminal block mounting screw locations MOUNTING SCREWS REPLACEMENT PROCEDURE 1. Carefully position new terminal block onto machine. 2. Using a small Phillips screwdriver, attach the two screws securing the terminal block to the machine.
  • Page 60 MOBIFLEX 200-M NOTES ® F-46...

  • Page 61: Motor Protection Switch Removal And Replacement Procedure

    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.
  • Page 62 4/T2 6/T3 REMOVAL PROCEDURE 1. Remove the input power to the Mobiflex 200-M machine. 2. Perform the Case Cover Removal Procedure. 3. Using a Phillips screwdriver, label and disconnect the eight leads connected to motor protection switch terminals 1/L1, 2/T1, 3/L2, 4/T2, 5/L3 and 6/T3.
  • Page 63 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® MOTOR PROTECTION SWITCH REMOVAL AND REPLACEMENT PROCEDURE (continued) REPLACEMENT PROCEDURE 1. Position the new motor protection switch in front of the DIN rail. 2. Rest the upper mounting tabs, on the rear of the motor protection switch, onto the DIN rail and rock the motor protection switch assembly downward until it snaps into the DIN rail.
  • Page 64 MOBIFLEX 200-M NOTES ® F-50...

  • Page 65: Motor And Fan Removal And Replacement Procedure

    MOTOR AND FAN 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.
  • Page 66 REMOVAL PROCEDURE 11. Using a 13mm socket and a 13mm open end wrench, remove 1. Remove the input power to the Mobiflex 200-M machine. the four nuts and bolts securing the motor assembly to the fan 2. Perform the Case Cover Removal Procedure. Removing housing.
  • Page 67 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® MOTOR AND FAN REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.24 – Motor capacitor cover removal MOTOR CAPACITOR COVER MOTOR AND FAN ASSEMBLY MOUNTING SCREW (4) Figure F.25 – Motor lead locations MOTOR CAPACITOR POWER CABLE MOTOR LEADS F-53...
  • Page 68 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® MOTOR AND FAN REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.26 – Motor and fan assembly removal WASHER MOUNTING BOLTS (4) FAN HOUSING MOTOR ASSEMBLY MOUNTING NUTS (4) 13. Carefully return the machine to its upright position. REPLACEMENT PROCEDURE 14.

  • Page 69: Motor Capacitor Removal And Replacement Procedure

    MOTOR CAPACITOR 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.
  • Page 70 MOUNTING SCREW (4) REMOVAL PROCEDURE 1. Remove the input power to the Mobiflex 200-M machine. 2. Perform the Case Cover Removal Procedure. 3. Perform the Motor And Fan Removal Procedure, to separate the motor and fan assembly from the machine.
  • Page 71 MOBIFLEX 200-M TROUBLESHOOTING AND REPAIR ® MOTOR CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE (continued) Figure F.28 – Motor capacitor lead location MOTOR CAPACITOR CAPACITOR LEAD REPLACEMENT PROCEDURE 1. Carefully position the motor capacitor into the motor capacitor compartment on the side of the motor and fan assembly. 2.
  • Page 72 MOBIFLEX 200-M DIAGRAMS ® TABLE OF CONTENTS - DIAGRAMS SECTION - Diagrams ..........................Section G Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2...

This manual is also suitable for:

K1653-1K1653-2K1653-3

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