Lincoln Electric SVM167-A service manual Perform the Main Transformer

Page 40

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F-4

TROUBLESHOOTING AND REPAIR

F-4

Troubleshooting Guide – See Wiring Diagrams for location of specified

Observe Safety Guidelines

components and for troubleshooting of specific circuits.

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

Lincoln

Electric

damage is evident.

Electric authorized field service

Service Department 1-888-

facility.

935-3877.

The machine is dead--no open

1. Make certain the input power

1. Check the input power switch

circuit voltage and no wire feed

switch (S1) is in the “ON”

(S1). It may be faulty.

when the gun trigger is activated.

position.

2. Check for broken or missing

The cooling fan is not running.

2. Check the input voltage at the

wires at the reconnect panel.

machine. The input voltage

3. Perform the Main Transformer

must match the rating plate and

the reconnect panel.

Test.

3. Check for blown or missing

fuses in the input lines.

There is no open circuit voltage

1. Make sure the input voltage is

1. The baffle mounted rectifier

or wire feed when the gun trigger

correct

and

matches

the

bridge may be faulty. Check

is activated. The cooling fan is

nameplate rating and reconnect

and replace if necessary.

running.

panel configuration.

2. Perform the Main Transformer

2. One of the two thermostats may

Test.

be open due to machine

3. Check the thermostats and

overheating.

If the machine

operates

normally

after a

associated leads for loose or

faulty connections. See the

cooling off period then check for

Wiring Diagram.

proper

fan

operation

and

ventilation.

Make certain the

4. The

internal

triggering

machine’s

duty cycle is

not

circuit/plugs may be faulty. See

being exceeded.

the Wiring Diagram.

5. The control board may be faulty.

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 dangerousCylinder may explode if damaged Welding and Cutting Sparks can cause fire or explosionIii Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SECTION Installation Technical Specifications Power MIGSafety Precautions Uncrating the Power MIGInstallation LocationOutput Polarity Connections GUN and Cable Installation AUXILIARY POWER RECEPTACLESShielding GAS Cylinder may explode if damagedPower MIG Operation SECTION OPERATIONB-2 Wear eye, ear and body protec- tionOperation Wire Reel Loading READI-REELS, Spools or Coils Procedure for Changing Drive AND IDLE Roll SetsTo Start the Welder Idle Roll Pressure Setting Feeding Wire ElectrodeWire Drive Configuration Making a Weld Figure B.2bAvoiding Wire Feeding Problems Wire Feed Overload ProtectionFAN Control Input Line Voltage VariationsPower MIG Accessories SECTION Accessories 3ACCESSORIESC-3 InstalledMaking a Weld with the Spool GUN 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 CircuitsProtective Devices and Circuits Wirefeed Overload ProtectionThermal and Overload Protection 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 Avoid contact with any portion These capacitors is toxicYour body Function Problems Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Test Description Main Transformer TestMaterials Needed ON/OFF Power Switch will be hot during these tests Test ProcedureMain Transformer Test X10 Table F.1. Test Points Input Voltage Test PointsWire Drive Motor and Wire Speed Potentiometer Test Black White1109 a Test for Feedback Voltage to Control BoardVDC 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