Lincoln Electric SVM103-C service manual Local Lincoln Electric Authorized, Field Service Facility

Page 53

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F-5

 

TROUBLESHOOTING

 

 

F-5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

 

RECOMMENDED

 

 

(SYMPTOMS)

MISADJUSTMENTS(S)

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

 

 

 

 

 

No weld output - auxiliary power

1. Check the open circuit voltage

1.

Check continuity (zero ohms) of

 

(230 - 115 VAC) operates normally -

(OCV) at the welder output termi-

 

lead W1A (black) from output

 

engine runs normally.

nals. If OCV is okay, go to Step

 

terminal to reactor (L1).

See the

 

 

 

2, below.

 

Wiring Diagram.

 

 

 

 

If OCV is not present at the welder

2.

Check continuity (zero ohms) of

 

 

 

output terminals, contact your

 

lead W2 (black) from output

 

 

 

local Lincoln Electric Authorized

 

terminal to stator winding. See

 

 

 

Field Service Facility.

 

the Wiring Diagram.

 

 

 

 

2. Check the welding cables,

3. Check continuity (zero ohms) of

 

 

 

clamps and electrode holder for

 

lead W1 (black) from reactor (L1)

 

 

 

loose or broken connections.

 

to stator winding.

See the

 

 

 

 

 

Wiring Diagram.

 

 

 

 

 

4.

Check reactor (L1) for continuity

 

 

 

 

 

of winding. See the Wiring Dia-

 

 

 

 

 

gram.

 

 

 

 

 

5.

Check the stator for continuity of

 

 

 

 

 

winding. See the Wiring Dia-

 

 

 

 

 

gram.

 

 

 

 

 

6.

Make certain the reactor and/or

 

 

 

 

 

stator are NOT grounded. Mini-

 

 

 

 

 

mum acceptable resistance to

 

 

 

 

 

ground is 500 K-ohms.

 

 

 

 

 

 

 

 

 

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 1-800-833-9353

POWER-ARC 4000

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Contents Safety Depends on You POWER-ARCCalifornia Proposition 65 Warnings SafetyElectric Shock can kill Welding Sparks can cause fire or explosion Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications POWER-ARC InstallationStoring Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service Cert. Kool Bore Spark ArresterWelding Cable Connections Electrical Output ConnectionsCable Size for 125 ampPlugs and HAND-HELD Equipment Auxiliary Power ReceptaclesMachine Grounding Circuit Breakers Premises WiringThese Devices Without POWER-ARC Table of Contents Operation Section Operation Safety InstructionsOperating Instructions General DescriptionDesign Features Advantages Operational Features and ControlsRecommended Applications Welding CapabilityGENERATOR/WELDER Controls Controls and Settings20 AMP, 120 Volt Duplex Receptacle Gasoline Engine ControlsStarting the Engine Engine OperationBefore Starting the Engine For a HOT Engine General Information To USE the Generator AS AN Auxiliary Power SupplyGenerator Operation Suggested Power Applications Running Watts Start-up Watts Table B.1 Generator Power ApplicationsWelding Operation Table B.2 Welding APPLICATIONS/ELECTRODE Selection Guide Welding GuidelinesOperation What Happens in the Arc? Correct Welding Position Correct Arc Length Use the following PracticeDo the following Butt WeldsPenetration Fillet WeldsVertical-Down Welding Vertical-Up WeldingWelding Sheet Metal Overhead WeldingHardfacing To Reduce Wear Cast Iron Plate Preparation Welding Cast IronLow Hydrogen Group Stable-Arc E7018 High-Speed Group AWS E6013Out-of-Position Group AWS E6011 Table of Contents Accessories Section Lincoln Electric Accessories AccessoriesOPTIONS/ACCESSORIES Table of Contents Maintenance Section Routine and Periodic Maintenance MaintenanceEngine Maintenance Engine AdjustmentsFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Table D.1 Engine Maintenance Schedule Do not attempt to polish slip rings while engine is running GENERATOR/WELDER MaintenanceFigure D.6. Major Component Locations Table of Contents Theory of Operation Section ENGINE, EXCITATION, Rotor and Stator Theory of OperationFigure E.3 Field Excitation and Auxiliary Power Rotor Field Feedback and Auxiliary PowerWeld Winding and Reactor Auxiliary Power Overcurrent ProtectionTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairOutput Problems TroubleshootingVice Facility Or contact your local LincolnElectric Authorized Field Ser Local Lincoln Electric Authorized Field Service FacilityTroubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment Rotor Voltage Test This procedure takes approximately 15 minutes to performTest Description Materials NeededRotor Voltage Test Test ProcedureRotor Resistance Test This procedure takes approximately 25 minutes to performRotor Resistance Test Figure F.3 Brushes Retained with Cable TIE This procedure takes approximately 20 minutes to perform Engine Throttle Adjustment TestOscilloscope Method Strobe-tach MethodFrequency Counter Method Wing NUT High Speed Stop Screw High Idle no Load Scope SettingsNormal Open Circuit Weld Voltage Waveform Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded to 125 Amps AT 23 VAC Typical Weld Output WaveformMachine Loaded Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal This procedure takes approximately 35 minutes to perform Capacitor AND/OR Diode Bridge Removal and ReplacementFigure F.8 Location and Discharging the Field Capacitor Procedure Capacitor Removal and REPLACE- MentFigure F.8A Field Diode Bridge Location Procedure Field Diode Bridge Removal and ReplacementInstructions STATOR/ROTOR Removal and ReplacementThis procedure takes approximately 3 hours to perform STATOR/ROTOR Removal and Replacement Troubleshooting & Repair Rotor Removal Procedure Figure F.12 Checking ROTOR-STATOR AIR GAP Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1Return to Section TOC Table of Contents Diagrams Section Wiring Diagram Power ARC DiagramsDIAGRAMSG-3 DIAGRAMSG-4 Dimension Print Power ARC Return to Section TOC SVM Error Reporting Form
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