Lincoln Electric SVM170-A Problems Possible Areas, Symptoms Misadjustments Course of Action

Page 45

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F-5

TROUBLESHOOTING AND REPAIR

F-5

 

 

 

Observe all Safety Guidelines detailed throughout this manual.

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS (Continued)

 

 

 

 

 

 

 

 

 

 

No open circuit voltage output but

1. Check the input voltage at the

1.

Check for loose or broken con-

wire feeds normally when gun trig-

machine. Input voltage must

 

nections at the output terminals,

ger is pulled.

 

match the rating plate and the

 

the chokes, the capacitor bank

 

 

reconnect panel.

 

and all heavy current carrying

 

 

 

 

leads. See Wiring Diagram.

 

 

2. The gun may be faulty. Check

 

 

 

 

 

 

 

 

or replace.

2.

Make sure that the transformer

 

 

 

 

secondary

leads

are

securely

 

 

 

 

connected to the SCR rectifier

 

 

 

 

assembly.

 

 

 

 

 

 

 

3.

Perform

the

SCR

Rectifier

 

 

 

 

Assembly Tests.

 

 

 

 

 

4.

Perform

Main

Transformer

 

 

 

 

Test.

 

 

 

 

 

 

 

5.

The control board may be faulty.

 

 

 

 

Replace.

 

 

 

 

 

 

 

 

Wire feeds but welding output is low

1. Make sure that the proper wire

1.

Check for loose or faulty con-

causing wire to “stub”.

Welds are

and procedures are being used.

 

nections of the heavy current

“cold”. Machine cannot

obtain full

 

 

carrying leads.

 

 

 

rated output of 200 amps at 28 volts.

2. Check gun and work cable for

 

 

 

 

 

 

 

 

loose or faulty connections.

2.

The output capacitor bank may

 

 

 

 

be faulty. Check for loose con-

 

 

 

 

nections at the capacitors. Also

 

 

 

 

check for leaky capacitors.

 

 

 

 

Replace if necessary.

 

 

 

 

 

WARNING: The liquid elec-

 

 

 

 

trolyte in these capacitors is

 

 

 

 

toxic. Avoid contact with any

 

 

 

 

portion of your body.

 

 

 

3.

Perform

the

SCR

Rectifier

 

 

 

 

Assembly Tests.

 

 

 

 

 

4.

Perform the Main Transformer

 

 

 

 

Test.

 

 

 

 

 

 

 

5.

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 1-888-935-3877.

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POWER MIG 255C

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Contents Power MIG 255C California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents For ALL Sections Table of Contents Installation Section InstallationTechnical Specifications Power MIG 255C Uncrating the Power MIG 255C Safety PrecautionsInput POWER, Grounding and Connection Diagrams LocationInstallation Figure A.2 Triple Voltage Machine Input Connections GUN and Cable Installation Auxiliary Power ReceptaclesShielding GAS Operation Table of Contents Operation SectionWear eye, ear and body protec- tion OPERATIONB-2Recommended Processes and Equipment Product DescriptionWelding Capability LimitationsWire Size Conversion Parts Wire Drive RollDescription of Controls Procedure for Changing Wire Reel Loading Readi REELS, Spools or CoilsDrive and Idle Roll Sets Idle Roll Pressure Setting Feeding Wire ElectrodeWire Drive Configuration To Start the WelderFigure B.4 Instructions to Enter Slow RUN-IN When Timer Option is not installedInstructions to Enter Fast RUN-IN Making a WeldWire Feed Overload Protection Avoiding Wire Feeding ProblemsFAN Control Input Line Voltage ProtectionOvercurrent Protection Welding Thermal Overload ProtectionTable of Contents Accessories Section AccessoriesMagnum GUN Connection KIT Drive Roll KitsK363P READI-REEL Adapter Dual Cylinder Mounting KIT K1702-1Connecting the Spool GUN to the Power MIG 255C Operating Instructions for Timer KITK1738-1 Spool Gun Hanger Accessory Spool GUNMaking a Weld with the Magnum SG Spool GUN Making a Weld with the Prince XL Spool GUNSG Spool Gun Wire Feed Speed Power MIG Table of Contents Maintenance Section MaintenanceGUN Cable Cleaning GUN Tubes and Nozzles General MaintenanceContact TIP and GAS Nozzle Installation Liner Removal and ReplacementTable D.1 GUN Handle DisassemblyEnglish Metric Description MAINTENANCED-4Theory of Operation Table of Contents Theory of Operation SectionMain Transformer Input Line VoltageFeedback Control Output RectificationFigure E.4 Constant Voltage Output Constant Voltage OutputFeedback Wire Drive MotorThermal and Overload Protection Wire Feed Overload ProtectionFigure E.6 SCR Operation SCR OperationPower MIG 255C Table of Contents Troubleshooting and Repair Section Troubleshooting and RepairHOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Output Problems Troubleshooting GuideSymptoms Misadjustments Course of Action Problems Possible AreasTrolyte in these capacitors is Toxic. Avoid contact with anyPerform the SCR Rectifier Function Problems Wire Feeding Problems Welding Problems Welding Problems Main Transformer Test Test ProceduresTest Description Materials NeededON/OFF Power Switch will be hot during these tests Test Procedure16J5 8J5 115VAC206 3J5 Rectifier Diode Bridge Test Figure F.2 G3521 Rectifier Diode Bridge Location 16TROUBLESHOOTING and REPAIRF-16354 206 36 VDC 208 206 28 VAC 209Power MIG 255C Static SCR Rectifier Assembly Test Static SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Power MIG 255C Active SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Figure F.7 Location Leads X2 Figure F.8 Wire Drive Motor and Tachometer Feedback Test 4J1 Wire Drive Motor and Tachometer Feedback Test515B 206B 15 VDC 5J1 1J1 Test for Supply Voltage to Tachometer555 206B To 3.5 VDC 6J1 1J1 Test for Feedback Voltage to Control BoardVolts Normal Open Circuit Voltage WaveformTypical Output Voltage Waveform Machine Loaded Machine Loaded to 250 Amps AT 26 VDC Scope SettingsMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting and Repair Typical SCR Gate Voltage Waveform Power MIG 255C Component Replacement Procedures Control PC Board Removal and ReplacementDescription Procedure Removal and ReplacementFigure F.11 Control Board Mounting Power MIG 255C Wire Drive Assembly Removal and Replacement Wire Drive Assembly Removal and Replacement Procedure Power MIG 255C SCR Output Rectifier Removal and Replacement SCR Output Rectifier Removal and Replacement Figure F.15 Right Heat Sink Lead Disconnection Power MIG 255C Capacitor Bank Removal and Replacement Capacitor Bank Removal and Replacement Main Transformer and Output Choke Removal and Replacement Main Transformer and Output Choke 52TROUBLESHOOTING and REPAIRF-52TOC Power MIG 255C FAN Motor Assembly Removal and Replacement FAN Motor Assembly Removal and Replacement Retest After Repair Wire Speed RangeOpen Circuit Voltage Input Volts/HertzPower MIG 255C Section G-1 Electrical Diagrams SectionWiring Diagram Entire Machine Code 11192 L12464 Electrical DiagramsWiring Diagram Entire Machine Code 11218 L12506 Schematic Entire Machine G4752 Schematic Control PC Board G4823-2D1 Sheet Electrical Diagrams Electrical Diagrams Item Used with QTY Part Number Description PC Board Assembly Control G4824-2D1Powermig Schematic Display PC Board L10951Lincoln Electric CO PC Board Assembly Display L10952SVM Error Reporting Form
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