Lincoln Electric POWER MIG SVM160-B Service Manual
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Lincoln Electric POWER MIG SVM160-B Service Manual

Lincoln electric welder user manual
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RETURN TO MAIN MENU
SVM160-B
POWER MIG
300
™
April, 2005
For use with machine Code Numbers: 10562, 10952, 10958, 11000, 11097, 11098
For use with machine
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 thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.

SERVICE MANUAL

Copyright © 2005 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: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric POWER MIG SVM160-B

  • Page 1: Service Manual

    RETURN TO MAIN MENU SVM160-B POWER MIG ™ April, 2005 For use with machine Code Numbers: 10562, 10952, 10958, 11000, 11097, 11098 For use with machine Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind.

  • Page 2: Safety

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

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS 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 How to Use Troubleshooting Guide...F-2 Troubleshooting Guide...F-4 Test Procedures ...F-14 Replacement Procedures ...F-36 Electrical Diagrams ...Section G Parts Manual...P409 &...
  • Page 7 TABLE OF CONTENTS - INSTALLATION SECTION - INSTALLATION...Section A Technical Specifications ...A-2 Safety Precautions...A-3 Input Supply Connection Diagram...A-4 Gun and Cable Installation...A-5 POWER MIG 300...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS – POWER MIG 300 Standard Voltage/Frequency 208/230/460/575/60 Hz Input Voltage Duty Cycle 230/460/575 208/230/460/575 100% Welding Current Range (Continuous) Maximum Open Circuit Voltage 5 – 350 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES - SINGLE PHASE Input Voltage/ 230Amps @ Frequency (Hz) 29 Volts...

  • Page 9: Safety Precautions

    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 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 inserted into the receptacle. INSTALLATION FIGURE A.2 —...

  • Page 11: Gun And Cable Installation

    .035-.045" (0.9-1.2 mm) electrode and contact tips for .035” (0.9mm) and .045” (1.2mm) are included for 15Ft.. WARNING Turn the welder power switch off before installing gun and cable. LINER INSTALLATION AND TRIMMING INSTRUCTION (SEE FIGURE A.3) 1. Remove the gas nozzle.
  • Page 12 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 away from the outlet and open the cylinder valve for an instant.
  • Page 13 TABLE OF CONTENTS - OPERATION SECTION - Operation...Section B Definitions of Welding Modes...B-2 Product Description ...B-3 Controls and Settings ...B-3/B-4 Setting and Configuring ...B-5 Multi-Process Panel Functions ...B-6 Arc Control...B-7 Wire Drive Roll ...B-8 Changing Drive and Idle Roll Sets ...B-9 Feeding Wire Electrode...B-10 Pulse Welding ...B-11 Pulse-On-Pulse...B-12...

  • Page 14: Operation

    Read entire Operation section before operating the POWER MIG 300. 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 15: Product Description

    PRODUCT DESCRIPTION The POWER MIG 300 is a complete semiautomatic multi-process DC arc welding machine offering CV and CC DC welding. It is rated for 300 amps, 32 volts at a 60% duty cycle. The standard machine is equipped to weld CC-Stick, CC-GTAW, CV-FCAW, and synergic and non-synergic CV-GMAW / GMAW-P and Pulse-on-Pulse and Power Mode welding processes.
  • Page 16 2. VOLT / TRIM METER - This meter displays either the voltage or trim value depending on the status of the machine. Located below the display is the text "Volts" and "Trim." An LED light is illuminated to the left of one of these in order to indicate the units of the value displayed in the meter.

  • Page 17: Operation

    SETTING AND CONFIGURING THE POWER MIG 300 FOR WELDING • Check that the electrode polarity is correct for the process and turn the Power Switch to the "ON" position. After the "boot-up" period (approximately 20 seconds), the POWER MIG 300 will default to the last preset weld mode that was active when the machine was powered down.

  • Page 18: Multi-Process Panel Functions

    MULTI-PROCESS PANEL FUNCTIONS Weld Mode Setting the Weld Mode is selecting the proper program from the ones available in the machine’s memory for a particular welding application. The table on the right side of the front panel (See Figure B.2) gives information on the different programs available in this machine.

  • Page 19: Arc Control

    Arc Control (See Table B.2) There are no specific unit values offered because the setting of this feature largely depends upon operator preference. Arc Control has a different effect on the character of the arc depending upon the welding process applied. In SMAW (STICK mode), arc control adjusts the arc force.

