TROUBLESHOOTING PROCEDURES
A.P.C. Board Troubleshooting Procedures
Perform the following checks before replacing the P.C. Board.
1.Remove the cover to the Wire Feed Module box located on the right side of the machine. With the engine running the green and red LED on the P.C. Board must be glowing. If not, check the following:
a)Check for loose connections in the P.C. Board plugs, pay close attention to J3.
b)With machine running at high idle, check the following voltages accessible at P.C. Board plug J3:
Lead Number | Voltage |
610 - 600 | 120 + |
If these voltages are not present, check the wiring connections between the engine welder and the Wire Feed Module. If wiring is good, then refer to the “Quick Check Procedure for Generator Only”. If generator is operating properly, refer to “Procedure for Replacing P.C. Boards”.
B.Procedures for Replacing P.C. Boards
Before replacing a P.C. Board which is suspected of being defective, visually inspect the P.C. Board in question for any electrical or mechanical damage to any of its components and conductors on the back of the board.
1.If there is no visible damage to the P.C. Board, install a new one and see if this reme- dies the problem. If the problem is remedied, reinstall the old P.C. Board to see if the prob- lem still exists. If it does no longer exist with the old P.C. Board:
a)Check the P.C. Board harness connector pins for corrosion, contamination, or loose- ness.
b)Check leads in the plug harness for loose or intermittent connection.
2.If P.C. Board is visibly damaged electrically, before possibly subjecting the new P.C. Board to the same cause of failure, check for possi- ble shorts, opens, or grounds caused by:
a)Frayed or pinched lead insulation.
b)Poor lead termination, such as a poor contact or a short to adjacent connection or surface.
c)Shorted or open leads, or other external leads.
d)Foreign matter or interference behind the P.C. Boards.
3.If P.C. Board is visibly damaged mechanically, inspect for cause then remedy before installing a replacement P.C. Board.
If there is damage to the P.C. Board or if replacing P.C. Board corrects problem, return it to the local Lincoln Electric Field Service Shop.
C.Output Voltage
Constant Voltage Mode
D.Procedure for Checking the Cold Tip Contactor (CR4)
1.If there is no output during the initial start up of the machine, check to see if the “Local/Remote” switch is in “LOCAL”, if so, switch to “REMOTE” and then back to “LOCAL” and check for output voltage. If switch is in “Remote” switch to the “LOCAL” position and check for output voltage.
2.Open side panel of wire feed module. With machine running, verify the P.C. Board is working by checking to see if the green and red LED’s are on. If LED’s are not on, see P.C. Board Troubleshooting Procedures. If the LED’s are on, check the voltage between the top left stud of the cold tip contactor (CR4) and the posi- tive output stud. The voltage should mea- sure between 7 and 55 volts DC depend- ing on the position of the CV voltage con- trol setting. Try adjusting the voltage con- trol to see if this voltage changes. If volt- age is present, go to step 3. If no voltage is present, check for loose cable or wiring connections. If voltage is still not present, refer to Troubleshooting Chart.
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