Lincoln Electric SP-100 service manual Feeding Problems

Page 43

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TROUBLESHOOTING & REPAIR

F-6

Observe Safety Guidelines

TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

FEEDING PROBLEMS

No wire feed when gun trigger is

1. If the wire drive motor is running

1. Check for a DC voltage at wire

pulled. Fan runs, gas flows and

check to see if the correct wire

drive motor armature (leads

machine has correct open circuit

is in the machine.

#539 to #541). The voltage

voltage (28 vdc maximum) – weld

should be between 2 vdc and 10

output.

2. If the wire drive motor is running

vdc. This voltage will vary with

make sure that the correct drive

the wire speed control setting. If

rolls are installed in the

the correct voltage is present,

machine.

the drive motor may be faulty.

Replace. See wiring diagram.

3. Check for clogged cable liner or

feeding problems.

2. If the motor armature voltage is

not present, then check for OCV

at leads #203 (3J2) and #204

(4J2) on the control board. If

correct voltage is present, go to

Step 3. If OCV is not present at

leads #203 and #204, check

continuity (zero ohms) of leads.

3. If the motor armature voltage is

not present, then check the wire

speed control potentiometer and

associated wires #208, #209

and #203 for faulty connections.

4. The control board may be faulty.

Replace.

Wire feed speed motor runs very

1. Make sure that the wire speed

1. Remove main supply power to

fast. Weld output, gas flow and fan

control is not set at maximum.

machine. Disconnect plug J2

operate normally.

from the control board. Test the

resistance from lead #539 (2J2)

in the harness plug to the wire

feed motor case. If the resis-

tance is below 500,000 ohms,

replace the drive motor.

2. Check the wire speed control

potentiometer and associated

wires #208, #209 and #203 for

loose or broken connections.

3. The control board 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, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.

SP-100

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Contents SP-100 Fumes and Gases can be dangerous SafetyElectric Shock can kill ARC Rays can burnWelding Sparks can cause fire or explosion Cylinder may explode if damagedMay be dangerous Electric and Magnetic FieldsSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Section Table of ContentsTechnical Specifications SP-100 InstallationIdentify and Locate Components Safety PrecautionsRead entire installation section before starting InstallationTilting Work Clamp InstallationSelect Suitable Location Output ConnectionsConnecting GUN Cable to the SP-100 GUN InstallationGAS Connection Input PowerInput Connections Gas Solenoid Inlet FittingRequirements for Rated Output Code Requirements for Input ConnectionsRequirements for Maximum Output Requirements for CSA Rated OutputSP-100 Table of Contents Wear eye, ear and body protec- tion OperationOff Operational Features and ControlsDesign Features Advantages General DescriptionSequence of Operation Wire LoadingWelding Operations Process GuidelinesRefer to Figure B-4 Friction Brake AdjustmentsMaking a Weld Shielding GASOverload Protection SP-100 Accessories Section Innershield Welding Kits 1ACCESSORIESReplacement Parts Lincoln GAS Regulator Kits K467 Input Line CordMaintenance Section Items Requiring no Maintenance MaintenanceRoutine and Periodic Maintenance Changing Drive Roll Changing the Contact TIPLiner trim length for the Magnum 100L gun red trigger Figure D.3 SP-100 SUB Assemblies SP-100 Theory of Operation Input Line VOLTAGE, FAN Motor and Main Transformer Figure E.1 Input Power CircuitsFigure E.2 Output Circuits Output CONTROL, RECTIFICA- Tion and Voltage Feedback3THEORY of Operation TRIGGER, GAS Solenoid and Wire DriveFigure E.4 SCR Operation SCR OperationThermostat protects the machine from Oscilloscope Waveforms Troubleshooting SectionHOW to USE Troubleshooting Guide 1TROUBLESHOOTING & RepairPC Board Troubleshooting Procedures Troubleshooting & RepairAuthorized Field Service Troubleshooting GuideFacility Below Code 9794 only Code 9794 and Above Problems SymptomsPossible Areas of Misadjustments Recommended Course of ActionFeeding Problems Troubleshooting Guide Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-100 PC Board Connector LocationsNormal Open Circuit Voltage Waveform 9TROUBLESHOOTING & RepairScope Settings Volts Volts/DivTypical Output Voltage Waveform Machine Loaded VoltsAbnormal Open Circuit Voltage Waveform Tools Required Procedure DescriptionProcedure FAN Blade and Motor Removal1B. for Codes below Wire Drive Assembly RemovalMotor Removal Procedure 1A. for Codes AboveInput Amps AT Rated Output Input Amps AC @ Output DC Wire Speed RangeRetest After Repair Main Transformer Secondary Voltages Test PointsSP-100 Electrical Diagrams Section Wiring Wiring DiagramsDiagram 4 5 1 M SP-100 Wiring Diagram Codes BelowElectrical Diagrams Control P.C. Board G1842 Electrical DiagramsControl P.C. Board G2314 SCR1, SCR2 SCR 81 Heatsink Asbly Control P.C. Board G2314Error Machine Schematic Codes 9794 and Above86R R63R64 1 5 K Machine Schematic Codes BelowSVM Error Reporting Form