Perform the Rotor Resistance | Lincoln Electric SVM153-A specs

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F-5

TROUBLESHOOTING & REPAIR

F-5

TROUBLESHOOTING GUIDE

Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

OUTPUT PROBLEMS

No welding output in neither Stick

1.

Check the brushes for wear and

1.

Perform the Rotor Resistance

or CV

modes. Also no auxiliary

proper contact to the rotor slip

Test.

power.

The engine operates nor-

rings.

2.

Perform

the

Flashing

and

mally.

2.

Make sure the engine is operat-

Rotor Voltage

Test.

If

the

ing at the correct high idle

"flashing" voltage is not present

speed (1900RPM).

the Battery PC board or leads

3.

Check for loose or faulty con-

#201 or #200

may

be faulty.

See the Wiring Diagram. Also

nections or leads on the auxil-

make sure that lead

#5P has

iary power studs in the control

continuity

(zero

ohms)

to

box. See the Wiring Diagram.

ground.

3. Check the field diode bridge and

capacitor. Replace if necessary.

4. Perform

the Stator Voltage

Test.

5. See the

Start-Up and OCV

Diagnostic Chart.

No auxiliary power at the recepta-

1.

The circuit breakers may be

1. Check the wiring between the

cles. The welding output is normal

tripped. Reset if necessary.

auxiliary receptacles, the con-

and the engine operates normally.

2.

Check for loose or faulty con-

nection studs in the control box,

and the main stator.

See the

nections at the auxiliary recep-

Wiring Diagram.

tacles.

2. Perform

the Stator Voltage

Test.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800-833-9353.

