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Lincoln Electric SVM157-A manual

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Table of contents for the manual

  • Page 1

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC View Safety Info View Safety Info View Safety Info View Safety Info PO WER MIG ™ 200 SER VICE MANUAL SVM157-A October 2001 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can[...]

  • Page 2

    POWER MIG 200 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilate[...]

  • Page 3

    POWER MIG 200 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I sta[...]

  • Page 4

    POWER MIG 200 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufactur[...]

  • Page 5

    POWER MIG 200 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv SAFETY iv 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: S?[...]

  • Page 6

    v v POWER MIG 200 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Operation . . . . . . . . . . . . . . . . . . . .[...]

  • Page 7

    T ABLE OF CONTENTS - INST ALLA TION SECTION - POWER MIG 200 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 8

    INST ALLA TION A-2 POWER MIG 200 A-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 75°C Copper Wire 75°C Copper Wire Input Ampere in Conduit in Conduit Input V oltage/ Fuse or Breaker Rating On A WG (IEC) Sizes A WG (IEC) [...]

  • Page 9

    INST ALLA TION A-3 POWER MIG 200 A-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Read entire installation section before starting installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel shoul[...]

  • Page 10

    INST ALLA TION A-4 POWER MIG 200 A-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A.1 — Dual V oltage Machine Input Connections 3. The 208/230 volt 60 Hz model POWER MIG is shipped with a 7 ft. input cable and plug[...]

  • Page 11

    INST ALLA TION A-5 POWER MIG 200 A-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A.2 — T riple V oltage Machine Input Connections FIGURE A.3 — Receptacle Diagram CONNECT TO A SYSTEM GROUNDING WIRE. SEE THE UNITE[...]

  • Page 12

    INST ALLA TION A-6 POWER MIG 200 A-6 GUN AND CABLE INST ALLA TION The Magnum 250L gun and cable provided with the POWER MIG 200 is factory installed with a liner for .035-.045" (0.9-1.2 mm) electrode and an .035" (0.9 mm) contact tip. Be sure that the contact tip, liner , and drive rolls all match the size of the wire being used. T urn th[...]

  • Page 13

    T ABLE OF CONTENTS - OPERA TION SECTION - POWER MIG 200 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 14

    OPERA TION B-2 B-2 POWER MIG 200 Read entire Operation section before operating the POWER MIG 200. 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. FUMES AND GASES can be dangerous. • Keep your head out of fumes.[...]

  • Page 15

    OPERA TION B-3 B-3 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRODUCT DESCRIPTION The POWER MIG™ 200 is a complete semiautomatic DC voltage arc welding machine built to meet NEMA specifications. It combine[...]

  • Page 16

    OPERA TION B-4 B-4 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS 1. Turn of f the power source. 2. Release the pressure on the idle roll by swinging the adjustabl[...]

  • Page 17

    OPERA TION B-5 B-5 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FEEDING WIRE ELECTRODE When triggering, the electrode and drive mecha- nism are electrically “hot” relative to work and ground and remain “[...]

  • Page 18

    OPERA TION B-6 B-6 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A VOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun handling procedures: 1. Do not kink or pull c[...]

  • Page 19

    T ABLE OF CONTENTS - ACCESSORIES SECTION - POWER MIG 200 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 3/64 ” (1.2mm) Aluminum Feeding Kit (K1703-1) . . . . . . . . . . . .[...]

  • Page 20

    ACCESSORIES C-2 C-2 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DRIVE ROLL KITS Refer to T able C.1 for various drive roll kits that are available for the POWER MIG 200.The item in Bold is supplied standard w[...]

  • Page 21

    ACCESSORIES C-3 C-3 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAKING A WELD WITH THE SPOOL GUN ADAPTER KIT AND SPOOL GUN INST ALLED In either toggle switch position, closing either gun trigger will cause th[...]

  • Page 22

    NOTES C-4 C-4 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 23

    T ABLE OF CONTENTS - MAINTENANCE SECTION - POWER MIG 200 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 24

    MAINTENANCE D-2 D-2 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • T urn the input power off at the fus[...]

  • Page 25

    MAINTENANCE D-3 D-3 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 th[...]

  • Page 26

    MAINTENANCE D-4 D-4 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GUN HANDLE DISASSEMBL Y The internal parts of the gun handle may be inspected or serviced if necessary . The gun handle consists of two halves t[...]

  • Page 27

    MAINTENANCE D-5 D-5 POWER MIG 200 6 2 3 4 5 1 1. Case Front Assembly 2. Rear Panel Assembly 3. Center Assembly 4. Wire Drive Assembly 5. Base & Power Component Assembly 6. Covers Assembly Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return [...]