  • Page 20: Wire Drive Roll

    In the case of special waveforms designed for pulsed weld- ing aluminum, Pulse on Pulse™, the effect is similar to what occurs with standard pulse. As the Arc Control is increased from +1 to +10 the frequency of the Pulse on Pulse array increases.

  • Page 21: Changing Drive And Idle Roll Sets

    PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS 1. Turn off the power source. 2. Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back of the machine. Lift the cast idle roll assembly and allow it to sit in an upright position.

  • Page 22: Feeding Wire Electrode

    OPERATION 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 23: Pulse Welding

    B-11 SPECIAL WELDING PROCESSES AVAILABLE ON THE POWER MIG 300 PULSE WELDING (GMAW-P) The pulsed-arc process is, by definition, a spray trans- fer process wherein spray transfer occurs in pulses at regularly spaced intervals. In the time between pulses, the welding current is reduced and no metal transfer occurs.

  • Page 24: Pulse-On-Pulse

    Arc Control can be used to vary the ripple spacing in the weld bead. BENEFITS OF PULSE ON PULSE FROM LINCOLN ELECTRIC • Excellent appearance of the weld bead • Improved cleaning action • Reduced porosity Table B.3 shows WFS and Trim settings for common...

  • Page 25: Power Mode

    B-13 POWER MODE™ The Power Mode™ process was developed by Lincoln to maintain a stable and smooth arc at low procedure settings which are needed to weld thin metal without pop-outs or burning-through. For Aluminum welding, it provides excellent control and the ability to maintain constant arc length.
  • Page 26 B-14 NOTES B-14 POWER MIG 300...

  • Page 27: Accessories

    TABLE OF CONTENTS - ACCESSORIES - Accessories...Section C Drive Roll Kits ...C-2 Push-Pull Feeding Connection Adapter Kit...C-3 POWER MIG 300...

  • Page 28: Drive Roll Kits

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

  • Page 29: Push-Pull Feeding Connection Adapter Kit

    ADAPTER KIT (K2154-1) The push-pull adapter kit provides direct connection of a Cobra Gold or Prince XL torch to the POWER MIG 300 wire feeder welder. The kit is intended for use with the following Cobra Gold or Prince XL torches:...
  • Page 30 NOTES POWER MIG 300...

  • Page 31: Maintenance

    TABLE OF CONTENTS -MAINTENANCE- Maintenance...Section D Safety Precautions & General Maintenance ...D-2 Liner Removal and Replacement...D-3 POWER MIG 300...

  • Page 32: 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 33: Liner Removal And Replacement

    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 prob- lems are experienced, try liner replacement, and refer to trouble shooting section on rough wire feeding.
  • Page 34 Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E General Description ...E-2 Input Voltage and Main Transformer ...E-3 Input Rectifier, Chopper Assembly And Feedback ...E-4 Diode Control Rectifier and Power Board ...E-5 Weld Control Board ...E-6 Wire Drive Motor and Feedback ...E-7 Thermal Protection, Over Current Protection, and Wire Feeder Overload Protection ...E-8 Insulated Gate Bipolar Transistor (IGBT) Operation ...E-9...

  • Page 35: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 – MAIN TRANSFORMER RECONNECT PANEL LINE SWITCH RELAY MOTOR FROM WELD CONTROL BOARD FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL) 24 VDC SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL) GENERAL DESCRIPTION The Power MIG 300 is a complete semiautomatic, multi-process DC arc welding machine offering CV and CC DC welding.

  • Page 36: Input Rectifier, Chopper Assembly And Feedback

    THEORY OF OPERATION FIGURE E.3 – INPUT RECTIFIER, CHOPPER ASSEMBLY AND FEEDBACK TRANSFORMER RECONNECT PANEL LINE SWITCH RELAY MOTOR FROM WELD CONTROL BOARD FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL) 24 VDC SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL) INPUT VOLTAGE AND MAIN TRANS- FORMER Single-phase input power is brought into the rear of the Power MIG 300 through a three-prong plug and input...

  • Page 37: Diode Control Rectifier And Power Board

    THEORY OF OPERATION FIGURE E.4 – DIODE CONTROL RECTIFIER AND POWER BOARD MAIN TRANSFORMER RECONNECT PANEL LINE SWITCH RELAY MOTOR FROM WELD CONTROL BOARD FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL) 24 VDC SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL) INPUT RECTIFIER, ASSEMBLY AND FEEDBACK The 60 VAC output from the main transformer sec-...

