Lincoln Electric POWER MIG SVM157-A Service Manual
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Lincoln Electric POWER MIG SVM157-A Service Manual

Lincoln electric welder user manual
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For use with machines having Code Numbers:
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.
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN MENU
POWER MIG
10564
10584
SERVICE MANUAL
• World's Leader in Welding and Cutting Products •
™
200
Copyright © 2001 Lincoln Global Inc.
SVM157-A
October 2001

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Summary of Contents for Lincoln Electric POWER MIG SVM157-A

  • Page 1 POWER MIG For use with machines having Code Numbers: 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.

  • Page 2: California Proposition 65 Warnings

    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 copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

  • Page 3: Fumes And Gases

    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 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 adjacent 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6: Table Of Contents

    RETURN TO MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety ........... . i-iv Installation .

  • Page 7: Installation Section

    Section A - INSTALLATION SECTION - Installation ..........Section A Technical Specifications .

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS – POWER MIG 200 Standard Voltage/Frequency 208/230/60 Hz Duty Cycle Welding Current Range 30 – 200 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage/ Fuse or Breaker Frequency (Hz) Size (Super Lag) 208/60 230/60 Height 31.79 in 808 mm Wire Speed INSTALLATION...

  • Page 9: Installation

    Roll the machine off the skid assembly. 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. A location that minimizes the amount of...

  • Page 10: Dual Voltage Machine Input Connections

    A green wire in the input cable connects this contact to the frame of the welder. This ensures proper grounding of the welder frame when the welder plug is insert- ed into a grounded receptacle. POWER MIG 200...

  • Page 11: Triple Voltage Machine Input Connections

    PHASE OF A TWO OR THREE PHASE SYSTEM. INSTALLATION 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 front panel.

  • Page 12: Gun And Cable Installation

    Be sure that the contact tip, liner, and drive rolls all match the size of the wire being used. WARNING Turn the welder power switch off before installing gun and cable. 1. Lay the cable out straight.

  • Page 13: Operation Section

    To Start the Welder ........

  • Page 14: Operation

    Read entire Operation section before operating the POWER MIG 200. Observe all safety information throughout this manual. OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground.

  • Page 15: Product Description

    PRODUCT DESCRIPTION The POWER MIG™ 200 is a complete semiautomatic DC voltage arc welding machine built to meet NEMA specifications. It combines a tapped transformer volt- age power source with a constant speed wire feeder to form a reliable robust performance welding system. A simple control scheme, consisting of continuous full range wire feed speed control, and 7 output voltage tap selections provides versatility with ease of use and...

  • Page 16: Operation

    Turn the “Power Switch” switch to “ON”. This lights the red LED dis- play lights. With the desired voltage and wire speed selected, oper- ate the gun trigger for welder output and to energize the wire feed motor. POWER MIG 200...

  • Page 17: Feeding Wire Electrode

    1. Press end of gun against a solid object that is elec- trically isolated from the welder output and press the gun trigger for several seconds. 2. If the wire “birdnests”, jams or breaks at the drive roll, the idle roll pressure is too great.

  • Page 18: Avoiding Wire Feeding Problems

    The POWER MIG 200 has built-in protective ther- mostats that respond to excessive temperature. They open the wire feed and welder output circuits if the machine exceeds the maximum safe operating tem- perature because of a frequent overload, or high ambi- ent temperature plus overload.
  • Page 19 Section C - ACCESSORIES SECTION - Accessories ..........Section C Drive Roll Kits .

  • Page 20: Accessories

    DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that are available for the POWER MIG 200.The item in Bold is supplied standard with the POWER MIG 200. Wire Size .023”-.030” (0.6-0.8 mm) Solid .035” (0.9 mm) Steel .045”...

  • Page 21: Making A Weld With The Spool Gun Adapter Kit And Spool Gun Installed

    MAKING A WELD WITH THE SPOOL GUN ADAPTER KIT AND SPOOL GUN INSTALLED CAUTION In either toggle switch position, closing either gun trigger will cause the electrode of both guns to be electrically “HOT”. Be sure unused gun is posi- tioned so electrode or tip will not contact metal case or other metal common to work.
  • Page 22 NOTES POWER MIG 200...

  • Page 23: Maintenance Section

    Section D - MAINTENANCE SECTION - Maintenance ..........Section D Safety Precautions .

  • Page 24: Contact Tip And Gas Nozzle Installation

    GENERAL MAINTENANCE In extremely dusty locations, dirt may clog the air pas- sages causing the welder to run hot. Blow dirt out of the welder with low-pressure air at regular intervals to eliminate excessive dirt and dust build-up on internal parts.

