Lincoln Electric SVM189-B service manual Wiring Diagram

Page 58

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F-4

TROUBLESHOOTING & REPAIR

F-4

 

 

 

 

 

 

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

Major physical or electrical

1. Contact your local Lincoln

1. Contact the Lincoln Electric

 

damage is evident.

 

Authorized Field Service

Service Dept.

 

 

 

Facility.

1-888-935-3877.

 

 

 

 

 

Machine is dead - no open

1. Make sure correct voltage is

1. Check input power switch

 

circuit voltage, wire feed, gas

applied to the machine.

(S1) it may be faulty. See

 

flow when trigger is pulled and

2. Make certain that the power

Wiring Diagram.

 

fan does not operate.

 

 

 

 

switch is in the “on” position.

2. Check lead connection and

 

 

 

 

 

 

3. Blown fuses in the input line.

correct function of circuit

 

 

 

breaker. See Wiring

 

 

 

Check circuit breaker on the

 

 

 

Diagram.

 

 

 

machine.

 

 

 

 

 

 

 

 

3. The Control P.C. Board may

 

 

 

 

be faulty

 

 

 

 

 

No weld output, wire feed, gas

1. The thermostat may be open

1. Check thermostat and

 

flow when the trigger is pulled.

due to machine overheating. If

associated leads for loose or

Fan does run.

 

machine operates normal after

broken connections. See

 

 

 

a cooling off period then check

wiring diagram.

 

 

 

for proper fan ventilation,

2. Remove main power supply to

 

 

remove any obstructions. Make

 

 

certain that the machine’s duty

the machine. With the gun

 

 

 

trigger pulled check for

 

 

 

cycle is not being exceeded.

 

 

 

continuity at pins 6 and 3 on

 

 

 

 

 

2. Gun trigger may be faulty.

plug J5 on the control board.

 

 

 

3. Perform the Transformer Test.

 

 

 

4. Check all heavy current

 

 

 

 

carrying leads. Check for loose

 

 

 

or broken connections at the

 

 

 

transformer, choke and

 

 

 

 

rectifier.

 

 

 

 

5. Make sure identity plug is not

 

 

 

missing on control board. See

 

 

 

Wiring Diagram.

 

 

 

 

6. Possible bad control board.

 

 

 

 

Replace.

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

COMPACT WIRE WELDERS

Image 58
Contents Safety Depends on You SVM189-BSafety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn For Electrically Welding CuttingIii Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical SpecificationsStacking Safety PrecautionsSelect Suitable Location TiltingIdentify and Locate Components Table of Contents Operation Section Common Welding Abbreviations OperationProduct Description Product Capabilities Wear eye, ear and body protec- tionSee Figure B.1 Controls and SettingsSee Figure B.2 See Figure B.3 Drive Roll Tension Thumbscrew TurningWire Diameter Drive Roll Drive Roll Part Inner Wire Guide Number Part NumberSetting UP and Making a FLUX-CORED Weld Items Needed for Flux Cored WeldingConnect Leads and Cables on Load Wire SpoolMachine Figure B.9 MIG Conversion Kit K2526-1 025Install Shielding GAS Shielding GAS11OPERATION Connect Leads and Cables on the Machine12OPERATION Do not Remove or Conceal Warning LabelsFigure B.20 Compact Wire Welders Table of Contents Accessories Section K2532-1 Magnum 100SG Spool Gun AccessoriesK2525-1 Spot Timer Kit K2377-1 Small Canvas CoverK520-Utility Cart K2275-1 Welding Cart Technical Specifications Magnum 100SG Spool GUN K2532-1 Unpacking the Spool GUNSafety Precautions Locating Spool GUN Components FeaturesAssembly of Items Inside the Magnum Spool GUN Figure C.3Recommended Welding Machines Safety Precautions Welding MachinesSpool GUN Disconnect input power from the machine Spool GUN / Wire Drive Selector Switch InstallationOpen the Machine 11.B. Connect P5 6-pin to harness J8 6-pin Electrical Connections11.C. Connect harness P8 6-pin to board J5 6- pin If Machine does have Optional Spot Timer .A. thru 12.D 544A 543AMounting the Switch RE-ASSEMBLE Machine AS FollowsRoutine Welding Machine Preparation ACCESSORIESC-13Disconnect input power to the machine Preparing the Spool GUNLoading Aluminum Wire Figure C.5Figure C.11 Connecting the GUN to the Welding Machine Figure C.17Table of Contents Maintenance Section Maintenance Safety Precautions MaintenanceRoutine Maintenance Overload Protection GUN and Cable MaintenanceFor Magnum 100L GUN GUN Handle Parts Changing LinerLiner trim length Major Component Locations Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation General DescriptionFigure E.3 Input Power Circuits Input Line VOLTAGE, FAN Motor & Main TransformerOutput CONTROL, Rectification & Voltage Feedback Figure E.4 Output CircuitsTRIGGER, GAS Solenoid and Wire Drive Figure E.5 TRIGGER, GAS Solenoid & Wire DriveSCR Operation Figure E.6 SCR OperationElectronic Wire Drive Motor Protection Compact Wire Welders Table of Contents Troubleshooting & Repair Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Wiring Diagram OUTPUT/FEEDING Problems Feeding Problems Welding Problems Maintenance Section Issues Maintenance Section Cone or gas diffuser Test Description Case Cover Removal and Replacement ProcedureMaterials Needed Procedure Figure F.1 Case RemovalGAS Solenoid Test GasSolenoid Leads Wire Drive Motor Test Test Procedure MOT-MOT+Main Transformer Test Secondary Test Procedure Secondary Lead Compact Wire Welders FAN Motor Test Figure F.5. Control Board Lead Locations Typical Output Voltage Waveform Machine Loaded Scope SettingsVolts 10Volts 20ms Abnormal Open Circuit Voltage Waveform Control Board Removal and Replacement Procedure See Figure F.7 Nameplate Control Knob Compact Wire Welders Power Module Removal and Replacement Procedure Viewed from Rear of Machine Center Panel PolarityPanel CenterPanelScrews OutputStuds Compact Wire Welders Misc. Hand Tools Dow Corning Fine Steel Wool See Figure F.12 Dow Corning Figure F.12 DOW Corning Application Areas Transformer Compact Wire Welders Wire Drive Motor Removal and Replacement Procedure Lincolnelectric Phillips Mounting Screws Compact Wire Welders FAN Motor Assembly Removal and Replacement Procedure Viewed from Rear of Machine Center Panel CenterPanelScrews Locking Tabs Fan Retest After Repair 140 AMP Units Troubleshooting & Repair Retest After Repair 125 AMP UnitsWire Speed Range Open Circuit VoltageTroubleshooting & Repair Retest After Repair 180 AMP Units Table of Contents Diagram Section Wiring Diagram COmpacT WirE WElDErSSpool GUN Interface Wiring Diagram Wiring Diagram M20410-3 a COmpacT WirE WElDErS Thermostat TMP FAN TS1SchEmaTic cOmplETE machiNE m21240 C12 R1Feed R24