  • Page 38: Diode Control Rectifier And Power Board

    THEORY OF OPERATION FIGURE E.5 – WELD CONTROL BOARD MAIN TRANSFORMER RECONNECT PANEL LINE SWITCH RELAY MOTOR FROM WELD CONTROL BOARD FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL) 24 VDC SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL) SOLENOID DIODE CONTROL RECTIFIER AND POWER BOARD The Power Board receives approximately 40 VDC from the Diode Control Rectifier.

  • Page 39: Wire Drive Motor And Feedback

    THEORY OF OPERATION FIGURE E.6 – WIRE DRIVE MOTOR AND FEEDBACK TRANSFORMER RECONNECT PANEL LINE SWITCH RELAY MOTOR FROM WELD CONTROL BOARD FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL) 24 VDC SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL) WELD CONTROL BOARD The Weld Control Board performs the primary interfac- ing functions to establish and maintain output control of the Power MIG 300 machine.

  • Page 40: Theory Of Operation

    THEORY OF OPERATION FIGURE E.7 – WIRE DRIVE MOTOR AND FEEDBACK TRANSFORMER RECONNECT PANEL LINE SWITCH RELAY MOTOR FROM WELD CONTROL BOARD FOOT AMPTROL OR REMOTE (6-PIN AMPHENOL) 24 VDC SPOOL GUN OR PUSH-PULL GUN (7-PIN AMPHENOL) WIRE DRIVE MOTOR AND FEED- BACK The Wire Drive Motor is controlled by the Feeder Board and the Weld Control Board.

  • Page 41: Thermal Protection

    THEORY OF OPERATION THERMAL PROTECTION Two normally closed (NC) thermostats protect the machine from excessive operating temperatures. These thermostats are wired in series and are con- nected to the Weld Control board. One of the ther- mostats is located on the Chopper Assembly board, and one is on the secondary of the Main Transformer.

  • Page 42: Insulated Gate Bipolar Transistor (Igbt) Operation

    THEORY OF OPERATION SOURCE DRAIN A. PASSIVE INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION An IGBT is a type of transistor. IGBTs are semiconduc- tors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source, and therefore, no current flow.

  • Page 43: Pulse Width Modulation

    E-10 THEORY OF OPERATION FIGURE E.9 – TYPICAL IGBT OUTPUTS PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle. Changing the pulse width is known as MODULATION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.

  • Page 44: Chopper Technology Fundamentals

    E-11 THEORY OF OPERATION CHOPPER TECHNOLOGY FUNDAMENTALS The new era of welding machines such as the Power MIG 300 employ a technology whereby a DC source is turned on and off (chopped up) at high speed, then smoothed through an inductor to control an arc. Hence the name “Chopper.”...
  • Page 45 Section F-1 TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section ...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures ...F-3 Troubleshooting Guide ...F-4 - F-11 Chopper Board Capacitor Discharge Procedure ...F-12 Main Transformer Test ...F-14 Chopper Board Test ...F-16 Control Rectifier Test ...F-19 Output Rectifier Assembly Test ...F-21 Wire Drive Motor and Tachometer Feedback Test ...F-23...

  • Page 46: Troubleshooting And Repair

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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 47: 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 48: Troubleshooting Guide

    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 electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 49 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 electrical troubleshooting assistance before you proceed. Call 1-800-833-9353.
  • Page 50 The wire is not feeding. 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 electrical troubleshooting assistance before you proceed. Call 1-800-833-9353.
  • Page 51 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 electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. detailed in the beginning of this manual.
  • Page 52 The machine stops feeding wire while welding. 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 electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 53 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 electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. detailed in the beginning of this manual.
  • Page 54 The arc striking is poor. 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 electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 55 --------- Scrolling dashes 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 electrical troubleshooting assistance before you proceed. Call 1-800-833-9353. TROUBLESHOOTING GUIDE CORRECTIVE...