  • Page 25: Maintenance

    CAUTION Excessive pressure at the start may cause the dirt to form a plug. Flex the cable over its entire length and again blow out the cable. Repeat this procedure until no further dirt comes out. If this has been done and feed problems are experienced, try liner replacement, and refer to the trouble shooting section on rough wire feeding.

  • Page 26: Gun Handle Disassembly

    GUN HANDLE DISASSEMBLY The internal parts of the gun handle may be inspected or serviced if necessary. The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counterclockwise (the same direction as removing a right hand thread) until the collar reaches a stop.
  • Page 27 MAINTENANCE 1. Case Front Assembly 2. Rear Panel Assembly 3. Center Assembly 4. Wire Drive Assembly 5. Base & Power Component Assembly 6. Covers Assembly POWER MIG 200...
  • Page 28 NOTES POWER MIG 200...

  • Page 29: Theory Of Operation Section

    Section E - THEORY OF OPERATION SECTION - Theory of Operation ......... Section E Input Power Circuit .

  • Page 30: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 – INPUT POWER CIRCUIT. RECTIFIER MOTOR DIODE BRIDGE LINE SWITCH RECONNECT MAIN PANEL TRANSFORMER INPUT LINE VOLTAGE, MAIN TRANSFORMER, VOLTAGE SELECTOR SWITCH AND BAFFLE MOUNTED DIODE BRIDGE The single phase input power is connected to the POWER MIG 200 through a line switch located on the front panel.
  • Page 31 THEORY OF OPERATION RECTIFIER MOTOR DIODE BRIDGE LINE SWITCH RECONNECT MAIN PANEL TRANSFORMER OUTPUT RECTIFICATION, CONTACTOR AND CONTROL BOARD The AC voltage developed on the secondary winding is applied, through the selector switch and output contactor, to the output rectifier bridge.
  • Page 32 THEORY OF OPERATION FIGURE E.4 – OPTIONAL CIRCUITS. RECTIFIER MOTOR DIODE BRIDGE LINE SWITCH RECONNECT MAIN PANEL TRANSFORMER CONTROL BOARD, GUN TRIGGER AND WIRE DRIVE MOTOR When the control board receives an activation command from the trigger circuit the control board activates the gas solenoid, output contactor, and the wire drive motor.

  • Page 33: Protective Devices And Circuits

    One is located on the main transformer. thermostat is located on the output rectifier heat sink assembly. They open the wire feed and welder output circuits if the machine exceeds the maximum safe operating temperature. This can be caused by a frequent overload or high ambient temperature.
  • Page 34 NOTES POWER MIG 200...
  • Page 35 Section F - TROUBLESHOOTING AND REPAIR SECTION - Troubleshooting and Repair ........Section F How to Use Troubleshooting Guide .

  • Page 36: Troubleshooting And Repair

    TROUBLESHOOTING AND 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 37: Pc Board Troubleshooting Procedures

    TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. • Have install and service this equipment. Turn the input power fuse box before working on equipment. Do not touch electrically hot parts. CAUTION Sometimes machine failures appear to be due to PC board failures.

  • Page 38: Troubleshooting And Repair

    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. See Wiring Diagrams for location of specified...
  • Page 39 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.
  • Page 40 The wire feed functions normal- 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.
  • Page 41 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 See Wiring Diagrams for location of specified...
  • Page 42 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 See Wiring Diagrams for location of specified...
  • Page 43 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 See Wiring Diagrams for location of specified...
  • Page 44 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 See Wiring Diagrams for location of specified...

  • Page 45: Main Transformer Test

    TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST WARNING 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 or machine operator and will invalidate your factory warranty.
  • Page 46 F-12 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST (continued) FIGURE F.1. – OUTPUT SELECTOR SWITCH TERMINALS TEST PROCEDURE WARNING THE ON/OFF POWER SWITCH will be “hot” during these tests. NOTE: Secondary voltages will vary proportionately with the primary input voltage. 1. Disconnect the main input power supply to the machine.
  • Page 47 F-13 F-13 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST (continued) FIGURE F.2. – LEAD X1 FIGURE F.3. – LEAD X9 & X10 POWER MIG 200...

  • Page 48: Input Voltage

    F-14 TROUBLESHOOTING AND REPAIR INPUT VOLTAGE 230 VAC 230 VAC 230 VAC 230 VAC 230 VAC 230 VAC 230 VAC 230 VAC 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.

  • Page 49: Wire Drive Motor And Tachometer Feedback Test

    WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST WARNING 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 or machine operator and will invalidate your factory warranty.

