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| TROUBLESHOOTING & REPAIR |
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| TROUBLESHOOTING GUIDE |
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| Observe Safety Guidelines | ||||
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| detailed in the beginning of this manual. | |||||
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| PROBLEMS |
| POSSIBLE AREAS OF | RECOMMENDED |
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| (SYMPTOMS) |
| MISADJUSTMENT(S) | COURSE OF ACTION | |||||
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| WELDING PROBLEMS |
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| The welding arc is “hot”, “spattery”, |
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| 10. Check all waveforms as illus- | ||||
| “cannonballs” or “flares up”. The |
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| trated | in | the Oscilloscope | |
| engine runs normally. The auxil- |
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| Wave forms Section. | |||
| iary power is normal. (Continued) |
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| 11. Perform | the Control Board | |||
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| Power Supply Test. | |||
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| Machine shuts down while arc |
| 1. Check to make sure that the | 1. | Check for poor connections at | ||||
| gouging and all lamp indicators on |
| machine settings match the |
| J4 pins 1, 2, 3, 6 & 7 at the con- | ||||
| front panel are lit. “ECL”, “ECH”, |
| weld application. |
| trol pc board. Also, perform the | ||||
| or “CCS” appears on display as |
| 2. Check to make sure the prop- |
| Exciter | Voltage | Feedback | ||
| machine is shutting down. |
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| Test. |
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| per carbon arc rod is being |
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| used. | The maximum carbon | 2. | Check for loose or faulty con- | |||
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| arc rod for the Commander 400 |
| nections or wires at the T1, T2, | ||||
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| is 5/16”. |
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| or T3 | capacitor | connection | |
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| 3. Attempt to arc gouge at a less- |
| block and back to the capacitor | ||||
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| bank. | On machines equipped | ||||
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| er current, if the application will |
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| with | Exciter | ||||
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| permit. |
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| Feedback module asbly, check | ||||
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| 4. If the machine shuts down |
| leads T1, T2, & T3 for faulty | ||||
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| while arc gouging in the gener- |
| connections. |
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| al fab | tap, use the CV tap | 3. Check for loose or faulty con- | ||||
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| instead. This is also an accept- | ||||||
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| nections at leads 268, 269 & | |||||
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| able process. |
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| 270 from the exciter pc board | |||||
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| to J4 pins 1, 2 & 3 on the con- | |||
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| trol board. |
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| 4. Perform the Exciter Capacitor | ||||
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| Bank Test. |
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| 5. Check for poor connections at | ||||
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| the J1 molex plug at the control | |||
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| pc board. Also, perform the | |||
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| Shunt Calibration Test. | |||
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| 6. Perform the Engine Throttle | ||||
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| Adjustment Test. |
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| 7. Check exciter waveforms as | ||||
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| illustrated in the Oscilloscope | |||
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| Waveforms Section. | |||
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-