  • Page 56: Chopper Board Capacitor Discharge Procedure

    TROUBLESHOOTING & REPAIR CHOPPER BOARD CAPACITOR DISCHARGE 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 57 F-13 TROUBLESHOOTING & REPAIR CHOPPER BOARD CAPACITOR DISCHARGE PROCEDURE (continued) FIGURE F.1 – CHOPPER BOARD CAPACITOR TERMINAL DISCHARGE PROCEDURE WARNING ELECTRIC SHOCK can kill. High voltage is present when input power is applied to the machine. Refer to Figure F.1. 1.

  • Page 58: Main Transformer Test

    TROUBLESHOOTING & REPAIR 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 59 F-15 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST (continued) FIGURE F.2 – MAIN TRANSFORMER TEST POINT LOCATIONS (SHOWN CONNECTED FOR 230V) RECONNECT PANEL PROCEDURE WARNING The ON/OFF POWER SWITCH will be "hot" during these tests. NOTE: Secondary voltages will vary proportionately with the primary input voltage.

  • Page 60: Chopper Board Test

    F-16 TROUBLESHOOTING & REPAIR 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 61 F-17 TROUBLESHOOTING & REPAIR CHOPPER BOARD TEST (continued) TEST PROCEDURE 1. Disconnect the main AC input power to the machine. 2. Remove the case side panels with a 3/8 in. nutdriv- 3. Locate plug J99. (Later machine do not have J99). 4.
  • Page 62 F-18 TROUBLESHOOTING & REPAIR CHOPPER BOARD TEST (continued) PWM SIGNAL TEST 1. Locate 607 (7J6) and 615 (15J6) on the control board. See Figure F.4. 2. Perform the following voltage test or hertz read- ings when the trigger is pulled. To Lead From Lead (7J6)

  • Page 63: Control Rectifier Test

    TROUBLESHOOTING & REPAIR CONTROL RECTIFIER 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 64 F-20 TROUBLESHOOTING & REPAIR CONTROL RECTIFIER TEST (continued) TEST PROCEDURE 1. Find the following leads at the control rectifier using figures F.5 and F.6. From Lead Expected Voltage To Lead 471B 472B FIGURE F.5 115 VAC 30 VAC CONTROL RECTIFIER LOCATED ON TRANSFORMER BAFFLE...

  • Page 65: Output Rectifier Assembly Test

    TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER ASSEMBLY 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 66 F-22 TROUBLESHOOTING & REPAIR OUTPUT RECTIFIER ASSEMBLY TEST (continued) FIGURE F.7– OUTPUT RECTIFIER ASSEMBLY LOCATION TEST PROCEDURE 1. Disconnect the main AC input power to the machine. 2. Perform the Chopper Assembly Capacitor Discharge procedure. 3. Locate and disconnect the negative lead from the output rectifier bridge assembly.
  • Page 67 TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK 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: Wire Drive Motor And Tachometer Feedback Test

    F-24 TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) FIGURE F. 8 – PLUG J83 AND J84 LOCATIONS ON FEEDER BOARD G3884 TEST PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. TEST FOR CORRECT WIRE DRIVE MOTOR ARMATURE VOLTAGE 1.
  • Page 69 F-25 TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) TEST SUPPLY VOLTAGE TACHOMETER AND FEEDBACK VOLTAGE 1. Locate the following leads on Plug J84. Leads 841 (1J84) and 844 (4J84) 2. Make the following voltage tests. From the table below.

  • Page 70: Encoder Pc Board Test (10562 & Above

    TROUBLESHOOTING & REPAIR ENCODER PC BOARD 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 71 F-27 TROUBLESHOOTING & REPAIR ENCODER PC BOARD TEST (continued) FIGURE F. 9 - FEEDHEAD P.C. BOARD 3243 TEST PROCEDURE 1. Disconnect the main AC input power to the machine. 2. Locate the following leads on Plug J85 and J86 located on the feedhead P.C. Board. See Figure F.9.
  • Page 72 F-28 TROUBLESHOOTING & REPAIR ENCODER PC BOARD TEST (continued) VOLT/TRIM ENCODER #1 FROM LEAD TO LEAD EXPECTED VOLTAGE 3243 5J85 3J82 8511 3243 11J85 3J82 3243 8J85 3J82 WMF/AMPS ENCODER #2 FROM LEAD TO LEAD EXPECTED VOLTAGE 3243 9J85 3J82 3243 7J85 3J82...