  • Page 50: Test Procedure

    F-16 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST 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. (continued) FIGURE F.4. – PLUG J4 Black Black White...
  • Page 51 F-17 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST 5. Make the following voltage tests: WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • All input power must be electri- cally disconnected before pro- ceeding.
  • Page 52 F-18 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST TEST FOR FEEDBACK VOLTAGE TO CONTROL BOARD 1. Disconnect the main AC input power to the machine. 2. Locate plug J4 and the tach leads. See Figure F.5. 3. Connect main input power to the machine.

  • Page 53: Output Bridge Rectifier Test

    TROUBLESHOOTING AND REPAIR OUTPUT BRIDGE RECTIFIER TEST 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 or machine operator and will invalidate your factory warranty.
  • Page 54 F-20 TROUBLESHOOTING AND REPAIR OUTPUT BRIDGE RECTIFIER TEST (continued) TEST PROCEDURE 1. Remove input power to the POWER MIG 200 machine. 2. Using the 3/8” nutdriver, remove the left case side. 3. Locate and disconnect the negative lead from the output rectifier bridge assembly. Be sure there is no electrical contact between the rectifier and the lead.

  • Page 55: Contactor Test

    F-21 TROUBLESHOOTING AND REPAIR 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 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 56 F-22 TROUBLESHOOTING AND REPAIR CONTACTOR TEST (Continued) TEST PROCEDURE 1. Remove the input power to the POWER MIG 200 machine. 2. Using the 5/16” Nutdriver, remove the tool tray. 3. Locate and remove leads 106B, 106C and 107A from the contactor coil terminals.

  • Page 57: Typical Output Voltage Waveform - Machine Loaded

    F-23 TROUBLESHOOTING AND REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED 10.0 V MACHINE LOADED TO 200 AMPS AT 22 VDC This is a typical DC output voltage wave- form generated from a properly operat- ing machine. Note that each vertical division represents 10 volts and that each horizontal division represents 5 milliseconds in time.
  • Page 58 F-24 TROUBLESHOOTING AND REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (MAX TAP “G”) 20.0 V 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.
  • Page 59 F-25 TROUBLESHOOTING AND REPAIR ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE ONE OUTPUT DIODE NOT FUNCTIONING 20.0 V MACHINE LOADED TO 180 AMPS AT 16 VDC This is NOT a typical DC output voltage waveform. One output diode is not func- tioning.
  • Page 60 F-26 TROUBLESHOOTING AND REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING (MAX TAP “G”) 20.0 V 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.

  • Page 61: Control Board Replacement

    TROUBLESHOOTING AND REPAIR CONTROL BOARD REPLACEMENT 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 or machine operator and will invalidate your factory warranty.
  • Page 62 F-28 TROUBLESHOOTING AND REPAIR CONTROL BOARD REPLACEMENT (continued) PROCEDURE 1. Remove power to the machine. 2. Using a 5/16” nutdriver, 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.

  • Page 63: Wire Drive Motor Assembly Replacement

    TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT 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 or machine operator and will invalidate your factory warranty.
  • Page 64 F-30 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued) FIGURE F.9. - WIRE DRIVE LOCATION PROCEDURE 1. Remove power to the machine. 2. Lift cover to gain access to the wire drive. See Figure F.9. 3. Using a pair of pliers, disconnect the gas hose from the bottom of the wire drive.
  • Page 65 F-31 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued) FIGURE F.10. - WIRE DRIVE HOSE & LEAD LOCATION 5/16" Monuting Screws FIGURE F.11. - MOUNTING SCREW LOCATIONS 5/16" Sheet Metal Screws 9/16" Bolt Gas Hose POWER MIG 200 F-31...
  • Page 66 F-32 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR ASSEMBLY REPLACEMENT (Continued) 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.

  • Page 67: Output Diode Bridge Rectifier Replacement

    TROUBLESHOOTING AND REPAIR OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT 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 or machine operator and will invalidate your factory warranty.
  • Page 68 F-34 TROUBLESHOOTING AND REPAIR OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED) PROCEDURE 1. Using a 3/8” nutdriver, remove the left side of the case wraparound cover. 2. Locate the output diode bridge rectifier. See Figure F.12. 3. Using a 1/2” nutdriver label and remove the four thick black leads connected to the rectifier.
  • Page 69 F-35 TROUBLESHOOTING AND REPAIR OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED) FIGURE F.13. - OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET 1/2" Rectifier Mounting Bolts 5/16" Mounting Bracket Mounting Bolts POWER MIG 200 F-35 Mounting Bracket...
  • Page 70 F-36 F-36 NOTES POWER MIG 200...

