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Lincoln Electric SVM172-A service manual Troubleshooting & Repair Section, Section F-1

Models: SVM172-A

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Section F-1	TABLE OF CONTENTS	Section F-1
	- TROUBLESHOOTING & REPAIR SECTION -

Troubleshooting & Repair Section	Section F
How to Use Troubleshooting Guide	F-2
PC Board Troubleshooting Procedures and Replacement	F-3
Test Procedures	F-17/F-21
Voltage Sense PC board Test	F-17
Tach Feedback Test	F-19
Drive Motor Test	F-21
Removal and Replacement Procedures	F-23/F-25
Gear Box and Drive Motor Removal and Replacement	F-23
Retest After Repair	F-26

POWER FEED 10M SINGLE/DUAL

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Lincoln Electric SVM172-A service manual Troubleshooting & Repair Section, Section F-1

Contents

Power Feed 10M SINGLE/DUAL Safety Electric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation SectionSection A-1 Installation Welding Capacity RatingAmp Rating Duty Cycle Wire Drive Mounting See Figure A.1 Safety PrecautionLocation MountingWeld Cable Sizing 4INSTALLATIONA-4Weld Cable Connection Table A.1Changing Electrode Polarity Setting Coaxial Weld CablesNegative Electrode Polarity Control Cable Control Cable SpecificationsControl Cable Connections OFFChanging Drive Rolls Wire Wire Drive SystemsGuides DescriptionChanging the GUN Receiver Bushing Drive Roll Pressure SettingTo change the gun bushing Set the drive roll pressure byGUN Receiver Bushing Welding GUNS, Torches and ACCES- SoriesWire Feed Shut Down Circuit Changing the Gear RatioTo change the gear ratio Spindle Placement Wire Reel LoadingDIP Switch #8 Position Gear Ratio Loading 16 to 44 lb .3 20kg Spools50-60 lb .7 27.2 kg Coil Mounting See Figure A.10 Using K1504-1 Coil ReelFigure A.11 Loading 30 lb .6 kg Readi-Reels See Figure A.11Shielding GAS Connection INSTALLATIONA-14Arclink Power Wave System Examples Connecting ANBench Model Features Boom ConfigurationControl BOX Wire Drive CV Welding Pulse Welding or STT WeldingSection B-1 Operation SectionOperation Safety PrecautionsDefinitions of Welding Modes Product Description Common Welding AbbreviationsRecommended Processes Additional Required Equipment Required EquipmentProcess Limitations Equipment LimitationsFigure B.1- Case Front Controls Description Front Panel Controls and ConnectionsWire Feed SPEED/AMMETER Display Status LEDOutput Knob Volts / Trim Display and Output Knob Prior to WeldingSynergic CV Voltage Display Overview Mode Select Panel 4 MSP4LAYOUT-CONTROLS see Figure B.3 LAYOUT-DIGITAL DisplayChanging Weld Modes POWER-UP SequenceChanging ARC Wave Control Changing Weld Sequence BehaviorSetup Features Menu Return Actuate while TIG welding, gas flow is manually Step / 4-STEP Trigger Switch Cold Feed / GAS Purge SwitchStep Trigger Step Trigger OperationStep Trigger Operation See Figure B.4Sequence of Operation Figure B.5 See Figure B.5Figure B.6 Process Setup and OperationARC Control Steel and Stainless Synergic GMAW-P Pulsed MIG WeldingAluminum Synergic GMAW-P Pulsed Migand GMAW-PP Pulse on Pulse WeldingPulse-on-Pulse Welding Machine Functionality by Weld Process CV GMAW/FCAW NON-SYNERGIC Process Weld ModeMaterial Process GAS Wire Size Gmaw Synergic030 035 045 052 Pulse and PULSE-0N-PULSE Modes STT and STT II Synergic 23OPERATIONB-23035 045 052 Transfer END OptionsGtaw Touch Start TIG Welding Gtaw TIG WeldingARC Control Output Control Knobs Touch StartUsing Procedure Memories Procedure Memory vs. User MemoryRecall a memory with memory buttons Recall a memory with the gun triggerHigh Limit Limit SettingLow Limit AttributeSection C-1 Accessories SectionOptional AccessoriesAccessories Accessories Section D-1 Maintenance SectionSafety Precautions Calibration Specification MaintenanceRoutine Maintenance Periodic MaintenanceFigure D.1 Major Component Location Power Feed 10M SINGLE/DUAL Section AA Section AA-1AA-2 Technical Specifications Power Feed 10M Dual Wire FeederElectrode Routing Available Cable AssembliesAA-3 Electrode Sense Polarity Output CABLES, Connections and LimitationsAA-4 Table AA.1Extremely high welding outputs may occur