  • Page 73: Current Transducer Test

    TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 74 F-30 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER TEST (continued) TEST PROCEDURE 1. Remove input power to the machine 2. Remove the left case side of the machine. 3. Remove the PC compartment door. 4. Locate plug J8 at the Control Board. See Figure F.10.
  • Page 75 F-31 TROUBLESHOOTING & REPAIR CURRENT TRANSDUCER TEST (continued) TABLE F.2 – CURRENT TRANSDUCER FEEDBACK VOLTAGE OUTPUT LOAD CURRENT EXPECTED TRANSDUCER FEEDBACK VOLTAGE POWER MIG 300 F-31...

  • Page 76: Power Mig Scrolling Dashes Test

    POWER MIG 300 SCROLLING DASHES TEST 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 77: Test Procedures

    F-33 TROUBLESHOOTING & REPAIR POWER MIG 300 SCROLLING DASHES TEST (continued) TEST PROCEDURES: For Machines with code 10952, 10958 and 11000. 1. Hold “select” switch up while powering up machine. 2. Release “select” switch when displays show “PrESSPin”. 3. Turn the right “encoder knob” until displays show “CLrAll”.

  • Page 78: Oscilloscope Waveforms

    F-34 TROUBLESHOOTING & REPAIR OSCILLOSCOPE WAVEFORMS MUST BE TAKEN IN MODE 201 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 20.0 V This is a typical DC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 2.00 milliseconds in time.
  • Page 79 F-35 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED MACHINE LOADED TO 250 AMPS AT 26 VDC 20.0 V This is a typical DC output voltage waveform generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 2.00 milliseconds in time.
  • Page 80 TROUBLESHOOTING & REPAIR MOTOR & GEAR BOX ASSEMBLY REMOVAL AND 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 81: Removal And Replacement Procedures

    F-37 TROUBLESHOOTING & REPAIR MOTOR & GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT (continued) REMOVAL PROCEDURE WARNING ELECTRIC SHOCK can kill. High voltage is present when input power is applied to the machine. 1. Disconnect main input power to the machine. 2.
  • Page 82 F-38 TROUBLESHOOTING & REPAIR MOTOR & GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. Bolt the wire drive assembly to the wire drive compartment. 2. Secure the wire drive compartment to the divider panel welded assembly. 3. Mount the motor/gearbox assembly to the wire drive assembly and attach with screws.
  • Page 83 F-39 F-39 TROUBLESHOOTING & REPAIR MOTOR & GEAR BOX ASSEMBLY REMOVAL AND REPLACEMENT (continued) FIGURE F.12 FOR CODES ABOVE 10958 POWER MIG 300...

  • Page 84: Output Rectifier Removal And Replacement

    TROUBLESHOOTING & REPAIR REMOVAL AND REPLACEMENT 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 85 F-41 TROUBLESHOOTING & REPAIR REMOVAL AND REPLACEMENT (continued) WARNING ELECTRIC SHOCK can kill. High voltage is present when input power is applied to the machine. NOTE: Cut cable ties as needed to improve access. See Figure F.13 for the following procedure. 1.
  • Page 86 F-42 TROUBLESHOOTING & REPAIR REMOVAL AND REPLACEMENT (continued) 9. Using a 3/8 in. wrench, remove the 4 nuts and lock washers holding the rectifier bracket to the machine base. 10. Clear the leads and carefully remove the output rectifier assembly. 11.
  • Page 87 TROUBLESHOOTING & REPAIR CHOPPER BOARD ASSEMBLY REMOVAL 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 88 F-44 TROUBLESHOOTING & REPAIR CHOPPER BOARD ASSEMBLY REMOVAL AND REPLACEMENT (continued) FIGURE F.14 – CHOPPER BOARD ASSEMBLY DETAILS REMOVAL PROCEDURE WARNING ELECTRIC SHOCK can kill. High voltage is present when input power is applied to the machine. NOTE: Cut cable ties as needed to improve access. See Figure F.14 for the following procedure.

  • Page 89: Chopper Board Assembly Removal And Replacement

    F-45 TROUBLESHOOTING & REPAIR CHOPPER BOARD ASSEMBLY REMOVAL AND REPLACEMENT (continued) REPLACEMENT PROCEDURE 1. Attach the chopper assembly brackets to the new chopper assembly. 2. Install the chopper board assembly. Fasten it to the machine base with 4 lock washers and nuts. 3.

