Lincoln Electric SVM 117-A service manual Main Transformer

Page 56

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F-3

TROUBLESHOOTING & REPAIR

F-3

 

 

 

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

 

 

PROBLEMS

 

 

POSSIBLE AREAS OF

 

 

RECOMMENDED

(SYMPTOMS)

 

 

MISADJUSTMENTS(S)

 

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Major Physical or Electrical Damage

1.

Contact

your

local Lincoln

1.

Contact

The Lincoln Electric

 

is Evident

 

 

Electric

Authorized

Field

 

Service Dept. (216) 383-2531 or

 

 

 

 

Service Facility.

 

 

 

1-800-833-9353 (WELD)

 

 

 

 

 

 

Machine is dead- No Open Circuit

1.

Make certain that the input

1. Check input power switch (S1).

 

Voltage output and No Wire Feed

 

power switch is in the "ON" posi-

 

It may be faulty.

 

when gun trigger is pulled.

 

 

tion.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. Check for lose or broken wires

 

 

 

2. Check the input voltage at the

 

at the reconnect panel.

 

 

 

 

machine.

Input

voltage

must

 

 

 

 

 

 

 

match the rating plate and the

3.

Perform

Main Transformer

 

 

 

 

reconnect panel.

 

 

 

Test.

 

 

 

 

3.

Blown or missing fuses in the

4. Check

the thermostats and

 

 

 

 

input line.

 

 

 

 

associated leads for loose or

 

 

 

 

 

 

 

 

 

broken connections. See wiring

 

 

 

4.

The thermostats may be open

 

diagram.

 

 

 

 

due to machine overheating. If

 

 

 

 

 

 

 

machine operates normally after

5. The control board may be faulty.

 

 

 

 

a cooling off period then check

 

Replace.

 

 

 

 

for proper fan operation and

 

 

 

 

 

 

 

ventilation. Make certain that

 

 

 

 

 

 

 

the machine's duty cycle is not

 

 

 

 

 

 

 

being exceeded.

 

 

 

 

 

 

 

 

5. Check the trigger circuit. Leads

 

 

 

 

 

 

 

#324 to #325 should have conti-

 

 

 

 

 

 

 

nuity (zero ohms) when the gun

 

 

 

 

 

 

 

trigger is pulled. If not then the

 

 

 

 

 

 

 

gun may be faulty - replace.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con- tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216- 383-2531 or 1-800-833-9353

WIRE-MATIC 250

Image 56
Contents WIRE-MATIC Safety Depends on YouSafety ARC Welding can be hazardousCylinder may explode if damaged Electric and MAG- Netic Fields IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcWIRE-MATIC Table of Contents Table of Contents Installation Duty Cycle Amps Volts at Rated Amps Current RangeFuse Superlag Type 750C CopperSafety Precautions Select Proper LocationInput Connections StackingFuse and Wire Sizes Input Power Connections and Ground ConnectionsConnect Shielding GAS Reconnect Procedure Figure A.4 Input Air Supply ConnectionsFigure A.5 Reconnect Diagram For 208/230/1/60 Machines Installation Install the Work ClampConnect Output Components GUN Liner and Contact Output Polarity ConnectionWire Size Conversion Parts GUN and Cable InstallationWIRE-MATIC Operation WELDING, Cutting Safety InstructionsGeneral Description Design Features Advantages Unit FeaturesPower Source Features Recommended Processes and EquipmentWire Feeder Features Machine CapabilityLimitations Duty Cycle Amps VoltsControls and Settings Figure B.1 Operator ControlsLoading the Wire Reel Using the Wire Drive RollProcedure for Changing Drive Roll To mount 10 to 30 lb. spools 8 and 12 diameter Proper Wire FeedingFeeding Electrode Starting the Welder Setting Idle Roll PressureOperating Steps Making a Weld WIRE-MATIC Accessories K607-1 Spool GUN Adapter KIT OPTIONS/ACCESSORIESInstalling the K607-1 Spool GUN Adapter KIT Installation Spool GUN Module BoardSpool GUN Connection BOX Installation Return Return to Section TOCSpool GUN Connection Spool GUN PreparationMaking a Weld with the Spool GUN Adapter K607-1 Installed Making the WeldTimer KIT K585-1 Steel Wire Sizes Part Number Aluminum Wire SizesDrive Roll Kits To Make Spot Plug WeldsMaintenance Routine and Periodic Maintenance Perform the following dailyMaintenance Contact TIP and GAS Nozzle Installation Cable CleaningDrive Rolls and Guide Tubes GUN Tubes and Nozzles DROP-IN Reel Spindle and ClipsLiner Removal Replacement Figure D.2 Liner maintenanceGUN Handle Disassembly To open up the handleDescription English Size Metric Size WIRE-MATIC Theory of Operation Input Line Voltage and Main TransformerOutput Rectification Feedback ControlConstant Voltage Output Figure E.4 Constant Voltage OutputWire Drive Motor FeedbackThermal Protection SCR Operation Figure E.6 SCR OperationWIRE-MATIC Troubleshooting & Repair HOW to USE Troubleshooting Guide Recommended Course of ActionBoard can be dam- aged by static electricity PC Board Troubleshooting ProceduresElectric Shock can kill Main Transformer Rectifier Assembly Test To Section TOC Perform the SCR Rectifier Perform the Wire Drive Motor Liquid elec Trolyte in these capacitors isPerform the Output Rectifier Materials Needed Main Transformer TestTest Description Main Transformer Test Test Procedure ON/OFF Power Switch will be hot during these testsMain Transformer Test Static SCR Rectifier Assembly Test Leads Figure F.4 SCR 1 Test Points Active SCR Rectifier Assembly Test Leads Figure F.7 SCR Tester Circuit SCR connectionsWire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test Procedure Test for Supply Voltage to Tachometer Test for Feedback Voltage to the Control BoardScope Settings Normal Open Circuit Voltage WaveformMachine Loaded to 250 Amps AT 26 VDC Scope Settings Typical Output Voltage Waveform Machine LoadedMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Materials Needed Control PC Board Removal and ReplacementRemoval and Replacement Procedure Removal and REPLACE- Ment Procedure Wire Drive Assembly Removal and Replacement Wire Drive Assembly Removal and Replacement Procedure Figure F.11 Wire Drive Assembly RemovalSCR Output Rectifier Removal & Replacement Right side heat sink See Figure F.14 Disconnection Heat Sink LeadCapacitor Bank Removal and Replacement Bank Removal Replacement ComponentsMain Transformer Removal and Replacement Power Switch FAN Motor and FAN Removal and Replacement FAN Motor and FAN Removal and Replacement Procedure Figure F.16 Fan Motor and Fan Removal ComponentsTroubleshooting & Repair Wire Speed Range Open Circuit VoltageInput Volts/Hertz 230/60 375WIRE-MATIC Table of Contents Electrical Diagrams Section WIRE-MATIC Electrical Diagrams Spool GUN Option Wiring Diagram 208/230 Code To Section Available from Lincoln Control PC Board G2332 Layout