Lincoln Electric SVM167-A These capacitors is toxic, Avoid contact with any portion, Your body

Page 42

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F-6

 

TROUBLESHOOTING AND REPAIR

 

 

F-6

 

 

 

 

 

 

 

 

 

 

 

 

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)

 

 

 

 

 

Output voltage and wire feed speed

1.

Remove the gun assembly.

If

 

1. Check for “shorts” in the trigger

is present when the gun trigger is

 

the problem is resolved, the gun

 

circuitry within the

POWER

NOT activated.

 

 

assembly

is faulty. Repair

or

 

MIG® 215 machine.

See the

 

 

 

 

replace.

If the problem is NOT

 

Wiring Diagram.

 

 

 

 

 

 

resolved, the fault is within the

 

 

 

 

 

 

 

 

 

POWER MIG® 215 machine.

 

 

2. The control board may be faulty.

 

 

 

 

 

The machines output is low. Welds

1.

Check the input voltage. Make

 

1. Check for loose or faulty con-

are “cold”. The

weld beads are

 

sure the machine is configured

 

nections on the heavy current

rounded or “humped” demonstrat-

 

properly for the input voltage

 

carrying

leads

inside the

ing poor wetting into the plate. The

 

being applied.

 

 

POWER MIG® 215.

See the

machine cannot obtain full rated

 

 

 

 

 

Wiring Diagram.

 

 

output of 200 amps at 22VDC.

2.

Make sure the settings for wire

 

 

 

 

 

 

 

 

 

feed speed and voltage are cor-

 

2. The output capacitors may be

 

 

 

 

rect for the process being used.

 

faulty. Check for loose connec-

 

 

 

 

 

 

 

 

tions at the capacitors. Also

 

 

 

3. Make sure the electrode polarity

 

check for

leaky

capacitors.

 

 

 

 

is correct for the process being

 

Replace if necessary.

 

 

 

 

 

used.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WARNING: The liquid electrolyte

 

 

 

4. Check the welding cables and

 

in these capacitors is toxic.

 

 

 

 

gun for loose or faulty connec-

 

Avoid contact with any portion of

 

 

 

 

tions.

 

 

 

your body.

 

 

 

 

 

 

 

 

 

 

 

3. The output selector switch may

 

 

 

 

 

 

 

 

be faulty. Check for good con-

 

 

 

 

 

 

 

 

tact and continuity (zero ohms)

 

 

 

 

 

 

 

 

through the switch. See the

 

 

 

 

 

 

 

 

Wiring Diagram.

 

 

 

 

 

 

 

 

 

 

4. Perform the Output Contactor

 

 

 

 

 

 

 

 

Test.

 

 

 

 

 

 

 

 

 

 

 

5. Perform the Output Bridge

 

 

 

 

 

 

 

 

Rectifier Test.

 

 

 

 

 

 

 

 

 

 

6. Perform the Main Transformer

 

 

 

 

 

 

 

 

Test.

 

 

 

 

 

 

The output voltage is continuous

1. The output contactor may be

1. Perform the Output Contactor

when the gun trigger is NOT activat-

 

stuck closed.

 

 

Test.

 

 

 

ed. The wire feed functions normal-

 

 

 

 

 

 

 

 

 

ly.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 dangerousWelding and Cutting Sparks can cause fire or explosion Cylinder may explode if damagedIii 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 Procedure for Changing Drive AND IDLE Roll Sets Wire Reel Loading READI-REELS, Spools or CoilsTo Start the Welder Feeding Wire Electrode Idle Roll Pressure SettingWire Drive Configuration 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 CircuitsWirefeed Overload Protection Protective Devices and CircuitsThermal 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 These capacitors is toxic Avoid contact with any portionYour body Function Problems Wire Speed Potentiometer Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Main Transformer Test Test DescriptionMaterials Needed Test Procedure ON/OFF Power Switch will be hot during these testsMain Transformer Test X10 Table F.1. Test Points Input Voltage Test PointsWire Drive Motor and Wire Speed Potentiometer Test Black WhiteTest for Feedback Voltage to Control Board 1109 aVDC 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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