  • Page 90: Main Transformer And Output Choke Removal And Replacement

    TROUBLESHOOTING & REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 91 F-47 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REMOVAL PROCEDURE WARNING ELECTRIC SHOCK can kill. High voltage is present when input power is applied to the machine. NOTE: Cut cable ties as needed to improve access. PREPARATION 1.
  • Page 92 F-48 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND LEAD DISCONNECTION 8. Using a phillips head screwdriver, remove fan lead X4 from fan relay terminal #1 and disconnect fan lead X3 from its in-line connector at the fan motor. Cut cable ties as needed pull the leads through the baffles to clear them.
  • Page 93 F-49 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND BACK SIDE (10) BACK SIDE REPLACEMENT (continued) FIGURE F.15 UNDER PANEL POWER MIG 300 F-49...

  • Page 94: Fan Motor Assembly Removal And Replacement

    TROUBLESHOOTING & REPAIR FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 95 F-51 TROUBLESHOOTING & REPAIR FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT FIGURE F.16 – FAN MOTOR ASSEMBLY REMOVAL REMOVAL PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the case side panels using a 3/8 in. nut- driver. 3. Cut the wire tie from around the fan motor leads. 4.

  • Page 96: Voltage & Current Calibration Procedure

    TROUBLESHOOTING & REPAIR VOLTAGE & CURRENT CALIBRATION 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 97 F-53 TROUBLESHOOTING & REPAIR VOLTAGE & CURRENT CALIBRATION PROCEDURE (continued) CALIBRATION CHECK (CODE 10562) The calibration of the Power Mig 300 can be checked using a resistive load bank with the Power Mig 300 in mode 200. Mode 200 is a con- stant current test mode.
  • Page 98 F-54 TROUBLESHOOTING & REPAIR VOLTAGE & CURRENT CALIBRATION PROCEDURE (continued) 9. Wait for the machine’s output to be automati- cally turned off and then back on. 10. Adjust the output control knob again if neces- sary to make the actual voltage output 20 volts +/- .5 volts.
  • Page 99 F-55 TROUBLESHOOTING & REPAIR VOLTAGE & CURRENT CALIBRATION PROCEDURE (continued) CALIBRATION CHECK (CODES 10952 AND UP) The calibration of the Power Mig 300 can be checked using a resistive load bank with the Power Mig 300 in mode 200. Mode 200 is a con- stant current test mode.
  • Page 100 F-56 TROUBLESHOOTING & REPAIR VOLTAGE & CURRENT CALIBRATION PROCEDURE (continued) 9. Wait for the machine’s output to be automati- cally turned off and then back on. 10. Adjust the output control knob again if neces- sary to make the actual voltage output 20 volts +/- .5 volts.

  • Page 101: Retest After Repair

    F-57 TROUBLESHOOTING & REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components. Input Volts/Hertz 230/60 AMPS...
  • Page 102 ELECTRICAL DIAGRAMS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS ............SECTION G WIRING DIAGRAM (CODE 10562 ONLY-G3852).

  • Page 103: Section E

    WIRING DIAGRAM - POWER MIG 300 CODE 10562 ONLY DISPLAY ENCODER MSP III CONTROL BOARD BOARD BOARD BOARD FLEX CIRCUIT SHIELDED CABLE CONTROL RECTIFIER SPOOL GUN FEEDER BOARD BOARD SHIELDED CABLE P.C. BOARD CONNECTION DETAIL H5 H2 H3 H4 (SHOWN CONNECTED FOR 230V) LINE...

