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| TROUBLESHOOTING AND REPAIR |
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Observe Safety Guidelines detailed in the beginning of this manual. |
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| PROBLEMS |
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| POSSIBLE AREAS OF |
| RECOMMENDED |
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| (SYMPTOMS) |
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| MISADJUSTMENT(S) |
| COURSE OF ACTION | ||||||
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| OUTPUT PROBLEMS |
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Machine input contactor | operates | 1. C h e ck L E D 1 0 o n t h e F i r i n g | 1. I f b o t h L E D s a r e O F F, t r y a n | |||||||||
but machine has no weld output with |
| Board and LED 6 on the Control |
| alternate method of triggering. | ||||||||
the Output terminal Switch ON. Fan |
| Board. Both Should be ON. |
| If LEDs come ON and machine | ||||||||
runs and pilot light glows. |
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| weld output is restored check | ||||
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| the Weld Terminal Switch (S2) | |||
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| and the associated wiring. If not, | |||
NOTE: Alternate Trigger methods. |
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| see the Internal Trigger Circuit | |||||
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| Test.If both LEDs are ON and | |||
• | Operate Wire Feeder trigger. | 2. Check all of the LEDs on both |
| there is still no output go to Step | ||||||||
• | Place a jumper across 2 & 4 on |
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| PC Boards for proper operation. |
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| the terminal strip | T.S.2. or |
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| 2. T h e F i r i n g B o a r d o r C o n t r o l | ||||||
| across pins C & D in 14 pin con- |
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| Board may be defective. See the | |||||
| nector. |
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| PC Board Troubleshooting | ||||
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| Guide. |
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The machine does not have maxi- | 1. | Check all three phase input | 1. | Check | the | Output | Control | |||||
mum weld output. |
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| lines | at the | DC600. | Make |
| Potentiometer (R1) and | ||||
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| sure | input | voltages | match |
| associated wiring for loose or | |||
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| machine rating and recon- |
| faulty | connections. | See | ||||
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| nect panel. |
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| wiring diagram. |
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| 2. | Put LOCAL/REMOTE Switch | 3. | Perform | the | Control | Board | |||
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| (SW3) in "LOCAL" position. |
| Test. |
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| If problem is solved then | 4. | Perform the Firing Board Test. | ||||||
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| check remote control unit or | ||||||||
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| wire feeder. |
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| 5. | Perform | the | SCR | Output | |
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| Bridge Test. |
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| 6. | Perform the Main Transformer | |||
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| Test. |
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The weld output terminals are | 1. | Remove any external | leads | 1. | Check for an internal short | |||||||
always electrically "hot". |
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| hooked to #2 and #4 on the ter- |
| between leads #2 and #4. See | |||||||
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| minal strip. If the problem dis- |
| wiring diagram. |
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| appears the fault is in the control |
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| cable or wire feeder. |
| 3. | Perform Firing Board Test. | |||||
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| 2. | If some open circuit voltage is | 4. | Perform Control Board Test. | ||||||
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| present (over 3VDC.) after per- |
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| forming Step #1. then the prob- | 5. | Perform | the | SCR | Output | |||
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| lem is within the DC600. |
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| Bridge Test. |
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| 6. | The SCR Snubber(s) may be | |||
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| "leaky". Check or replace. | |||
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call
