Lincoln Electric SVM167-A Troubleshooting and Repair, How To Use Troubleshooting Guide

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F-2

TROUBLESHOOTING AND REPAIR

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How To Use Troubleshooting Guide

WARNING

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 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.

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This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three step procedure below.

Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machinery may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped according to: feeding problems and function problems.

Step 2. PERFORM EXTERNAL TESTS. The second column labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap- around cover.

Step 3. PERFORM COMPONENT TESTS. The last column labeled “RECOMMENDED COURSE OF ACTION” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either bad or good. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.

All the necessary test specifications and repair procedures are described in detail following the troubleshooting guide. All electrical test points, terminal strips, junctions, etc., can be found on the electrical wiring diagrams and schematics in the Electrical Diagram Section.

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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.

POWER MIG® 215

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Contents Power MIG Safety Depends on YouSafety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burn Can be dangerousIii Welding and Cutting Sparks can cause fire or explosionCylinder may explode if damaged Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SECTION Installation Technical Specifications Power MIGInstallation Safety PrecautionsUncrating the Power MIG LocationOutput Polarity Connections Shielding GAS GUN and Cable InstallationAUXILIARY POWER RECEPTACLES Cylinder may explode if damagedPower MIG Operation SECTION  OPERATIONB-2 Wear eye, ear and body protec- tionOperation To Start the Welder Procedure for Changing Drive AND IDLE Roll SetsWire Reel Loading READI-REELS, Spools or Coils Wire Drive Configuration Feeding Wire ElectrodeIdle Roll Pressure Setting Making a Weld Figure B.2bFAN Control Avoiding Wire Feeding ProblemsWire Feed Overload Protection Input Line Voltage VariationsPower MIG Accessories SECTION  Accessories Making a Weld with the Spool GUN 3ACCESSORIESC-3Installed Adapter KIT and Spool GUNPower MIG Maintenance SECTION  Maintenance Liner Removal and Replace Ment Table D.1GUN Handle Disassembly English Metric Description SizeFigure D.2 Major Component Locations Power MIG Line Switch Theory of Operation SECTION Figure E.2 Input Power Circuit Theory of OperationOutput Rectification Contactor and Control Board Figure E.3 Control CircuitsControl BOARD, GUN Trigger and Wire Drive Motor Figure E.4 Optional CircuitsThermal and Overload Protection Wirefeed Overload ProtectionProtective Devices and Circuits Power MIG TROUBLESHOOTING AND REPAIR SECTION  Troubleshooting and Repair How To Use Troubleshooting GuidePC Board Troubleshooting Procedures Perform the Main Transformer Perform the Output Contactor Your body These capacitors is toxicAvoid contact with any portion Function Problems Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Materials Needed Main Transformer TestTest Description Main Transformer Test Test ProcedureON/OFF Power Switch will be hot during these tests X10 Table F.1. Test Points Input Voltage Test PointsWire Drive Motor and Wire Speed Potentiometer Test Black WhiteVDC Test for Feedback Voltage to Control Board1109 a Power MIG Output Bridge Rectifier Test Negative Lead Output Bridge Rectifier TestContactor Test Contactor Test Figure F.7. Contactor Terminals and LeadsVolts 10.0 Typical Output Voltage Waveform Machine Loaded MAX TAP GVolts 20.0 Normal Open Circuit Voltage Waveform MAX TAP GMachine Loaded to 180 Amps AT 16 VDC Scope Settings Volts 20.0 Control Board Replacement DescriptionControl Board Replacement ProcedureWire Drive Motor Assembly Replacement Wire Drive Wire Drive Motor Assembly ReplacementBolt Gas Hose TOC Output Diode Bridge Rectifier Replacement Output Diode Bridge Rectifier Mounting Bracket Mounting Bolts Rectifier Power MIG Output Capacitors Replacement Output Capacitors Replacement Figure F.14. Capacitor Bank LocationLead Mounting Bolts Nuts Lock washers 3 places Power MIG 41TROUBLESHOOTING and Repair F-41 Main Transformer ReplacementMain Transformer Replacement See Figure F.17Replacement Figure F.17. Leads X9, X10, 104B,104C, & H1BX2 X3 X4 X5 X6 X7 Lead Power MIG FAN BLADE/MOTOR Replacement FAN BLADE/MOTOR Replacement Perform the Output Capacitor Bank Removal ProcedureOutput Contactor Replacement Output Contactor Replacement Figure F.24Mounting Bolts Retest After Repair Electrical Diagrams Table of Contents Electrical Diagrams SectionPower MIG 215 208/220/230V POWEr miGPower MIG 215 208/220/230V for Codes 11099 SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG1 L12308SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG2 ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS
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