Miller Electric TM-353E manual Troubleshooting Table

Page 26

SECTION 6 – TROUBLESHOOTING

6-1. Troubleshooting Table

.

.

See Section 6-2 for test points and values and Section 10 for parts location.

Use MILLER Testing Booklet (Part No. 150 853) when servicing this unit.

Trouble

Remedy

 

 

 

 

Prior to Serial No. KG164875, no weld

Be sure line disconnect switch is in the On position.

output; unit completely inoperative –

 

Effective with Serial No. KG164875,

 

no weld output; unit completely inop-

 

erative; PL2 off.

 

 

 

 

Replace building line fuse(s) or reset circuit breaker(s) if open.

 

 

 

Check for proper electrical input connections (see Section 3-11).

 

 

 

Check for proper jumper link position (see Section 3-11).

 

 

 

Check Power switch S1 and replace if necessary.

 

 

Prior to Serial No. KG164875, no weld

If using remote control, place Output (Contactor) switch S3 in Remote 14 position, and connect re-

output; fan runs – Effective with Serial

mote control to Remote 14 receptacle RC1 (see Sections 3-8 and Section 4-8). If remote is not being

No. KG164875, no weld output; fan

used, place Output switch S3 in On position.

runs; PL2 on.

 

 

 

 

Check, repair or replace remote control device.

 

 

 

Allow a cooling period of approximately 15 minutes. If thermostats TP1 remain open, check continuity

 

and replace if necessary (see Section 3-3).

 

 

 

Check circuit breaker CB1, and reset if open (see Section 7-2).

 

 

 

Place Output Selector switch S4 in desired position (see Section 4-2).

 

 

 

Check optional preflow timer board TD3, and replace if necessary.

 

 

 

Check optional spot timer relay TD2 for proper connections and resistance. Replace TD2 if

 

necessary.

 

 

 

Check continuity of Spot Time switch S8. Check condition of contacts. Repair or replace S8 if neces-

 

sary.

 

 

 

Check SR1, and replace necessary components. If components are replaced, check capacitors C7

 

thru C10. Replace capacitor(s) if necessary.

 

 

 

Check control board PC1 and connections, and replace if necessary.

 

 

 

Effective with Serial No. KB110695, check resistance and connections of HD1; HD1 is 1600 ohms

 

± 10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if

 

necessary.

 

 

Unit provides only minimum weld

Check position of Amperage Control switch S5 (see Section 4-7).

output.

 

 

 

 

Increase Amperage Adjustment control R1 setting if a remote control is used (see Section 4-7).

 

 

 

Check, repair or replace remote control device.

 

 

 

Check resistance and connections of Amperage Adjustment control R1; R1 is 1000 ohms ± 10%.

 

Replace R1 if necessary.

 

 

 

Check SCRs in main rectifier SR1, and replace if necessary. If any SCRs are replaced, Check capac-

 

itors C7 through C10 for a short or open, and check for proper connections. Replace C7 through C10

 

if necessary.

 

 

 

Check control board PC1 and connections, and replace if necessary.

 

 

 

Effective with Serial No. KB110695, check resistance and connections of HD1; HD1 is 1600 ohms

 

± 10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if

 

necessary.

 

 

Unit provides only maximum weld

Check Amperage Adjustment control R1 for proper connections and resistance; R1 is 1000 ohms

output.

± 10%. Replace R1 if necessary.

 

 

 

Effective with Serial No. KB110695, check resistance and connections of HD1; HD1 is 1600 ohms

 

± 10% between pins 1 and 3 of plug PLG3. Check input and output voltages. Replace HD1 if

 

necessary.

 

 

 

Check connections for continuity to shunt device on units with Serial No. prior to KB110695.

 

 

 

Check bypass capacitors C13, C14, C16, C17, C18, and C19 for broken leads, shorts, and leakage.

 

Replace if necessary.

 

 

TM-353 Page 22

Syncrowave 250

Image 26
Contents SyncrowaveR Table of Contents Declaration of Conformity For European Community CE Products Page Marks a special safety message Safety Precautions for ServicingSymbol Usage Servicing HazardsEMF Information About Pacemakers+ + + DefinitionsISO/IEC Rating Label For CE ProductsSymbols And Definitions Some symbols are found only on CE productsVolt-Ampere Curves InstallationSpecifications 220 230 260 380 415 460Overheating Duty Cycle And Overheating60% Duty Cycle At 200 Amperes Movement Location And Airflow Dimensions And WeightsSelecting a Location Weld Output Terminals And Selecting Cable Sizes Be careful when placing or moving unit over uneven surfacesTipping ARC Welding can cause Electromagnetic InterferenceVolts AC Duplex Receptacle And Shielding Gas Connections Turn Off power before connecting to receptacleRemote 14 Receptacle SocketElectrical Service Guide All values calculated at 60% duty cyclePlacing Jumper Links And Connecting Input Power Check label inside your unit- only one label is on unitOperation ControlsOutput Selector Switch MetersApplication Crater Time ControlsSpot Time Controls Balance Control AC Gtaw Setting Output WaveformsAC Balance Control Amperage Adjustment Controls Output Contactor Control SwitchFor AC And DC Smaw Welding Arc ControlsPostflow Time Control High Frequency Controls Preflow Time Control OptionalTheory of Operation SCRHD1 Troubleshooting Troubleshooting TableNecessary parts Dition of contacts. Replace CR5 if necessary Contacts. Replace CR2 if necessary Troubleshooting Circuit Diagram For Welding Power Source V24 See -1 forHD1 location D, EWaveforms For Section GndAC Output, 100 Amperes, 24 Volts AC Re- sistive Load Control Board PC1 Testing Information Use With Section Control Board PC1 Test Point Values Reference for gate pulse to SCR4 RC54 Not usedReceptacle Pin Value Remote Board PC2 Testing Information Use With Section RC3 Meter Calibration Input Voltage Labels And Connections Months MaintenanceRoutine Maintenance Circuit Breaker CB1Fuses F1 And F2 Adjusting Spark GapsTurn Off power before adjusting spark gaps High Frequency HF Welding Processes Using HFSources Of HF Radiation From Incorrect Installation Correct Installation Electrical Diagrams Model Serial Or Style Number Circuit Diagram Wiring DiagramSC-114 SC-120 SC-121 SC-124 SC-124 785-B SC-132 697-A SC-137 SC-135 SC-142 SC-148 SC-154 649-C SC-178 SC-179 303-A SC-181 109-E SC-188 161-A Syncrowave TM-353 TM-353 SD-188 162-A TM-353 SD-187 644 1 TM-353 SD-187 644 2 SA-121 SA-044 725-C TM-353 Description Parts List Main AssemblyPLG51 114 BASE, Prior to KE727074 170 Panel, Front w/Components Panel, Front w/ Components Rectifier, Si Diode -1 Item Panel, Mtg Components -1 Item Control Panel, Lower Front 126 Capacitor ASSEMBLY, Eff w/JK537589 thru JK690986 C14 124 COIL, HF coupling Eff w/JK572898 thru KF959378 174 Optional Equipment Page Miller