  • Page 28

    NOTES D-6 D-6 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 29

    T ABLE OF CONTENTS - THEOR Y OF OPERA TION SECTION - POWER MIG 200 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E Input Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2 Input Line V oltage . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 30

    THEOR Y OF OPERA TION E-2 E-2 POWER MIG 200 FIGURE E.2 – INPUT POWER CIRCUIT . INPUT LINE VOL T AGE, MAIN TRANSFORMER, VOL T AGE SELECT OR 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. A reconnect panel allows the user to configure the machin[...]

  • Page 31

    THEOR Y OF OPERA TION E-3 E-3 POWER MIG 200 OUTPUT RECTIFICA TION, CONT ACTOR 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. This DC welding voltage is filtered by the output capacitors and applied to the output terminals and welding [...]

  • Page 32

    THEOR Y OF OPERA TION E-4 E-4 POWER MIG 200 CONTROL BOARD, GUN TRIGGER AND WIRE DRIVE MOT OR 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 . The control board monitors the motor ’ s tach feedback signals and compares these to[...]

  • Page 33

    THEOR Y OF OPERA TION E-5 E-5 POWER MIG 200 PROTECTIVE DEVICES AND CIRCUITS THERMAL AND OVERLOAD PROTECTION The POWER MIG 200 has two built-in protective thermostats that respond to excessive temperatures. One is located on the main transformer . The other thermostat is located on the output rectifier heat sink assembly . They open the wire feed an[...]

  • Page 34

    NOTES E-6 E-6 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 35

    T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR SECTION - POWER MIG 200 T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F How to Use T roubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2 PC Board T roubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 36

    F-2 TROUBLESHOOTING AND REP AIR F-2 POWER MIG 200 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353. Service and Repair should only be performed by Lincoln Ele[...]

  • Page 37

    F-3 TROUBLESHOOTING AND REP AIR F-3 POWER MIG 200 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical con- nections. T o avoid problems when trou- bleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that th[...]

  • Page 38

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for tr[...]

  • Page 39

    When the gun trigger is activated and the wire feeds normally , but there is no open circuit voltage. OUTPUT PROBLEMS (Continued) TROUBLESHOOTING AND REP AIR Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circ[...]

  • Page 40

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT PROBLEMS (Continued) Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified component[...]

  • Page 41

    TROUBLESHOOTING AND REP AIR Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-7 F-7 POWER MIG 200 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs[...]

  • Page 42

    TROUBLESHOOTING AND REP AIR Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-8 F-8 POWER MIG 200 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs[...]

  • Page 43

    TROUBLESHOOTING AND REP AIR Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-9 F-9 POWER MIG 200 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs[...]

  • Page 44

    TROUBLESHOOTING AND REP AIR Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide – See Wiring Diagrams for location of specified components and for troubleshooting of specific circuits. F-10 F-10 POWER MIG 200 If for any reason you do not understand the test procedures or are unable to perform the tests/repai[...]

  • Page 45

    TROUBLESHOOTING AND REP AIR F-11 F-11 POWER MIG 200 TEST DESCRIPTION This test will determine if the correct voltages are being applied. a. Applied to the primary windings of the main transformers. b. Induced on the secondary and auxiliary windings of the main transformer . MA TERIALS NEEDED 3/8” Nutdriver 5/16” Nutdriver V olt-ohmmeter MAIN TR[...]

  • Page 46

    TEST PROCEDURE 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. 2. Remove the case top and side panels with a 3/8” nutdriver . 3. Remove the tool tray with a 5/16” nut driver . 4. Locate leads[...]

  • Page 47

    F-13 TROUBLESHOOTING AND REP AIR F-13 POWER MIG 200 MAIN TRANSFORMER TEST (continued) FIGURE F .2. – LEAD X1 FIGURE F .3. – LEAD X9 & X10 X1 X9 X10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 48

    TROUBLESHOOTING AND REP AIR F-14 F-14 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT VOL T AGE TEST POINTS EXPECTED VOL T AGE READING 1 1.9-13.0 V AC 14.1-15.2 V AC 16.2-17.5 V AC 18.4-19.7 V AC 20.5-22.0 [...]

  • Page 49

    TROUBLESHOOTING AND REP AIR F-15 F-15 POWER MIG 200 WIRE DRIVE MOT OR AND T ACHOMETER FEEDBACK TEST W ARNING This procedur e takes approximately 30 minutes to perform. 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 [...]

  • Page 50

    TROUBLESHOOTING AND REP AIR F-16 F-16 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRE DRIVE MOT OR AND T ACHOMETER FEEDBACK TEST (continued) FIGURE F .4. – PLUG J4 Black Tach J11 Black Arm White Arm Blue T[...]

  • Page 51

    TROUBLESHOOTING AND REP AIR F-17 F-17 POWER MIG 200 WIRE DRIVE MOT OR AND T ACHOMETER FEEDBACK TEST (continued) 5. Make the following voltage tests: a. T urn the machine OFF between each test. b. Carefully insert the meter probes into the lead side of plug J4. See Figure F .4. c. T urn the machine ON and pull the gun trigger to conduct the voltage [...]

