Lincoln Electric SVM167-A service manual Weld bead is narrow or ropy Make sure the welding proce

Page 46

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F-10

 

TROUBLESHOOTING AND REPAIR

F-10

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

WELDING PROBLEMS

 

 

 

 

 

 

 

 

The weld bead is narrow or ropy.

1.

Make sure the welding proce-

 

1. Perform the Output Bridge Rectifier

May have porosity with the elec-

 

dures and electrode polarity are

 

Test.

 

trode stubbing into the plate.

 

correct for the process being

 

 

 

 

 

 

 

used.

 

2. The output capacitors may be faulty.

 

 

 

 

 

 

Check for loose connections at the

 

 

 

2.

Make certain the shielding gas is

 

capacitors. Also check

for leaky

 

 

 

 

correct and the flow is proper.

 

capacitors. Replace if necessary.

 

 

 

3.

Make sure the weld joint is not

 

WARNING: The liquid electrolyte in

 

 

 

 

“contaminated”.

 

these capacitors is toxic. Avoid con-

 

 

 

 

 

 

tact with any portion of your body.

 

 

 

 

 

 

The contact tip seizes in the gas dif-

1.

The tip is being over heated due

 

 

 

fuser.

 

 

to excessive current and/or high

 

 

 

 

 

 

 

duty cycle.

 

 

 

 

 

 

2.

A light application of high temper-

 

 

 

 

 

 

 

ature anti-seize lubricant may be

 

 

 

 

 

 

 

applied to the contact tip threads.

 

 

 

 

 

 

 

 

 

 

 

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 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 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.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 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
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