Lincoln Electric SVM189-B service manual OUTPUT/FEEDING Problems

Page 59

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F-5

TROUBLESHOOTING & REPAIR

F-5

 

 

 

 

 

 

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

OUTPUT/FEEDING PROBLEMS

 

 

The machine has output, wire

1. Possible faulty fan motor.

1. Perform the Fan Motor Test.

feed, gas flow but NO fan.

2. Possible faulty Control P.C.

2. Check for continuity between

 

 

 

 

Board.

#6 to Fan or #1 to Fan on

 

 

 

 

Control P.C. Board. Replace.

 

 

 

The machine has output, gas

1. Possible bad drive motor.

1. Perform the Wire Drive Test.

flow and fan but does not have

2. Possible bad Control P.C.

2. If 3 - 30 vdc is not at the drive

wire drive.

 

 

Board.

motor check for OCV at the

 

 

 

 

 

 

 

board on pins 1 and 10 on J3.

 

 

 

If OCV is present possible

 

 

 

 

faulty Control P.C Board.

 

 

 

 

Replace. If OCV is not

 

 

 

 

present check continuity of

 

 

 

 

wires CAP- and CAP+.

 

 

 

 

No wire feed when gun trigger is

1. If the wire drive motor is

1. Perform the Wire Drive Test.

pulled. Fan runs, gas flows and

running, make sure that the

2. If wire drive test is OK, then

 

machine has correct open circuit

correct drive roll and wire

 

check for OCV at CAP- and

 

voltage. ( 33 vdc maximum) -

guide is installed in the

 

CAP+ on the control board. If

weld output.

 

machine.

 

correct voltage is present,

 

 

 

 

 

 

 

2. Check for clogged cable liner

possible faulty Control P.C.

 

 

 

or contact tip.

Board. Replace.

 

 

 

3. Check for proper size cable

3. If open circuit voltage is not

 

 

 

liner and contact tip.

present at CAP- and CAP+ on

 

 

 

control board check continuity

 

 

 

of leads.

 

 

 

 

 

 

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

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Contents SVM189-B Safety Depends on YouCalifornia Proposition 65 Warnings SafetyElectric Shock can kill ARC Rays can burn Iii Welding CuttingFor Electrically Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications InstallationTilting Safety PrecautionsSelect Suitable Location StackingIdentify and Locate Components Table of Contents Operation Section Wear eye, ear and body protec- tion OperationProduct Description Product Capabilities Common Welding AbbreviationsSee Figure B.2 Controls and SettingsSee Figure B.1 Drive Roll Tension Thumbscrew Turning See Figure B.3Number Part Number Wire Diameter Drive Roll Drive Roll Part Inner Wire GuideItems Needed for Flux Cored Welding Setting UP and Making a FLUX-CORED WeldMachine Load Wire SpoolConnect Leads and Cables on Figure B.9 025 MIG Conversion Kit K2526-1Shielding GAS Install Shielding GASConnect Leads and Cables on the Machine 11OPERATIONDo not Remove or Conceal Warning Labels 12OPERATIONFigure B.20 Compact Wire Welders Table of Contents Accessories Section K2377-1 Small Canvas Cover AccessoriesK2525-1 Spot Timer Kit K2532-1 Magnum 100SG Spool GunK520-Utility Cart K2275-1 Welding Cart Unpacking the Spool GUN Technical Specifications Magnum 100SG Spool GUN K2532-1Locating Spool GUN Components Features Safety PrecautionsFigure C.3 Assembly of Items Inside the Magnum Spool GUNSpool GUN Safety Precautions Welding MachinesRecommended Welding Machines Open the Machine Spool GUN / Wire Drive Selector Switch InstallationDisconnect input power from the machine 11.C. Connect harness P8 6-pin to board J5 6- pin Electrical Connections11.B. Connect P5 6-pin to harness J8 6-pin 544A 543A If Machine does have Optional Spot Timer .A. thru 12.DRE-ASSEMBLE Machine AS Follows Mounting the SwitchPreparing the Spool GUN ACCESSORIESC-13Disconnect input power to the machine Routine Welding Machine PreparationFigure C.5 Loading Aluminum WireFigure C.11 Figure C.17 Connecting the GUN to the Welding MachineTable of Contents Maintenance Section Routine Maintenance MaintenanceMaintenance Safety Precautions For Magnum 100L GUN GUN and Cable MaintenanceOverload Protection Liner trim length Changing LinerGUN Handle Parts Major Component Locations Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 General Description Theory of OperationInput Line VOLTAGE, FAN Motor & Main Transformer Figure E.3 Input Power CircuitsFigure E.4 Output Circuits Output CONTROL, Rectification & Voltage FeedbackFigure E.5 TRIGGER, GAS Solenoid & Wire Drive TRIGGER, GAS Solenoid and Wire DriveFigure E.6 SCR Operation SCR OperationElectronic Wire Drive Motor Protection Compact Wire Welders Table of Contents Troubleshooting & Repair HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board Troubleshooting Procedures Wiring Diagram OUTPUT/FEEDING Problems Feeding Problems Welding Problems Maintenance Section Issues Maintenance Section Cone or gas diffuser Materials Needed Case Cover Removal and Replacement ProcedureTest Description Figure F.1 Case Removal ProcedureGAS Solenoid Test GasSolenoid Leads Wire Drive Motor Test MOT-MOT+ Test ProcedureMain Transformer Test Secondary Test Procedure Secondary Lead Compact Wire Welders FAN Motor Test Figure F.5. Control Board Lead Locations Volts 10Volts 20ms Scope SettingsTypical Output Voltage Waveform Machine Loaded 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 Open Circuit Voltage Troubleshooting & Repair Retest After Repair 125 AMP UnitsWire Speed Range Retest After Repair 140 AMP UnitsTroubleshooting & Repair Retest After Repair 180 AMP Units Table of Contents Diagram Section COmpacT WirE WElDErS Wiring DiagramSpool GUN Interface Wiring Diagram Wiring Diagram Thermostat TMP FAN TS1 M20410-3 a COmpacT WirE WElDErSSchEmaTic cOmplETE machiNE m21240 C12 R1Feed R24
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