Lincoln Electric SVM135-B service manual Performance Troubleshooting Guide

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F-94	TROUBLESHOOTING AND REPAIR						F-94
FLOWCHART - PERFORMANCE TROUBLESHOOTING GUIDE
							Performance Troubleshooting Guide
		Performance Test Configuration (USE STD
						Alternate CV Configuration:
		GMAW	(.045 Steel - 3/8" Plate)
		STUD)**
						Grid Load (300A / 30V)
		Mode = 5					(Semi Automatic PW-455, PW455/STT)
	Grid Load (300A / 30V)
	Alternate CC Configuration:					Mode = 201
		WFS =400 ipm
						Voltage = 30V
		Voltage = 28V
	Mode = 200						(For Codes 10555 and Below)
						Arc Control = 0
		Arc Control= 0				Note: Mode 201 requires an
	Current = 300	Gas =90/10 ArCO2
	Arc Control = 0
						electrode sense lead (67).
		** Configuration may be altered based on available
		materials. A spray procedure was selected for
A NOTE ON VOLTAGE SENSING:				Turn On
					Y

All CV and Pulse modes utilize the electrode sense lead (lead #67) built into the control cable. As with any sense lead it's performance is only as good as the worst connection.

For diagnostic purposes, an external sense lead can be used to bypass the entire electrode sense network. This can be accomplished by removing the front cover of the PW-455, and connecting a lead (20 AWG minimum) from pin 5 of the exposed 6 pin UI molex connector (P6), to the feedplate on the feeder.

All Status Lights green?

UI functional with noN errors displayed? FH

functional?

Y

See Functional

Troubleshooting

Guide

Matches Display

Under load as definedpreviously: Check for actual voltageat the PS

Activate output (trigger the welding output).

**Note: The accuracy of measuring equipment plays a significant role.Generally speaking,

Key:

Value +/- 1V

Control PC Bd., from P20-8to P20-2

meters of reasonable accuracy should give

PS = Power Source

(P20-8 to P20-4 if usinga remote work

sense lead)

The Power Source Control PC Board is interpreting voltage correctly, but
	there is a bad or incorrect connection in the feedback path.		Does not match
		Display Value +/- 1V

Check to make sure the weld polarity matches the Electrode Sense Polarity dipswitch in the FH (SW-7). The default setting is electrode positive.

Check connections in the entire electrode sense path (wire #67) from the 2 pin output connector on the Voltage Sense PC Board, through the FH wiring harness, control cable(s), UI wiring harness (if system is configured with the UI between the FH and PS), and up to P20-8 on the Control PC Board inside of the PS.

Increase or Decrease the output settings as required to achieve a stable output.

Using the appropiate measuring

equipment, compare the Actual Current,

Voltage, and WFS to the readings displayed on the UI

Y

Do you get output

Nfrom the machine (can you weld)?

Y

readings within the stated limits. The intent here is to establish proper performance, not absolute accuracy.

Perform tachometer test.

Repair / replace as necessary.

Y

Correct FH

Dipswitch

setting.

N

UI = User Interface (Control

Box)

FH = Feed Head

Check for proper Drive Roll tension.

Check the work sense path (wire #202) from P20-2 on the PS Control PC

Actual vs Displayed

Motor running full Does FH gear ratio Check for proper Drive Rolls.

Board to the Work Stud, or (wire #21) from P20-4 to the remote work

sense lead depending on the configuration.

OK

WFS: +/-10 ipm?**

Y

N

speed regardless of	N	dipswitch setting match		Y
WFS setting?			pinion gear size?
					Verify software is correct version
						(PF-10 vs.PF-11).

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The PS Control PC Board is NOT interpreting voltage correctly.

On "-3" and higher vintage PS Control PC Boards the Voltage feedback can be calibrated. Perform the "Voltage Calibration Procedure".

If unable to calibrate, replace the Control PC Board. Please note the statement regarding test meter accuracy, and follow all applicable board replacement procedures when replacing this board.

			Under load as defined
Matches Display
		previously: Check for actual
	Value +/- 1V	voltage at the PS Control PC
		Bd., from P20-6 to P20-2.
					Does not match
				Display Value +/- 1V

The Power Source Control PC Board is interpreting voltage correctly, but there is a bad connection in the feedback path.

Check connections in the electrode sense path (wire #206) from P20-6 on the Control PC Board to the electrode(+) stud inside of the PS.

Check the work sense path (wire #202) from P20-2 on the Control

PC Board to the Work Stud.

The PS Control PC Board is NOT interpreting voltage correctly.

On "-3" and higher vintage PS Control PC Boards the Voltage feedback can be calibrated. Perform the "Voltage Calibration Procedure".

If unable to calibrate, replace the Control PC Board. Please note the statement regarding test meter accuracy, and follow all applicable board replacement procedures when replacing this board.

Perform the Voltage Sense PC Board Test.

ALL VOLTAGE MEASUREMENTS SHOULD BE MADE

AT THE SOURCE OF THE VOLTAGE FEEDBACK.

The source of voltage feedback is mode dependent. Mode

Test being

Actual vs Displayed

N

N

200 senses voltage from the output studs of the machine.

performed in Mode

Voltage:

200?

+/-1 Volt?**

Modes 5 and 201 sense from the Conductor Block on the

feeder to the negative stud of the machine, unless the

Y

Y

Voltage Sense Plug (P26) is removed from the Control PC

Bd., inwhich case the remote work sense plug is used

instead of the negative stud.

The PS Control PC Board is NOT interpreting current correctly.

Check the connections at P21 on the Control PC Board. Particularly the

signal pins (1 and 6).

Actual vs Displayed

Perform the PS

Depending on the magnitude of the descrepency, the current feedback

Current:

N

Current Transducer

Pass

can be calibrated. Perform the "Current Calibration Procedure".

+/- 10 Amps?**

Test

If unable to calibrate, and the connections are OK, replace the Control PC

Fail

Board. Please note the statement regarding test meter accuracy, and

Y

follow all applicable board replacement procedures when replacing this

board.

Replace the current

Transducer.

STT Performance Test Configuration (USE STT STUD)**

GMAW (.045 Steel - 1/4" Plate)

Using the Arc Scope function in

Mode = 117

Wave Designer / Wave Surfer, or

WFS =170 ipm

an oscilloscope equiped with a

Trim = 1.00

STT Machine?

Y

current probe, capture an STT

Gas =CO2

waveform, and compare it to the

Arc Control= 0

sample STT waveform (shown at

** Configuration may be altered based on available

right).

N

materials, but basic waveshape should remain the same.

!!CANNOT BE TESTED WITH STATIC GRID LOAD!!

Are the wave shapes

The STT portion of the system

similar, and does current

Y

drop in the middle of the

is operating properly

pulse as indicated?

N

The STT Chopper PC Board appears to be shorted, and therefore,

The STT Chopper PC Board appears to be "open".

The system is monitoring and

the resulting current waveform does not drop in the middle of the

controlling WFS, Voltage,

pulse as indicated in the Sample STT Waveform

Check for 18Vac at J10 pins 1 & 4 on the STT Chopper Board.

and Current correctly.

Does the machine

Performance checks OK.

N

noodle weld ( low output)?

Y

Disconnect J10 from the STT Chopper PC Board, and make

Check for loose or broken connections. Inspect the PC board for physical

another test weld. If the same symptoms result, perform the STT

damage

chopper PCBD test. If the machine noodle welds, the problem is

related to the control signal from the Control PC Board.

Perform the STT Chopper Board Test.

POWER WAVE 455/POWER FEED 10