Lincoln Electric SVM114-C Troubleshooting and Repair, PC Board Troubleshooting Procedures

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TROUBLESHOOTING AND REPAIR

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PC BOARD TROUBLESHOOTING PROCEDURES

 

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WARNING

ELECTRIC SHOCK can kill.

•Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.

CAUTION

Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure:

1.Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2.Check for loose connections at the PC board to assure that the PC board is properly connected.

3.If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

PC board can be damaged by static electricity.

-Remove the PC board from the static-shielding bag and place it directly into the equipment. Don’t set the PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can’t be installed immediately, put it back in the static-shield- ing bag.

-If the PC board uses protective shorting jumpers, don’t remove them until installation is complete.

-If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- er failure analysis.

4.Test the machine to determine if the failure symptom has been corrected by the replacement PC board.

NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

5.Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.

a.If the original problem does not reappear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.

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ATTENTION

Static-Sensitive

Devices

Handle only at

Static-Safe

Workstations

-Remove your body’s static charge before opening the static- shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.

-If you don’t have a wrist strap, touch an un-painted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.

b. If the original problem is recreated by the substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.

6.Always indicate that this procedure was followed when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

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-Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.

LN-25™

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Contents Semiautomatic Wire Feeder California Proposition 65 Warnings SafetyCan be dangerous Electric Shock can killFumes and Gases Iii 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 LN-25 InstallationWire Feed Speed CurrentrentPower Source Connection Safety PrecautionsGUN Cable Connection to Feeder INVERTEC, CV300 and Other Newer Lincoln Power SourcesWith CV Adapter For GMA GUN and CablesWeld Cable Connection Wire Feed Drive Roll and Guide Tube KitsElectrode Cable Connection Work Cable ConnectionLN-25 Operation Section Read and Understand Entire Section Before Operating Machine OperationWelding Capability Wire Feed Mode Switch Electrode Polarity SwitchWire Speed Dial and Range Switch LN-25 Instruments ControlsWork Clip Lead GAS Post PRE-FLOW Timers OptionalAWG Remote ARC Voltage Control OptionalLoading Electrode Sequence of OperationMounting 22 to 30 LB READI-REELCOILS Mounting 10 to 30 LB SpoolsIdle Roll Pressure Setting Loading Wire DriveGrooves READI-REEL Inside Cage Wires 6OPERATIONB-6Setting Constant Wire Feed Speed CV Mode Presetting Wire Feed SpeedSetting ARC Sensing Wire Feed Speed CC Mode Minimum Arc VoltsMaking a Weld Figure B.4 VV CC Wire Speed SettingCylinder may explode if damaged Procedure AT END of CoilWelding Motor Overload Shutdown Circuit Protection and Automatic ShutdownOvervoltage Shutdown Accessories Section C Accessories SectionLN-25 Option Chart AccessoriesHow to use Table C.1 Table C.1GAS Solenoid KIT K430-2 for Codes Optional AccessoriesK434-1 GAS Flow Timer KIT K432 Remote Control Cable Assembly K433 Power Source Remote BOXRemote Output Control Options and Control Cable Assemblies LN-25 Contactor KIT K443-1 for CodesK625, K626, K627 Remote Control Cable Assembly K439 Remote Extension Cable