  • Page 104: Electrical Diagrams

    WIRING DIAGRAM - POWER MIG 300 CODE 10952 ONLY DISPLAY MSP III CONTROL 3233 BOARD BOARD BOARD FLEX CIRCUIT SHIELDED CABLE CONTROL RECTIFIER SPOOL GUN FEEDER BOARD BOARD SHIELDED CABLE P.C. BOARD CONNECTION DETAIL H5 H2 H3 H4 (SHOWN CONNECTED FOR 230V) LINE SWITCH...
  • Page 105 WIRING DIAGRAM - POWER MIG 300 CODE 10958 AND 11000 ONLY DISPLAY MSP III CONTROL 3233 BOARD BOARD BOARD FLEX CIRCUIT SHIELDED CABLE CONTROL RECTIFIER SPOOL GUN FEEDER BOARD BOARD SHIELDED CABLE P.C. BOARD CONNECTION DETAIL H5 H2 H3 H4 (SHOWN CONNECTED FOR 230V)
  • Page 106 WIRING DIAGRAM - POWER MIG 300 CODE 11097 AND 11098 ONLY DISPLAY MSP III CONTROL 3233 BOARD BOARD BOARD FLEX CIRCUIT SHIELDED CABLE CONTROL RECTIFIER P.C. BOARD CONNECTION DETAIL H5 H2 H3 H4 (SHOWN CONNECTED FOR 230V) LINE SWITCH RECONNECT PANEL MSP III BOARD SE T SE LECT...
  • Page 107 SCHEMATIC - COMPLETE MACHINE - CODE 10958 AND 11000 ONLY G4315 ENGINEERING CONTROLLED CHANGE DETAIL: VARIOUS CORRECTIONS. MANUFACTURER: LOCATED ON FRONT OF MACHINE'S BASE MAIN TRANSFORMER LOCATED ON MACHINE'S BASE (STORAGE COMPARTMENT SIDE) (SHOWN CONNECTED RECTIFIER FOR 230V) LINE SWITCH RECONNECT PANEL 57 VAC 115 VAC...
  • Page 108 SCHEMATIC - COMPLETE MACHINE - CODE 11097 AND 11098 ONLY G4512 ENGINEERING CONTROLLED CHANGE DETAIL: RELEASED A.01 FROM X. MANUFACTURER: LOCATED ON FRONT OF MACHINE'S BASE MAIN TRANSFORMER (SHOWN CONNECTED FOR 230V) LINE SWITCH RECONNECT PANEL 57 VAC 115 VAC 30 VAC DIODE RECTIFIER FAN STAYS ON FOR 5 MIN AFTER...
  • Page 109 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD #1 - CODE 10562 - 11098 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER MIG 300...
  • Page 110 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD #2 - CODE 10562 - 11098 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER MIG 300...
  • Page 111 G-10 G-10 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD #3 - CODE 10562 - 11098 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER MIG 300...
  • Page 112 G-11 G-11 ELECTRICAL DIAGRAMS SCHEMATIC - DIGITAL CONTROL PC BOARD #4 - CODE 10562 - 11098 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER MIG 300...
  • Page 113 FRAME CONNECTION EARTH GROUND CONNECTION THIS SHEET CONTAINS PROPRIETARY INFORMATION OWNED BY THE LINCOLN ELECTRIC COMPANY AND IS NOT TO BE REPRODUCED, DISCLOSED OR USED WITHOUT THE EXPRESS WRITTEN PERMISSION OF THE LINCOLN ELECTRIC COMPANY, CLEVELAND, OHIO U.S.A. Digital Systems UNLESS OTHERWISE SPECIFIED TOLERANCE "X"...
  • Page 114 G-13 G-13 ELECTRICAL DIAGRAMS SCHEMATIC - CHOPPER BOARD - CODE 10562 - 11098 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER MIG 300...
  • Page 115 G-14 G-14 ELECTRICAL DIAGRAMS SCHEMATIC - MSP3 PC BOARD - CODE 10562 - 11098 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER MIG 300...
  • Page 116 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 117 G-16 G-16 ELECTRICAL DIAGRAMS SCHEMATIC - FEEDER PC BOARD BOARD - CODE 10562 - 11098 - SHEET 1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER MIG 300...
  • Page 118 G-17 G-17 ELECTRICAL DIAGRAMS SCHEMATIC - FEEDER PC BOARD BOARD - CODE 10562 - 11098 - SHEET 2 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER MIG 300...
  • Page 119 G-18 G-18 ELECTRICAL DIAGRAMS SCHEMATIC - SPOOL GUN PC BOARD - CODE 10562 - 11098 - SHEET 1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER MIG 300...
  • Page 120 G-19 G-19 ELECTRICAL DIAGRAMS SCHEMATIC - SPOOL GUN PC BOARD - CODE 10562 - 11098 - SHEET 2 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER MIG 300...
  • Page 121 G-20 G-20 ELECTRICAL DIAGRAMS SCHEMATIC - ENCODER PC BOARD - CODE 10562 ONLY NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER MIG 300...
  • Page 122 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 123 G-22 G-22 ELECTRICAL DIAGRAMS SCHEMATIC - DISPLAY PC BOARD - CODE 10562 - 11098 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. POWER MIG 300...
  • Page 124 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 125 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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