Lincoln Electric SP-100 service manual Troubleshooting Guide

Page 44

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F-7

 

TROUBLESHOOTING & REPAIR

 

 

 

Observe Safety Guidelines

 

 

 

TROUBLESHOOTING GUIDE

 

detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

 

(SYMPTOMS)

 

 

 

MISADJUSTMENT(S)

 

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GAS FLOW PROBLEMS

 

 

 

 

 

 

 

Low or no gas flow when gun

 

 

1. Check gas supply, flow regulator

 

 

1. Check for 115 vac at the gas

 

 

 

trigger is pulled. Wire feed, weld

 

 

and gas hoses.

 

 

solenoid leads #7 to #32A. If the

 

 

 

output and fan operate normally.

 

 

 

 

 

correct voltage is present but

 

 

 

 

 

 

 

 

2. Check gun connection to

 

 

the solenoid does not activate,

 

 

 

 

 

 

 

 

machine for obstruction or leaky

 

 

replace solenoid. See wiring dia-

 

 

 

 

 

 

 

 

seals.

 

 

gram .

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. If voltage is not present at leads

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

#7 to #32A, remove main supply

 

 

 

 

 

 

 

 

 

 

 

power to machine. Test leads #7

 

 

 

 

 

 

 

 

 

 

 

and #32A for continuity (zero

 

 

 

 

 

 

 

 

 

 

 

ohms) to the control board.

 

 

 

 

 

 

 

 

 

 

 

3. Control board may be faulty.

 

 

 

 

 

 

 

 

 

 

 

Replace.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

 

 

 

POSSIBLE AREAS OF

 

 

RECOMMENDED

 

 

(SYMPTOMS)

 

 

 

MISADJUSTMENT(S)

 

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WELDING PROBLEMS

 

 

 

 

 

 

 

Arc is unstable – Poor starting

 

 

1. Check for correct input voltage

 

 

1. Check for correct open circuit

 

 

 

 

 

 

 

 

to machine – 115 vac.

 

 

voltage (OCV) at machine’s out-

 

 

 

 

 

 

 

 

 

 

 

put terminals, 10 vdc to 28 vdc,

 

 

 

 

 

 

 

 

2. Check for proper electrode

 

 

depending on arc voltage con-

 

 

 

 

 

 

 

 

polarity for process.

 

 

trol setting. If correct OCV is

 

 

 

 

 

 

 

 

 

 

 

present check gun and work

 

 

 

 

 

 

 

 

3. Check gun tip for wear or dam-

 

 

cable.

 

 

 

 

 

 

 

 

age – Replace.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. If OCV is low, check output

 

 

 

 

 

 

 

 

4. Check for proper gas and flow

 

 

capacitor and output diodes.

 

 

 

 

 

 

 

 

rate for process.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3. Check arc voltage control poten-

 

 

 

 

 

 

 

 

5. Check work cable for loose or

 

 

tiometer and associated wires

 

 

 

 

 

 

 

 

faulty connections.

 

 

#205, #206 and #207 for loose

 

 

 

 

 

 

 

 

 

 

 

or broken connections. See

 

 

 

 

 

 

 

 

6. Check gun for damage or

 

 

wiring diagram.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

breaks.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4. 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

Image 44
Contents SP-100 Safety Electric Shock can killARC Rays can burn Fumes and Gases can be dangerousCylinder may explode if damaged Welding Sparks can cause fire or explosionElectric and Magnetic Fields May be dangerousPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionInstallation Technical Specifications SP-100Safety Precautions Read entire installation section before startingInstallation Identify and Locate ComponentsWork Clamp Installation Select Suitable LocationOutput Connections TiltingGAS Connection GUN InstallationConnecting GUN Cable to the SP-100 Power Input ConnectionsGas Solenoid Inlet Fitting InputCode Requirements for Input Connections Requirements for Maximum OutputRequirements for CSA Rated Output Requirements for Rated OutputSP-100 Table of Contents Operation Wear eye, ear and body protec- tionOperational Features and Controls Design Features AdvantagesGeneral Description OffWire Loading Welding OperationsProcess Guidelines Sequence of OperationFriction Brake Adjustments Refer to Figure B-4Shielding GAS Making a WeldOverload Protection SP-100 Accessories Section 1ACCESSORIES Replacement PartsLincoln GAS Regulator Kits K467 Input Line Cord Innershield Welding KitsMaintenance Section Routine and Periodic Maintenance MaintenanceItems Requiring no Maintenance Liner trim length for the Magnum 100L gun red trigger Changing the Contact TIPChanging Drive Roll Figure D.3 SP-100 SUB Assemblies SP-100 Theory of Operation Figure E.1 Input Power Circuits Input Line VOLTAGE, FAN Motor and Main TransformerOutput CONTROL, RECTIFICA- Tion and Voltage Feedback Figure E.2 Output CircuitsTRIGGER, GAS Solenoid and Wire Drive 3THEORY of OperationSCR Operation Figure E.4 SCR OperationThermostat protects the machine from Troubleshooting Section Oscilloscope Waveforms1TROUBLESHOOTING & Repair HOW to USE Troubleshooting GuideTroubleshooting & Repair PC Board Troubleshooting ProceduresFacility Troubleshooting GuideAuthorized Field Service Below Code 9794 only Problems Symptoms Possible Areas of MisadjustmentsRecommended Course of Action Code 9794 and AboveFeeding Problems Troubleshooting Guide PC Board Connector Locations Codes 9794 and above 6J1 10J2 1J1 1J2 Codes below SP-1009TROUBLESHOOTING & Repair Scope SettingsVolts Volts/Div Normal Open Circuit Voltage WaveformVolts Typical Output Voltage Waveform Machine LoadedAbnormal Open Circuit Voltage Waveform Procedure Description ProcedureFAN Blade and Motor Removal Tools RequiredWire Drive Assembly Removal Motor Removal Procedure1A. for Codes Above 1B. for Codes belowWire Speed Range Retest After RepairMain Transformer Secondary Voltages Test Points Input Amps AT Rated Output Input Amps AC @ Output DCSP-100 Electrical Diagrams Section Diagram Wiring DiagramsWiring SP-100 Wiring Diagram Codes Below 4 5 1 MElectrical Diagrams Electrical Diagrams Control P.C. Board G1842Control P.C. Board G2314 Control P.C. Board G2314 SCR1, SCR2 SCR 81 Heatsink AsblyMachine Schematic Codes 9794 and Above ErrorMachine Schematic Codes Below 86R R63R64 1 5 KSVM Error Reporting Form