Lincoln Electric SVM189-B service manual Feeding Problems

Page 60

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F-6

TROUBLESHOOTING & REPAIR

F-6

 

 

 

 

 

 

Observe Safety Guidelines detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

 

 

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

FEEDING PROBLEMS

 

 

The machine stops feeding wire

1. Check for adequate wire

1. Check the motor armature

 

with trigger pulled. Re-trigger

supply.

current. If high (over 2.5

 

and machine starts feeding wire

2. Check for mechanical

amps) and there are no

 

again.

restrictions in the wire feeding

restrictions in the wire feeding

 

 

path, then the motor or gear

 

 

path. The gun may be clogged.

 

 

box may be faulty. Replace.

 

 

 

 

 

 

 

3. Make sure the gun liner and

2. If motor armature current is

 

 

 

tip are correct for the wire size

 

 

 

below 2.5 amps. The Control

 

 

being used.

 

 

P.C. board may be faulty.

 

 

 

 

 

 

 

4. Check spindle for ease of

Replace.

 

 

 

 

 

 

 

rotation.

 

 

 

 

 

1. Wire drive speed stays on one

1. Possible faulty drive motor.

1. Remove main supply power to

 

speed. No wire speed control.

2. Possible faulty Control board.

the machine. Disconnect plug

 

 

 

J3 from the control board.

 

 

 

 

Test the resistance from lead

 

 

 

MOT- in the harness plug to

 

 

 

 

the wire feed motor case. If

 

 

 

 

resistance is below 500,000

 

 

 

 

ohms, replace the drive

 

 

 

 

motor.

 

 

 

 

2. If no voltage charge is seen

 

 

 

 

on MOT+ and MOT- when

 

 

 

 

turning wire speed

 

 

 

 

potentiometer, the Control

 

 

 

 

P.C. Board may be faulty.

 

 

 

 

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

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Contents Safety Depends on You SVM189-BSafety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn Welding Cutting For ElectricallyIii Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical SpecificationsSafety Precautions Select Suitable LocationStacking TiltingIdentify and Locate Components Table of Contents Operation Section Operation Product Description Product CapabilitiesCommon Welding Abbreviations Wear eye, ear and body protec- tionControls and Settings See Figure B.1See 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 WeldingLoad Wire Spool Connect Leads and Cables onMachine 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 Accessories K2525-1 Spot Timer KitK2532-1 Magnum 100SG Spool Gun 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.3Safety Precautions Welding Machines Recommended Welding MachinesSpool GUN Spool GUN / Wire Drive Selector Switch Installation Disconnect input power from the machineOpen the Machine Electrical Connections 11.B. Connect P5 6-pin to harness J8 6-pin11.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 FollowsACCESSORIESC-13 Disconnect input power to the machineRoutine Welding Machine Preparation 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 Maintenance Safety PrecautionsRoutine Maintenance GUN and Cable Maintenance Overload ProtectionFor Magnum 100L GUN Changing Liner GUN Handle PartsLiner 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 Case Cover Removal and Replacement Procedure Test DescriptionMaterials 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 Scope Settings Typical Output Voltage Waveform Machine LoadedVolts 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 Troubleshooting & Repair Retest After Repair 125 AMP Units Wire Speed RangeRetest After Repair 140 AMP Units 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
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