COMMANDER 500

Image 58

Lincoln Electric SVM153-A service manual Perform the Rotor Resistance

Contents

CommanderTM Safety California Proposition 65 Warnings Electric Shock can kill Welding Sparks can cause fire or explosion Iii Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Commander 500 K1639-1 Storing Safety PrecautionsLocation / Ventilation Stacking Towing High Temperature OperationLifting High Altitude Operation PRE-OPERATION Engine Service Muffler Outlet Pipe Spark Arrester Welding Output Cables Auxiliary Power ReceptaclesStandby Power Connections Machine Grounding Company Table of Contents Operation Section Operating Instructions Safety InstructionsOperation General Description Design Features and Advantages Recommended Applications K1639-1 Commander 500 Standard Model Controls and SettingsWelding Capability Start Pushbutton RUN/STOP SwitchIdler Switch Fuel Level Gauge and Light Table B.1 Weld Mode and Output Control Functions Weld Mode Output ControlWelding Terminals Switch Hour Meter Auxiliary Power Controls BREAK-IN Period Engine OperationStarting the Engine Typical Fuel Consumption Constant Current CC Welding Welder OperationStick Welding TIG Welding Table B.3 Typical Current RANGES1 for Tungsten ELECTRODES2 Commander 500 Settings When Using the K799 HI-FREQ UnitCommander 500 Settings When Using the K930-1 TIG Module TIG Torch Simultaneous Welding and Auxiliary Power Loads Auxiliary Power OperationWire Feed Constant Voltage Welding ARC Gouging Extension Cord Recommendations Permissible Permissible Auxiliary Table of Contents Accessories Section Field Installed Options AccessoriesOPTIONS/ACCESSORIES Stick Welding Accessories Other Wire Feeders for the Commander Semiautomatic Welding AccessoriesConnection of Lincoln Electric Wire Feeders High Frequency Generators for TIG Applications To Work Electrode Cable To Wire Feed Unit ING CV ING CV ING CV Figure C.5 Commander 500/LN-23P Connection Diagram ING Terminals Always on Table of Contents Maintenance Section Engine Maintenance MaintenanceRoutine and Periodic Maintenance Daily Figure D.1 OIL Drain and Refill Figure D.2 Fuel PRE-FILTER/WATER Separator Assembly Fuel Filters Figure D.3 Secondary Fuel Filter AIR Filter Maintenance Frequency Maintenance Required Table D.2 Engine Maintenance Parts Manufacturer Part Number Battery Maintenance Connecting a Battery Charger WELDER/GENERATOR Maintenance Figure D.5 Major Component Locations Commander Table of Contents Theory of Operation Section Commander Theory of Operation Weld WINDINGS, RECTIFIER, Power Modules and Feedback Analog Control Power Supply Board and Weld Control Board Insulated Gate Bipolar Transistor Igbt Operation Minimum Output Pulse Width Modulation6E-6 Maximum Output Chopper Technology Fundamentals External DC Solid State Inductor ARC Source Switch Diode70-80VDC Troubleshooting & Repair Section Table of ContentsSection F-1 Troubleshooting & Repair HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures PC Board can be damaged by static electricity Observe Safety Guidelines Troubleshooting GuideDetailed in the beginning of this manual Perform the Rotor Resistance Justment Test Function Problems Charging Circuit Test Engine Problems Shutdown Perform the Idler Solenoid Problems Possible Areas Symptoms Misadjustments Course of Action Engine Starting Diagnostic Chart START-UP and OCV Diagnostic Chart Return Description Case Cover Removal and Replacement ProcedureMaterials Needed Case Cover Removal Replacement Procedure Procedure Figure F.1 Case Front Knobs Removal and Replacement Procedure Removal Power Module Capacitor Discharge Procedure Procedure Idler Solenoid Test Test Description Test Procedure Figure F.5 Idler Solenoid Leads Shutdown Solenoid Test Figure F.6 Shutdown Solenoid Lead Terminals Engine Throttle Adjustment Test Figure F.7 Strobe Mark Location Mark Blower Paddle Here Strobe-tach Method Locking NUT Frequency Counter Method 28F-28Oscilloscope Method Rotor Resistance Test Test Procedure Flashing and Rotor Voltage Test 10 11 12 13 14 15 Lead # 201A Troubleshooting & Repair Stator Voltage Test Figure F.13 Front Control Panel Removal Screws Troubleshooting & Repair Auxiliary Leads #5B, #5E, #8, #9, #11, #12 Auxiliary Power and Weld Windings TestBehind Panel W6W1 Weld Winding Lead Connections Analog Power Supply PC Board Voltage Test 40F-40 Control Circuit Input PowerJ41 Analog Control Power Supply PC Board Test Test Points Component Tested Voltage Reading Output Rectifier Bridge Test Perform the Power Module Capacitor Discharge Procedure Troubleshooting & Repair Figure F.20 Diode Lead Removal Power Module Test Power Module PC Board Diode Lead D4 Positive + Strap Temperature SwitchW10 Check Igbt For Shorts When all tests are complete Check Diode Module Charging Circuit Test Figure F.24 Engine Alternator Location #239 #281 #238 High Idle no Load Scope SettingsNormal Open Circuit Voltage Waveform 115VAC Supply 15.8 ms Volts 50V5ms MAX TAP MAX Control POT High Idle no Load Normal Open Circuit Voltage Waveform StickVolts 50V5ms Machine Loaded to 500 Amps AT 40 Volts Normal Weld Voltage Waveform Stick CCVolts 20V0.1ms Normal Weld Voltage Waveform Wire CV Loaded to 200A 16 Volts Normal TIG Mode Voltage WaveformVolts 10V50ms Normal Open Circuit Voltage Waveform Wire CV TAP MAX Control POT High Idle no Load Shutdown Solenoid Removal and Replacement Figure F Shutdown Solenoid Lead Connections Reassembly Figure F Shutdown Solenoid Linkage ARM Assembly Description Control Panel Removal Screws Front Green Ground Lead Figure F Power Module Capacitor Lead Removal Troubleshooting & Repair Replacement Procedure Description Power Module PC Board Removal Figure F.30 Power Module PC Board Power Module PC Board Replacement Diode Module Replacement Diode Module Removal Output Rectifier Bridge Diode Removal and Replacement Refer to Figure F.32 Turn the engine off Return Section TOC Diode Stud Size Foot Pounds Inch Pounds STATOR/ROTOR Removal and Replacement Leads #229 #242D Preparation and Lead Removal ProcedurePlug Fuel Lines Bolts #200D #5P #201 #201A Filter Field Diode Capacitor Figure F.35 Brush Holder and Lead Removal #232M Figure F.37 Alternator Shroud Removal Screws Acoustical Foam Figure F.38 Lift Frame and Associated Component Removal Stator Removal Procedure Figure F.39 Stator Removal Rotor Removal Procedure Reassembly Notes Engine Lead Reconnection ChecklistOutput Panel and Control BOX Engine RPM Welder CV Wire OutputRetest After Repair Welder DC Stick Output Touch Start TIG Mode Output Auxiliary Power Output Electrical Diagrams Table of Contents Electrical Diagrams Section Electrical Diagrams Schematic Complete Machine Commander G3834 Schematic Battery PC Board PC Board Assembly Battery PC Board Return to Section Schematic Chopper PC Board PWM Input PC Board Assembly Chopper PC Board Return to Section Return to Section TOC Schematic Peripheral PC Board PC Board Assembly Peripheral PC Board Return to Section Schematic Power Supply Analog PC Board PC Board Assembly Power Supply Analog PC Board PC Board Reference QTY Designators Description Schematic PULL-COIL PC Board PC Board Assembly PULL-COIL PC Board MOSFET/HEATSINK ASBLY,T12704-82&S1810 Schematic Weld Control PC Board Sheet Electrical Diagrams Electrical Diagrams Electrical Diagrams Electrical Diagrams PC Board Assembly Weld Control PC Board RESISTOR,SMD,METAL FILM,1/10W,150OHMS SVM Error Reporting Form