Lincoln Electric IM511-D manual Output System Trouble Cause What to do

OUTPUT SYSTEM

TROUBLE	CAUSE		WHAT TO DO
A. No welder or power output.	1. Open lead in flashing or field circuit.		1.	Refer to wiring diagram and check
				related leads.
				(#7 & #9; #200, #201 and #219)
	2.	Faulty rotor.	2.	Lift brushes and check rotor
				continuity between slip rings.
				(Should be approx. 7.3Ω)
	3.	Faulty stator field.	3.	Disconnect lead #7 at D2 and
				check for continuity between
				leads #7 and #9.
	4.	Faulty field rectifier D2.	4.	Replace with known good one.
	5.	Output contactor does not pull in.	5.	Refer to wiring diagram and check
				related leads and contactor.
	6.	Faulty P.C. Board.	6.	Replace P.C. Board with known
				good one.
B. Output control on welder not	1. Output control switch in wrong		1.	Place switch in “Output Control
functioning.		position.		at Welder”.
	2.	Output control switch defective.	2.	Check and replace switch if faulty.
	3.	Output control potentiometer	3.	Check and replace potentiometer
		defective.		if faulty.
	4.	Faulty wiring.	4.	Check for broken leads #75, #76,
				and #77 from P.C. Board and
				#75A, #76D, and #77D from
				potentiometer to remote switch.
	5.	Faulty P.C. Board	5.	Replace P.C. Board with known
				good one.
C. Output control or remote not	1. Output control switch in wrong		1.	Place switch in “Remote” position.
functioning.		position.
	2.	Leads #75, #76, #77 broken at P.C.	2.	Repair.
		Board or S4.
	3.	Leads #75A, #76A, #77A broken at	3.	Repair.
		S4 or amphenol.
	4.	Remote control leads broken in	4.	Repair.
		control cable.
	5.	Faulty wire feeder.	5.	Replace wire feeder with known
				good one.
	6.	Faulty P.C. Board.	6.	Replace P.C. Board with known
				good one.
D. Wire feeder does not work when	1. Wire feeder circuit breaker open or		1.	Reset or replace.
connected to welder amphenol.		faulty.
	2.	Broken #31, #32, or #42 lead at	2.	Repair.
		amphenol.
	3.	No 115V or 42V output from stator.	3.	Check continuity on #31, #32, and
				#42 at stator. Check buildup. If
				O.K. , stator may be faulty.
				Replace.
	4.	Faulty wiring in control cable.	4.	Repair or replace cable.
	5.	Faulty wire feeder.	5.	Replace P.C. Board with known
				good one.

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