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TROUBLESHOOTING & REPAIR

 

F-4

 

Observe Safety Guidelines

 

 

TROUBLESHOOTING GUIDE

 

detailed in the beginning of this manual.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

 

 

 

 

(SYMPTOMS)

 

 

MISADJUSTMENT(S)

 

 

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

 

 

No weld output when gun trigger is

 

 

1. Arc voltage may be set too low.

 

 

1. Check for open circuit voltage

 

 

 

 

pulled. Fan runs, gas flows and

 

 

 

 

 

(OCV) at the machine’s output

 

 

 

wire feeds normally.

 

 

2. Gun tip may be worn – Replace.

 

 

terminals, located in wire drive

 

 

 

 

 

 

 

 

 

 

compartment. Normal OCV is

 

 

 

 

 

 

 

 

3. Check for correct input voltage

 

 

from 10 vdc to 28 vdc depending

 

 

 

 

 

 

 

to machine.

 

 

on arc voltage control setting. If

 

 

 

 

 

 

 

 

 

 

correct OCV is present, check

 

 

 

 

 

 

 

 

4. Gun or work cable may be

 

 

gun and work cable.

 

 

 

 

 

 

 

 

faulty.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. If correct OCV is not present at

 

 

 

 

 

 

 

 

 

 

the output terminals, then check

 

 

 

 

 

 

 

 

 

 

for broken leads at the output

 

 

 

 

 

 

 

 

 

 

 

choke or at the positive output

 

 

 

 

 

 

 

 

 

 

terminal.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BELOW CODE 9794 ONLY

 

 

1. Check the circuit breaker locat-

 

 

1. Remove main power supply to

 

 

 

 

 

 

 

ed in the machine’s wire drive

 

 

SP-100. With gun trigger pulled,

 

 

 

No wire feed, weld output or gas

 

 

compartment. Reset if tripped.

 

 

check for continuity (zero ohms)

 

 

 

flow when gun trigger is pulled Fan

 

 

 

 

 

from 8J2 (lead #213) to 9J2 (lead

 

 

 

operates normally.

 

 

2. The thermostat may be tripped

 

 

#211 ) at harness plug. If zero

 

 

 

 

 

 

 

 

due to overheating. Let machine

 

 

ohms is indicated, then trigger

 

 

 

 

 

 

 

cool. Weld within the duty cycle

 

 

circuit is OK. See wiring diagram

 

 

 

 

 

 

 

or remove any air obstruction to

 

 

and Figure F.1.

 

 

 

 

 

 

 

 

machine.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2. If an open circuit or high resis-

 

 

 

 

 

 

 

3. Wire feed motor may be over-

 

 

tance is indicated in Step 1, then

 

 

 

 

 

 

 

loaded. Correct feeding prob-

 

 

check leads #211,#212 and #213

 

 

 

 

 

 

 

lem.

 

 

for loose or broken connections.

 

 

 

 

 

 

 

 

 

 

Also check the normally closed

 

 

 

 

 

 

 

4. Gun trigger may be faulty.

 

 

thermostat mounted on the diode

 

 

 

 

 

 

 

 

 

 

heat sink assembly. See wiring

 

 

 

 

 

 

 

 

 

 

diagram.

 

 

 

 

 

 

 

 

 

 

 

3. Check for 115 vac at lead #31A

 

 

 

 

 

 

 

 

 

 

to plug 3J1 on control board. If

 

 

 

 

 

 

 

 

 

 

115 vac is NOT present, remove

 

 

 

 

 

 

 

 

 

 

main supply power to machine.

 

 

 

 

 

 

 

 

 

 

Test continuity (zero ohms) of

 

 

 

 

 

 

 

 

 

 

 

leads #32 and #31A. See Figure

 

 

 

 

 

 

 

 

 

 

F.1.

 

 

 

 

 

 

 

 

 

 

 

4. If 115 vac is present at lead

 

 

 

 

 

 

 

 

 

 

 

#31A to plug 3J1 (lead #32), then

 

 

 

 

 

 

 

 

 

 

control board may be faulty –

 

 

 

 

 

 

 

 

 

 

 

Replace. See Figure F.1.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

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Lincoln Electric SP-100 service manual Below Code 9794 only