Lincoln Electric SVM167-A service manual Function Problems

Page 43

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F-7

 

TROUBLESHOOTING AND REPAIR

F-7

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

FUNCTION PROBLEMS

 

 

 

 

 

 

 

 

 

There is no gas flow when the gun

1. If a spool gun adapter is installed,

 

1. Check plug J1 on the control board

trigger is activated . The wire feeds

make certain the toggle switch in

 

for loose or faulty connections. See

and the arc voltage is present.

the spool gun kit in the correct

 

Wiring Diagram.

 

 

 

 

position.

 

 

 

 

 

 

 

 

 

 

2. Check the gas solenoid by discon-

 

 

 

2. If a spool gun adapter is NOT

 

necting it from leads #108A and

 

 

 

installed, make certain

the

 

#116A&B. Apply a 12VDC external

 

 

 

jumper plug is installed in J5.

 

supply to the solenoid.

If the sole-

 

 

 

See the Wiring Diagram.

 

 

noid does NOT activate then it may

 

 

 

 

 

 

be faulty. Replace.

 

 

 

 

3. Check the gas source and hoses

 

 

 

 

 

 

for kinks or leaks.

 

 

 

 

 

 

 

 

The machine stops feeding wire

1. Check for a mechanical restric-

 

1. Check the motor armature current.

while welding.

When the gun trig-

tion in the wire feed path.

The

 

Normal armature current is 2.0 to 2.7

ger is released and pulled again,

gun may be clogged.

 

 

amps maximum. If the motor arma-

the wire feed starts.

 

 

 

ture current is normal, and the motor

 

 

 

2. Make sure the drive rolls and

 

continues to shut-off, the control

 

 

 

guide plates are clean and are

 

board may be faulty. Replace.

 

 

 

the correct size.

 

 

 

 

 

 

 

 

 

 

2. If the motor armature current is high

 

 

 

3. Check the spindle for ease of

 

(over 2.7 amps) and there are NO

 

 

 

rotation.

 

 

restrictions in the wire feeding path

 

 

 

 

 

 

then the motor or gearbox may be

 

 

 

 

 

 

defective. 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

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 burnCylinder may explode if damaged Welding and Cutting Sparks can cause fire or explosionIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation SECTION  Table of ContentsTechnical Specifications Power MIG InstallationLocation Safety PrecautionsUncrating the Power MIG InstallationOutput Polarity Connections Cylinder may explode if damaged GUN and Cable InstallationAUXILIARY POWER RECEPTACLES Shielding GASPower MIG Operation SECTION  Wear eye, ear and body protec- tion OPERATIONB-2Operation 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 Figure B.2b Making a WeldInput Line Voltage Variations Avoiding Wire Feeding ProblemsWire Feed Overload Protection FAN ControlPower MIG Accessories SECTION  Accessories Adapter KIT and Spool GUN 3ACCESSORIESC-3Installed Making a Weld with the 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 MotorProtective Devices and Circuits Wirefeed Overload ProtectionThermal and Overload Protection 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 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 Input Voltage Test Points Table F.1. Test PointsWire Drive Motor and Wire Speed Potentiometer Test White Black1109 a Test for Feedback Voltage to Control BoardVDC 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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