Lincoln Electric SVM167-A service manual Perform the Output Contactor

Page 41

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F-5

 

TROUBLESHOOTING AND REPAIR

F-5

 

 

 

 

 

 

 

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 (Continued)

 

 

 

(continued from previous page)

3. Check the gun trigger leads.

 

 

 

 

 

 

Leads #324 to #325 should

 

 

 

 

 

 

have continuity (zero ohms)

 

 

 

 

 

 

when the gun trigger is activat-

 

 

 

 

 

 

ed. If not, the gun trigger or

 

 

 

 

 

 

cable may be faulty. Check or

 

 

 

 

 

 

replace.

 

 

 

 

 

 

4. If a spool gum option kit is

 

 

 

 

 

 

installed, check to make sure it

 

 

 

 

 

 

is set to the “normal” position if

 

 

 

 

 

 

using the POWER MIG® 215

 

 

 

 

 

 

built in wire feeder.

 

 

 

 

 

 

 

When the gun trigger is activated

1. Make sure the gun cable and

 

1. Check the output selector

and the wire feeds normally, but

work cables are connected

 

switch for proper operation and

there is no open circuit voltage.

properly and in good condition.

 

good connections.

 

 

 

 

2. Make sure the output selector

 

2. Perform the Output Contactor

 

 

 

switch is in a good condition

 

Test.

 

 

 

 

position and not between posi-

 

 

 

 

 

 

tions.

 

3. Perform the Output Bridge

 

 

 

 

 

Rectifier Test.

 

 

 

 

 

 

4. Perform the Main Transformer

 

 

 

 

 

Test.

 

 

 

 

 

 

5. Check the heavy current carry-

 

 

 

 

 

ing leads between the output

 

 

 

 

 

selector switch, output contac-

 

 

 

 

 

tor, output bridge rectifier, and

 

 

 

 

 

the output terminals for loose or

 

 

 

 

 

faulty connections.

See Wiring

 

 

 

 

 

Diagram.

 

 

 

 

 

 

 

 

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 Safety Depends on You Power MIGCalifornia Proposition 65 Warnings SafetyCan be dangerous Electric Shock can kill ARC Rays can burnIii Welding and Cutting Sparks can cause fire or explosionCylinder may explode if damaged Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation SECTION  Table of ContentsTechnical Specifications Power MIG InstallationUncrating the Power MIG Safety PrecautionsInstallation LocationOutput Polarity Connections AUXILIARY POWER RECEPTACLES GUN and Cable InstallationShielding GAS Cylinder may explode if damagedPower MIG Operation SECTION  Wear eye, ear and body protec- tion OPERATIONB-2Operation 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 Figure B.2b Making a WeldWire Feed Overload Protection Avoiding Wire Feeding ProblemsFAN Control Input Line Voltage VariationsPower MIG Accessories SECTION  Accessories Installed 3ACCESSORIESC-3Making a Weld with the Spool GUN Adapter KIT and Spool GUNPower MIG Maintenance SECTION  Maintenance Table D.1 Liner Removal and Replace MentEnglish Metric Description Size GUN Handle DisassemblyFigure D.2 Major Component Locations Power MIG Theory of Operation SECTION  Line SwitchTheory of Operation Figure E.2 Input Power CircuitFigure E.3 Control Circuits Output Rectification Contactor and Control BoardFigure E.4 Optional Circuits Control BOARD, GUN Trigger and Wire Drive MotorThermal and Overload Protection Wirefeed Overload ProtectionProtective Devices and Circuits Power MIG TROUBLESHOOTING AND REPAIR SECTION  How To Use Troubleshooting Guide Troubleshooting and RepairPC 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 Input Voltage Test Points Table F.1. Test PointsWire Drive Motor and Wire Speed Potentiometer Test White BlackVDC Test for Feedback Voltage to Control Board1109 a Power MIG Output Bridge Rectifier Test Output Bridge Rectifier Test Negative LeadContactor Test Figure F.7. Contactor Terminals and Leads Contactor TestTypical Output Voltage Waveform Machine Loaded MAX TAP G Volts 10.0Normal Open Circuit Voltage Waveform MAX TAP G Volts 20.0Machine Loaded to 180 Amps AT 16 VDC Scope Settings Volts 20.0 Description Control Board ReplacementProcedure Control Board ReplacementWire Drive Motor Assembly Replacement Wire Drive Motor Assembly Replacement Wire DriveBolt Gas Hose TOC Output Diode Bridge Rectifier Replacement Output Diode Bridge Rectifier Mounting Bracket Mounting Bolts Rectifier Power MIG Output Capacitors Replacement Figure F.14. Capacitor Bank Location Output Capacitors ReplacementLead Mounting Bolts Nuts Lock washers 3 places Power MIG Main Transformer Replacement 41TROUBLESHOOTING and Repair F-41See Figure F.17 Main Transformer ReplacementFigure F.17. Leads X9, X10, 104B,104C, & H1B ReplacementX2 X3 X4 X5 X6 X7 Lead Power MIG FAN BLADE/MOTOR Replacement Perform the Output Capacitor Bank Removal Procedure FAN BLADE/MOTOR ReplacementOutput Contactor Replacement Figure F.24 Output Contactor ReplacementMounting Bolts Retest After Repair Table of Contents Electrical Diagrams Section Electrical DiagramsPOWEr miG Power MIG 215 208/220/230VPower MIG 215 208/220/230V for Codes 11099 L12308 SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG1SchEmaTic cOmplETE machiNE cODE 11247 l12308 pG2 ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS ElEcTrical DiaGramS
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