  • Page 52

    TROUBLESHOOTING AND REP AIR F-18 F-18 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRE DRIVE MOT OR AND T ACHOMETER FEEDBACK TEST (continued) TEST FOR FEEDBACK VOL T AGE TO CONTROL BOARD 1. Disconnect the mai[...]

  • Page 53

    TROUBLESHOOTING AND REP AIR F-19 F-19 POWER MIG 200 OUTPUT BRIDGE RECTIFIER TEST Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauth[...]

  • Page 54

    TROUBLESHOOTING AND REP AIR F-20 F-20 POWER MIG 200 OUTPUT BRIDGE RECTIFIER TEST (continued) Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST PROCEDURE 1. Remove input power to the POWER MIG 200 machine. 2. Using the 3/8 ?[...]

  • Page 55

    TROUBLESHOOTING AND REP AIR F-21 F-21 POWER MIG 200 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 ob[...]

  • Page 56

    TROUBLESHOOTING AND REP AIR F-22 F-22 POWER MIG 200 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. See Figure F .7. See the Wiring Diagram. 4. Using the 7/16 ” wrench, remove one lead f[...]

  • Page 57

    TROUBLESHOOTING AND REP AIR F-23 F-23 POWER MIG 200 TYPICAL OUTPUT VOL T AGE W A VEFORM - MACHINE LOADED (MAX T AP “ G ” ) 10.0 V 5 ms 0 V olts 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 millisec[...]

  • Page 58

    TROUBLESHOOTING AND REP AIR F-24 F-24 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NORMAL OPEN CIRCUIT VOL T AGE W A VEFORM (MAX T AP “ G ” ) 20.0 V 1.0 ms 0 V olts This is a typical DC output voltage wave[...]

  • Page 59

    TROUBLESHOOTING AND REP AIR F-25 F-25 POWER MIG 200 ABNORMAL OUTPUT VOL T AGE W A VEFORM - MACHINE LOADED (MAX T AP “ G ” ) ONE OUTPUT DIODE NOT FUNCTIONING 20.0 V 5 ms 0 V olts This is NOT a typical DC output voltage waveform. One output diode is not func- tioning. Note the increased ripple con- tent. One diode was disconnected to simulate an [...]

  • Page 60

    TROUBLESHOOTING AND REP AIR F-26 F-26 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ABNORMAL OPEN CIRCUIT VOL T AGE OUTPUT CAP ACIT OR BANK NOT FUNCTIONING (MAX T AP “ G ” ) 20.0 V 5 ms 0 V olts This is NOT[...]

  • Page 61

    TROUBLESHOOTING AND REP AIR F-27 F-27 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC This procedur e takes approximately 20 minutes to perform. CONTROL BOARD REPLACEMENT Service and repair should only be perform[...]

  • Page 62

    TROUBLESHOOTING AND REP AIR F-28 F-28 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONTROL BOARD REPLACEMENT (continued) PROCEDURE 1. Remove power to the machine. 2. Using a 5/16 ” nutdriver , remove the thr[...]

  • Page 63

    F-29 TROUBLESHOOTING AND REP AIR F-29 POWER MIG 200 This procedur e takes approximately 50 minutes to perform. WIRE DRIVE MOT OR ASSEMBL Y 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 [...]

  • Page 64

    F-30 TROUBLESHOOTING AND REP AIR F-30 POWER MIG 200 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. See Figure F .10. 4. Using a 9/16 ” nut driver , remove the thick black positive lead located just abov[...]

  • Page 65

    F-31 TROUBLESHOOTING AND REP AIR F-31 POWER MIG 200 WIRE DRIVE MOT OR ASSEMBL Y REPLACEMENT (Continued) FIGURE F .10. - WIRE DRIVE HOSE & LEAD LOCA TION FIGURE F .1 1. - MOUNTING SCREW LOCA TIONS Gas Hose 9/16" Bolt 5/16" Sheet Metal Screws 5/16" Monuting Screws Return to Section TOC Return to Section TOC Return to Section TOC Re[...]

  • Page 66

    TROUBLESHOOTING AND REP AIR F-32 F-32 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1. Place the new wire drive assembly into its proper position. 2. Connect plug J4. 3. Maneuver assembly back into its original[...]

  • Page 67

    F-33 TROUBLESHOOTING AND REP AIR F-33 POWER MIG 200 This procedur e takes approximately 50 minutes to perform. 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 operato[...]

  • Page 68

    F-34 TROUBLESHOOTING AND REP AIR F-34 POWER MIG 200 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 t[...]