AssemblyK624-1 42V Remote Output Control Module K444, K444-1 or K444-2 Remote Voltage Control KITTo GUN Switch Connect Leads to Pins a and C Connector Must be Insulated in this AreaStyle a DIA. HoleMaintenance Section Adjusting Speed Sensor Module MaintenanceRoutine Maintenance Calibration of LN-25 Wire Speed Dial LN-25 Theory of Operation Section Figure E.1 Theory of Operation Block DiagramTheory of Operation Input Power CircuitGeneral Description Control Circuit OperationTrigger Circuit Feedback and Control CircuitsContactor Optional CircuitsGAS Solenoid Later ModelsControl PC Board Fuses Protective Devices Circuits LN-25 Troubleshooting and Repair Section HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Troubleshooting and RepairFeeding Problems Feeding Problems Hall Effect Test Description GAS Solenoid Valve and Solenoid PC Board TestMaterials Needed For Codes below 10500 onlyScrew Wire Reel Retaining Collar Test ProcedureCase Door GAS Solenoid ValveFigure F.2 Solenoid Leads Troubleshooting and Repair 512 GAS Solenoid Valve and Solenoid PC Board Test624A 621 J11 PC Board for K430 GAS Solenoid KITLN-25 For Codes Above 10500 only GAS Solenoid Valve and Control PC Board TestFigure F.5 Control BOX Cover Removal For Codes Above 10500 onlyFigure F.6. Solenoid Leads Solenoid LeadsControl PC Board Solenoid Circuitry Test Figure F.7. Applied Voltage Polarity667 555 691 621 500 512 690 G3425LN-25 Hall Effect Module Test 539 G1757 Hall Effect Module TestG2196 539 541 500 Figure F.11 Control PC Board Codes Above LN-25 Wire Drive Motor Test Drive Motor Lead IN-LINE Connector Hall Effect Module Contactor & Contactor PC Board Test Contactor & Contactor PC Board Test Contactor Test ProcedureContactor Coil Leads S20963667 28TROUBLESHOOTING and Repair F-28Contactor PC Board Test J14 LN-25 Tools Required Contactor PC Board ReplacementRepair Procedure Contactor PC Board Replacement33TROUBLESHOOTING and Repair F-33 Figure F.17 Control PC Board Replacement Figure F.21. Control PC Board Codes 9812 and below Control PC Board ReplacementJ14 Figure F.22. Plug Locations for L12253- Control BoardFigure F.24. Control Board Replacement PC Board Screw For Codes below Contactor ReplacementContactor Replacement 40TROUBLESHOOTING and Repair F-40For Codes Above Figure F.26 Phillips Head Screwdriver Wrench Pliers Purge Switch Leads Solenoid Plug J11 Present ReplacementGAS Solenoid Valve AND/OR Solenoid PC Board if GAS SolenoidFigure F.29. Solenoid Assembly Wiring Codes 9812 and below Figure F.31. GAS Solenoid Assembly for Earlier Codes Phillips Head Screwdriver Wrench Slot Head Screwdriver Drive Motor and Gearbox Replacement and Access to 48TROUBLESHOOTING and Repair F-48Hall Effect Module Mylar Insulation Electrode CableG1757 Figure F.34. Drive Motor Replacement Retest After Repair LN-25 Table of Contents Electrical Diagrams Section Electrical DiagramsOptional 42 Volt Remote Output Control Wiring Diagram Above Code 11140 G4679Wiring Diagram Code 10556 Thru 10500 L10925 Wiring Diagram Code 10100 Thru 10500 L9644 Wiring Diagram below Code 9900 L7545 LN-25 Across the ARC Model Schematic Complete Machine Codes Above 11140 G5366Schematic Complete Machine below Code 9900 only G1833 Schematic Control PC BD Above Code 11140 G4616-5 Schematic Control PC BD Code 10556 Thru 10558 G3424-3 Schematic Control PC BD Code 10100 Thru 10500 G2194 L12253-3 PC Board Assembly Control Abovr Code 11140 L12253-3L12253 G3425 PC Board Assembly Control Code 10556 Thru 10558 G3425-3PC Board Assembly Control Code 10100 Thru 10500 G2196-1 LN-25 Control PC Board Assembly Control below Code 9900 G1757-6Contactor Schematic Contactor PC BD Above Code 10500 M10965Schematic Contactor PC BD Code 10100 Thru 10500 M17621 Electrical Diagrams Electrical Diagrams L10863 PC Board Assembly Contactor Above Code 10500 L10863-1PC Board Assembly Contactor Code 10100 Thru 10500 L9670-1 PC Board Assembly Contactor below Code 9900 L9185-2
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