Lincoln Electric SVM135-B service manual Functional Troubleshooting Guide

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F-95	TROUBLESHOOTING AND REPAIR	F-95
FLOWCHART - FUNCTIONAL TROUBLESHOOTING GUIDE

See UI Error					Functional Troubleshooting Guide
					(Semi Automatic PW-455, PW455/STT)
Chart for	N	Error 006?	N	Error 100?
additional error
codes.					Turn On
		Y		Y	(For Codes 10555 and Below)

Main UI Display

N

UI Status

Y

Condition of

Other

Status Light on the PS

N

on?

panel on?

on?

Status Light?

At this point, voltage is being supplied to the UI Control

Y

Solid Green

N

Board, and the on board supply is properly converting it to

Y

12Vdc. This has been verified by the condition of the Status

light and by measurement at the display.

Errors on UI

Y

Verify 12 VDC is being

Because the Status light indicates a healthy condition, the

Communication Fault.

Go To PS

Display?

supplied to UI Display

Y

problem is most likely in the harness from

the Display to

Check Wiring and

Solid

Condition of

Flashing

Error

PCBD (J1 pin 7 to 8)

the UI Control board or in the Display board itself. Check the

Linc-Net Cables for

Red

Status light

Red and Green

Interpretation

N

harness, and run the Display Panel Check.

open circuit

Guide.

PS Status

N

N

There is a remote possibility that the Communications

Flashing Green

Select a CV

on?

Mode

Hardware on the UI Control board is not functioning

properly.

Check connections from UI Control Board to

Y

Display panel. If the display and Status light are

System is stuck in Remapping loop.

still not functioning, remove P4 from the UI

Most likely cause is the loss of the

Can you adjust

Control Board.

+5Vcan Supply. Check J27 on PS

N

Check for 12 VDC at J4 pins 1 to 4 , and J4

Control Board, check Power Board,

WFS and Voltage?

pins 3 to 8 on the UI Control board. If voltage is

Etc.

not present, replace UI Control Board

At this point, voltage is being supplied to the UI Control

Y

Board, and the on board supply is properly converting it to

Check Status Light and harness

Y

N

12Vdc, which has been verified at the display.

Verify all connections to the PS Control Board

Does Wire feed when

The Status light is not functioning, so the most likely

Errors on UI

Check For

Verify 12 VDC is being

problem is that the UI Control board is "lost".Try reloading

5

Green LED's

lit on

N

N

Y

Perform Power Board test to verify correct

Display?

you pull the trigger?

40VDC at UI

OK

supplied to UI Display

Y

the UI Software. If problem still exists, Replace the Control

the PS Control

Control Board

PCBD (J1 pin 7 to 8)

board.

Board?

voltage levels

Y

Reload the PS Software. If Problem still

Not OK

There is a remote possibility that a multiple fault exists in

N

exists, replace PS Control Board.

the harness from the Display to the UI Control board, or in

Y

any combination of the following: The harness, the Display

Is there OCV from the

board, and the Status light.

Check PS breaker (CB1), Linc-Net

Errors on UI

brass block to the work stud

N

cables, wiring in UI and PS.

Display?

with the trigger pulled

+40 VDC section of Power Board

N

Y

may be malfunctioning, Perform

Power Board test

UNHEALTHY STATUS LIGHT WITH BLANK DISPLAY:

Look for open

Improper system configuration (dipswitch settings) can result in

circuit in the

System is functional. If

mapping errors that cause PS to continuously issue a system reset

PS secondary

performance problems

command. The result is the UI gets stuck in a reset loop, usually

exist see System

accompanied by a blank display with a green and/or red flashing

Performance

status light. Correct the system configuration.

Troubleshooting guide

Verify no Limits are set.

Check the connections on wires 541 & 542, and pins A & B in the

Check/repair harness between:

Linc-Net control cable.

Check Harness for UI Control Board

The Power Board and the Control Board.

to the Dislay Panel (specifically the

Run Power

UI software may be corrupt. Reload UI soft ware

Pass

- AND/OR -

wires to the Encoder Board.

Board Test

The Power Board and the wire feeder

receptacle (S1), including the output

Run The Dual Encoder PC Board

Fail

circuit breaker (CB1).

Test

FH does not appear to have power.

Was 60-80 VDC at Power

Replace the

Y

Board input connector

Power Board.

FH Status On?

N

Check +40 VDC connections on

pins "D" & "E" of the Linc Net

N

receptacle in the FH.

Y

Be sure the trigger is engaged long enough to overcome any set preflow

Check/repair harness

Voltage at the Power

delay, or turn the preflow timer off.

The FH has detected no activity from the

Y

between the Power

communication network.

Board Capacitor?

FH Status

Board and the Capacitor.

Green

Red

Check trigger circuit operation from the gun to the FH Control Board.

Condition?

Check the connections on wires 541 & 542, and pins

N

Perform the Drive Motor Test to verify motor voltage is present when the

A & B in the Linc-Net control cable.

trigger is pulled.

Flashing

Check for 60 to 80 VDC at the

Output of the rectifier. If present,

Voltage at the input to

FH Status

Y

Flashing Red

Flashing Green

the Rectifier?

check harness from rectifier to

Condition?

Capacitor. If not replace rectifier

Flashing

N

Check the continuity of the Shutdown circuit in the FH (wires

Red and Green

570 & 571). If the path between these wires is interrupted the

Check the system configuration.

FH will not operate and the Status light will flash red while all

If the FH is not recognized as part of a valid group, or if

other nodes appear normal.

Key:

FH has a motor

improper dipswitch settings result in a duplicate or invalid

A rapidly flashing red Status light indicates the node needs to be

overcurrent/overtemperature

network assignment, a mapping error will be generated.

PS = Power Source

Input power does not appear to be

error.

reprogrammed.

UI = User Interface (Control

supplied to aux. transformers

Box)

Check input power, check reconnect,

FH = Feed Head

check Breakers, check Line Switch, etc.

POWER WAVE 455/POWER FEED 10