  • Page 69

    F-35 TROUBLESHOOTING AND REP AIR F-35 POWER MIG 200 OUTPUT DIODE BRIDGE RECTIFIER REPLACEMENT (CONTINUED) 5/16" Mounting Bracket Mounting Bolts 1/2" Rectifier Mounting Bolts Mounting Bracket FIGURE F .13. - OUTPUT DIODE BRIDGE RECTIFIER MOUNTING BRACKET Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TO[...]

  • Page 70

    F-36 NOTES F-36 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 71

    F-37 TROUBLESHOOTING AND REP AIR F-37 POWER MIG 200 This procedur e takes approximately 30 minutes to perform. OUTPUT CAP ACIT ORS 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[...]

  • Page 72

    F-38 TROUBLESHOOTING AND REP AIR F-38 POWER MIG 200 OUTPUT CAP ACIT ORS 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 ” wrench. Note was[...]

  • Page 73

    F-39 TROUBLESHOOTING AND REP AIR F-39 POWER MIG 200 OUTPUT CAP ACIT ORS REPLACEMENT (Continued) FIGURE F .15. - MOUNTING SCREW/BOL T LOCA TIONS } { 3/8" Nuts & Lock washers (3 places) Lead Mounting Bolts Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return [...]

  • Page 74

    F-40 NOTES F-40 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 75

    F-41 TROUBLESHOOTING AND REP AIR F-41 POWER MIG 200 This procedur e takes approximately 80 minutes to perform. 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 in[...]

  • Page 76

    F-42 TROUBLESHOOTING AND REP AIR F-42 POWER MIG 200 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, & 104C. See [...]

  • Page 77

    F-43 TROUBLESHOOTING AND REP AIR F-43 POWER MIG 200 MAIN TRANSFORMER REPLACEMENT (Continued) 15. Carefully maneuver the main transformer out the left side of the machine. NOTE: T wo 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 [...]

  • Page 78

    F-44 TROUBLESHOOTING AND REP AIR F-44 POWER MIG 200 MAIN TRANSFORMER REPLACEMENT (Continued) FIGURE F .18. - LEADS SWITCH LEADS FIGURE F .19. - LEAD 121 & 1 18 X8 X7 X6 X5 X4 X3 X2 Front - + 121 11 8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master[...]

  • Page 79

    F-45 TROUBLESHOOTING AND REP AIR F-45 POWER MIG 200 MAIN TRANSFORMER REPLACEMENT (Continued) 5/16" Nut REAR ACCESS P ANEL FIGURE F .20. - REAR ACCESS P ANEL FIGURE F .21. - REAR ACCESS P ANEL (CLOSE-UP) 230V 208V 4 L1 L2 Lead 1 18 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur[...]

  • Page 80

    F-46 NOTES F-46 POWER MIG 200 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 81

    F-47 TROUBLESHOOTING AND REP AIR F-47 POWER MIG 200 This procedur e takes approximately 45 minutes to perform. F AN 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 in[...]

  • Page 82

    F-48 TROUBLESHOOTING AND REP AIR F-48 POWER MIG 200 F AN 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. See[...]

  • Page 83

    F-49 TROUBLESHOOTING AND REP AIR F-49 POWER MIG 200 This procedur e takes approximately 40 minutes to perform. OUTPUT CONT ACT OR 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 [...]

  • Page 84

    F-50 TROUBLESHOOTING AND REP AIR F-50 POWER MIG 200 OUTPUT CONT ACT OR REPLACEMENT (Continued) PROCEDURE 1. Using a 5/16 ” nutdriver , remove the three screws securing the tool tray . 2. Locate the output contactor . See Figure F .23. 3. Using a 7/16 ” wrench, label and remove the two thick black leads at the top of the output contactor . Note [...]

  • Page 85

    F-51 TROUBLESHOOTING AND REP AIR F-51 POWER MIG 200 OUTPUT CONT ACT OR REPLACEMENT (Continued) 7/16" Mounting Bolts FIGURE F .24. - OUTPUT CONT ACTOR MOUNTING BOL TS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 86

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-52 TROUBLESHOOTING AND REP AIR F-52 POWER MIG 200 RETEST AFTER REP AIR INPUT IDLE AMPS AND W A TTS OPEN CIRCUIT VOL T AGE WIRE SPEED RANGE Input V olts/Herts 230/60 Maximum Idl[...]

  • Page 87

    POWER MIG 200 G-1 ELECTRICAL DIAGRAMS G-1 T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 88

    ELECTRICAL DIAGRAMS G-2 WIRING DIAGRAM - POW ER MIG 200 ( 208/23 0V) L11424 10-10- 2000 J1 CAVI TY NUM BER ING SE QU ENCE (COMPONEN T SID E OF P.C. BOARD) J2 NOTES: N.A. W ELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY “POSITIV[...]

  • Page 89

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-3 SCHEMA TIC - CONTROL PC BOARD G-3 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.[...]

  • Page 90

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 91

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information w[...]