Lincoln Electric SVM167-A service manual Wire Speed Potentiometer Test

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F-8		TROUBLESHOOTING AND REPAIR				F-8

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

WIRE FEEDING PROBLEMS

Rough wire feeding or the wire will 1. The gun cable may be kinked or not feed but the drive rolls are turn- twisted.

ing.

2.Check the drive roll tension and the position of the grooves.

3.Electrode may be rusted or dirty.

4.The contact tip may be damaged or not the correct size.

5.Check the wire spindle for ease of rotation.

6.Make certain the gun is pushed all the way into the gun mount and properly seated.

No control of wire feed speed.	1.	The wire feed speed control may	1.	The wire speed control potentiometer
Other machine functions are nor-		be dirty. Rotate several times		may be	faulty.	Check or replace.
mal.		and check if the problem is		Normal	potentiometer resistance is
		resolved.		10K ohms.
			2.	Perform the Wire Drive Motor and
				Wire Speed Potentiometer Test.
			3.	The control board may be faulty.

There is no wire feed when the gun	1.	Check for adequate wire supply.	1.	Perform the Wire Drive Motor and
trigger is activated. Normal open				Wire Speed Potentiometer Test.
circuit weld voltage is present and	2.	If the drive rolls are turning,
the gas solenoid functions normally.		check for a mechanical restriction	2.	The wire speed control potentiometer
		in the wire feed path.		may be	faulty.	Check or replace.
				Normal	potentiometer resistance is
	3.	The gun liner may be clogged.		10K ohms.
		Check or replace.
			3.	The control board may be faulty.
	4.	If the drive rolls are not turning
		when the gun trigger is activated,
		contact your local Lincoln Electric
		Authorized Field Service Facility.

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 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 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.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 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