AA-5AA-6 Work Voltage SensingElectrode Voltage Sensing Gear Ratio Change Procedure Changing the Wire Drive Gear RatioGear Ratio Recognition Table AA.3Wire Feed Drive Roll Kits Procedure to Install Drive Rolls and Wire GuidesAA-8 Gmaw Shielding GAS General GUN Connection GuidelinesAA-9 Cylinder may explode if damagedWire Feed Shut Down Circuit Optional Wire Spindle PlacementWater Connections for Water Cooled Guns AA-10Examples of Connecting AN Arclink Power Wave System AA-11Hard Automation System AA-12 Section BB Section BB-1Definitions of Welding Modes Common Welding Abbreviations Safety PrecautionsBB-2 Wear eye, ear and body protec- tionRecommended Processes and Equipment Product DescriptionRecommended Equipment BB-3Operational Features Wire Feed Speed WFS / AMP MeterControls Dual Procedure / Dual Head Select W/MEMORY Panel BB-5Output Controls BB-6 BB-7 Unsecured Parameters BB-8BB-9 BB-10 Left MSP4 button to exit 104 Hardware Version BB-11BB-12 OPERATIONBB-12Dual Procedure / Head Select Dual Head / Dual Procedure with MemoryBB-13 MemoryStep / 4 Step Operation Cold FEED/GAS Purge Switch BB-15WFS vs. Work point Waveform HOT Inch Wire Reel Loading READI-REELS, Spools or CoilsFoot Amptrol Electrode PolarityFigure BB.5 Figure BB.4Drive Roll Pressure Setting Feeding Electrode and Brake AdjustmentProcedure for Setting Angle of Feedplate GAS Guard Regulator SettingBB-19 Making a WeldComponent Status Lights Status Light StatesBB-20 BB-21 Status Light States CON’TMemory Value High Limit Low Limit BB-22Section CC-1 Table CC.1 Drive Roll and Guide Tube Kits ACCESSORIESCC-2Field Installed K162-1 Wire Spindle AdapterOPTIONS/ACCESSORIES K1504-1 Coil AdapterK363P READI-REEL Adapter K435 Coil AdapterK438 READI-REEL Adapter Guns and GUN AdaptersConduit Adapters Dual Procedure Switch OptionsK1556-1 Light Duty Caster KIT K659-1 GAS Guard RegulatorK1555-2 Insulated Lift Hook K1546-1 Conduit AdapterSection DD Section DD-1Maintenance Figure DD.1 Major Component Location DD-3DD-4 Section E Theory of OperationPower Feed 10M Feed Head Control BOX User Interface Power Feed 10M SINGLE/DUAL Section F-1 Troubleshooting & Repair SectionHOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board Troubleshooting Procedures Make certain the Power Wave 455M power source is funcTioning correctly Function Problems Function Problems Troubleshooting & Repair Troubleshooting & Repair Powerfeed 10M Welding Problems Err 003 Err 001Err 004 Err 005Err 100 Err 020Err 200 Err 201Err 211 Err 212Three dashes Problems Possible Problems Possible Recommended Power Feed 10M SINGLE/DUAL Test Description Voltage Sense PC Board TestTest Procedure Tach Feedback Test Troubleshooting and RepairBlack RED Test ProcedureBlue J84Drive Motor Test Figure F.3 Drive Motor Test ProcedureGear BOX and Drive Motor Removal and Replacement Figure F.4- Gear BOX and Drive Motor Removal and Replacement Replacement Procedures To Remove the Wire Drive Assembly from the Gear BOXTo Remove the Drive Motor From the Gear BOX Retest a machine SET UPSection G-1 Electrical Diagrams SectionPower Feed 10M SINGLE/DUAL Wiring Diagram Power Feed 10M DualWiring Diagram Entire Machine Code 11086, 11216 G4439 Wiring Diagram Power Feed 10M Single Feed HeadWiring Diagram Entire Machine Code 11193 G4439-1 Wiring Diagram Power Feed 10M Single Boom FeederG4320 Schematic Entire Machine Code 10962 G4320-1Schematic Entire Machine Code 11086, 11216 G4440 Return to Section Section TOC Schematic Entire Machine Code 11193 G5002G5003 Schematic Entire Machine Code 11194 G5003Schematic Wire Drive PC Board G3883 Sheet Schematic Wire Drive PC Board ALL Codes G3883 Sheet PC Board Assembly Wire Drive ALL Codes G3884-2F0 Schematic Voltage Sense PC Board ALL Codes S24779-3C0 PC Board Assembly Voltage Sense ALL Codes M19540-3 Schematic MSP4 Display PC Board ALL Codes G4456 PC Board Assembly MSP4 Display ALL Codes L12116-1B0 Schematic Display PC Board ALL Codes L11756 PC Board Assembly Display ALL Codes L11757-1 Schematic Spool GUN PC Board ALL Codes L12008-3E0 PC Board Assembly Spool GUN ALL Codes M20159-3 Schematic Filter PC Board ALL Codes M19487-2B0 PC Board Assembly Filter ALL Codes M19488-2