  • Page 71: Output Capacitors Replacement

    TROUBLESHOOTING AND REPAIR OUTPUT CAPACITORS REPLACEMENT 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 or machine operator and will invalidate your factory warranty.
  • Page 72 F-38 TROUBLESHOOTING AND REPAIR OUTPUT CAPACITORS REPLACEMENT (Continued) PROCEDURE 1. Using a 3/8” nutdriver, remove the lower right side case wraparound cover. See Figure F.14. 2. Locate capacitor bank. See Figure F.14. 3. Label and remove the five leads connected to the capacitor bank using a 1/2”...
  • Page 73 F-39 F-39 TROUBLESHOOTING AND REPAIR OUTPUT CAPACITORS REPLACEMENT (Continued) FIGURE F.15. - MOUNTING SCREW/BOLT LOCATIONS Lead Mounting Bolts 3/8" Nuts & Lock washers (3 places) POWER MIG 200...
  • Page 74 F-40 F-40 NOTES POWER MIG 200...

  • Page 75: Main Transformer Replacement

    TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT 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 or machine operator and will invalidate your factory warranty.

  • Page 76: Main Transformer

    F-42 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT (Continued) PROCEDURE 1. Using a 3/8” nutdriver, remove both sides of the case wraparound cover. 2. Using a 5/16” nutdriver, remove the tool tray. 3. Locate the main transformer. See Figure F.16. 4. Label and disconnect leads X9, X10, 104B, &...
  • Page 77 F-43 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT (Continued) 15. Carefully maneuver the main transformer out the left side of the machine. NOTE: Two people may be needed to maneu- ver the main transformer out of the machine. REPLACEMENT 1. Carefully maneuver the new main trans- former back into the machine and onto its mounting studs.
  • Page 78 F-44 F-44 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT (Continued) FIGURE F.18. - LEADS SWITCH LEADS FIGURE F.19. - LEAD 121 & 118 POWER MIG 200...
  • Page 79 F-45 F-45 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER REPLACEMENT (Continued) FIGURE F.20. - REAR ACCESS PANEL 5/16" Nut REAR ACCESS PANEL Lead 118 230V 208V FIGURE F.21. - REAR ACCESS PANEL (CLOSE-UP) POWER MIG 200...
  • Page 80 F-46 F-46 NOTES POWER MIG 200...

  • Page 81: Fan Blade/Motor Replacement

    TROUBLESHOOTING AND REPAIR FAN BLADE/MOTOR REPLACEMENT 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 or machine operator and will invalidate your factory warranty.
  • Page 82 F-48 TROUBLESHOOTING AND REPAIR FAN BLADE/MOTOR REPLACEMENT (Continued) PROCEDURE 1. Using a 3/8” nutdriver, remove the lower right side of the case wraparound cover. 2. Perform the Output Capacitor Bank Removal Procedure. 3. Using a 5/16” nutdriver, remove the four fan mounting screws from the rear of the machine.

  • Page 83: Output Contactor Replacement

    TROUBLESHOOTING AND REPAIR OUTPUT CONTACTOR REPLACEMENT 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 or machine operator and will invalidate your factory warranty.
  • Page 84 F-50 TROUBLESHOOTING AND REPAIR OUTPUT CONTACTOR REPLACEMENT (Continued) PROCEDURE 1. Using a 5/16” nutdriver, remove the three screws securing the tool tray. 2. Locate the output contactor. F.23. 3. Using a 7/16” wrench, label and remove the two thick black leads at the top of the output contactor.
  • Page 85 F-51 F-51 TROUBLESHOOTING AND REPAIR OUTPUT CONTACTOR REPLACEMENT (Continued) FIGURE F.24. - OUTPUT CONTACTOR MOUNTING BOLTS 7/16" Mounting Bolts POWER MIG 200...

  • Page 86: Retest After Repair

    F-52 F-52 TROUBLESHOOTING AND REPAIR RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS Input Volts/Herts Maximum Idle Amps Maximum Idle Watts 230/60 OPEN CIRCUIT VOLTAGE 35 - 40 VDC WIRE SPEED RANGE 50 - 700 IPM (1.27 - 17.8 m/minute) POWER MIG 200...

  • Page 87: Electrical Diagrams Section

    ELECTRICAL DIAGRAMS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS ............SECTION G WIRING DIAGRAM .
  • Page 88 WIRING DIAGRAM - CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P.C. BOARD) 106A 114A BAFFLE MOUNTED RECTIFIER DIODE BRIDGE 106B TO SINGLE PHASE SUPPLY LINE 230V 208V RECONNECT PANEL LINE SWITCH TO GROUND PER NATIONAL ELECTRICAL CODE MOTOR 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 POWER MIG 200 (208/230V) GENERAL INFORMATION...

  • Page 89: Electrical Diagrams

    ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
  • Page 90 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 91 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99 Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...

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