OUTPUT/FEEDING Problems | Lincoln Electric SVM189-B guide

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	F-5	TROUBLESHOOTING & REPAIR			F-5
	F-5				F-5

	Observe Safety Guidelines detailed in the beginning of this manual.

	PROBLEMS		POSSIBLE AREAS OF	RECOMMENDED
	(SYMPTOMS)		MISADJUSTMENT(S)	COURSE OF ACTION

			OUTPUT/FEEDING PROBLEMS
	The machine has output, wire		1. Possible faulty fan motor.	1. Perform the Fan Motor Test.
	feed, gas flow but NO fan.		2. Possible faulty Control P.C.	2. Check for continuity between
			2. Possible faulty Control P.C.	2. Check for continuity between
			Board.	#6 to Fan or #1 to Fan on
				Control P.C. Board. Replace.

	The machine has output, gas		1. Possible bad drive motor.	1. Perform the Wire Drive Test.
	flow and fan but does not have		2. Possible bad Control P.C.	2. If 3 - 30 vdc is not at the drive
	wire drive.		2. Possible bad Control P.C.	2. If 3 - 30 vdc is not at the drive
	wire drive.		Board.	motor check for OCV at the
			Board.	motor check for OCV at the
				board on pins 1 and 10 on J3.
				If OCV is present possible
				faulty Control P.C Board.
				Replace. If OCV is not
				present check continuity of
				wires CAP- and CAP+.

	No wire feed when gun trigger is		1. If the wire drive motor is	1. Perform the Wire Drive Test.
	pulled. Fan runs, gas flows and		running, make sure that the	2. If wire drive test is OK, then
	machine has correct open circuit		correct drive roll and wire	2. If wire drive test is OK, then
	machine has correct open circuit		correct drive roll and wire	check for OCV at CAP- and
	voltage. ( 33 vdc maximum) -		guide is installed in the	check for OCV at CAP- and
	voltage. ( 33 vdc maximum) -		guide is installed in the	CAP+ on the control board. If
	weld output.		machine.	CAP+ on the control board. If
	weld output.		machine.	correct voltage is present,
				correct voltage is present,
			2. Check for clogged cable liner	possible faulty Control P.C.
			or contact tip.	Board. Replace.
			3. Check for proper size cable	3. If open circuit voltage is not
			liner and contact tip.	present at CAP- and CAP+ on
				control board check continuity
				of leads.

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 1-888-935-3877.

COMPACT WIRE WELDERS

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Lincoln Electric SVM189-B service manual OUTPUT/FEEDING Problems

Contents

SVM189-B Safety Depends on You California Proposition 65 Warnings Safety Electric Shock can kill ARC Rays can burn Iii Welding CuttingFor Electrically Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Installation Tilting Safety PrecautionsSelect Suitable Location Stacking Identify and Locate Components Table of Contents Operation Section Wear eye, ear and body protec- tion OperationProduct Description Product Capabilities Common Welding Abbreviations See Figure B.2 Controls and SettingsSee Figure B.1 Drive Roll Tension Thumbscrew Turning See Figure B.3 Number Part Number Wire Diameter Drive Roll Drive Roll Part Inner Wire Guide Items Needed for Flux Cored Welding Setting UP and Making a FLUX-CORED Weld Machine Load Wire SpoolConnect Leads and Cables on Figure B.9 025 MIG Conversion Kit K2526-1 Shielding GAS Install Shielding GAS Connect Leads and Cables on the Machine 11OPERATION Do not Remove or Conceal Warning Labels 12OPERATION Figure B.20 Compact Wire Welders Table of Contents Accessories Section K2377-1 Small Canvas Cover AccessoriesK2525-1 Spot Timer Kit K2532-1 Magnum 100SG Spool Gun K520-Utility Cart K2275-1 Welding Cart Unpacking the Spool GUN Technical Specifications Magnum 100SG Spool GUN K2532-1 Locating Spool GUN Components Features Safety Precautions Figure C.3 Assembly of Items Inside the Magnum Spool GUN Spool GUN Safety Precautions Welding MachinesRecommended Welding Machines Open the Machine Spool GUN / Wire Drive Selector Switch InstallationDisconnect input power from the machine 11.C. Connect harness P8 6-pin to board J5 6- pin Electrical Connections11.B. Connect P5 6-pin to harness J8 6-pin 544A 543A If Machine does have Optional Spot Timer .A. thru 12.D RE-ASSEMBLE Machine AS Follows Mounting the Switch Preparing the Spool GUN ACCESSORIESC-13Disconnect input power to the machine Routine Welding Machine Preparation Figure C.5 Loading Aluminum Wire Figure C.11 Figure C.17 Connecting the GUN to the Welding Machine Table of Contents Maintenance Section Routine Maintenance MaintenanceMaintenance Safety Precautions For Magnum 100L GUN GUN and Cable MaintenanceOverload Protection Liner trim length Changing LinerGUN Handle Parts Major Component Locations Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 General Description Theory of Operation Input Line VOLTAGE, FAN Motor & Main Transformer Figure E.3 Input Power Circuits Figure E.4 Output Circuits Output CONTROL, Rectification & Voltage Feedback Figure E.5 TRIGGER, GAS Solenoid & Wire Drive TRIGGER, GAS Solenoid and Wire Drive Figure E.6 SCR Operation SCR Operation Electronic Wire Drive Motor Protection Compact Wire Welders Table of Contents Troubleshooting & Repair HOW to USE Troubleshooting Guide Troubleshooting & Repair PC Board Troubleshooting Procedures Wiring Diagram OUTPUT/FEEDING Problems Feeding Problems Welding Problems Maintenance Section Issues Maintenance Section Cone or gas diffuser Materials Needed Case Cover Removal and Replacement ProcedureTest Description Figure F.1 Case Removal Procedure GAS Solenoid Test GasSolenoid Leads Wire Drive Motor Test MOT-MOT+ Test Procedure Main Transformer Test Secondary Test Procedure Secondary Lead Compact Wire Welders FAN Motor Test Figure F.5. Control Board Lead Locations Volts 10Volts 20ms Scope SettingsTypical Output Voltage Waveform Machine Loaded Abnormal Open Circuit Voltage Waveform Control Board Removal and Replacement Procedure See Figure F.7 Nameplate Control Knob Compact Wire Welders Power Module Removal and Replacement Procedure Viewed from Rear of Machine Center Panel PolarityPanel CenterPanelScrews OutputStuds Compact Wire Welders Misc. Hand Tools Dow Corning Fine Steel Wool See Figure F.12 Dow Corning Figure F.12 DOW Corning Application Areas Transformer Compact Wire Welders Wire Drive Motor Removal and Replacement Procedure Lincolnelectric Phillips Mounting Screws Compact Wire Welders FAN Motor Assembly Removal and Replacement Procedure Viewed from Rear of Machine Center Panel CenterPanelScrews Locking Tabs Fan Open Circuit Voltage Troubleshooting & Repair Retest After Repair 125 AMP UnitsWire Speed Range Retest After Repair 140 AMP Units Troubleshooting & Repair Retest After Repair 180 AMP Units Table of Contents Diagram Section COmpacT WirE WElDErS Wiring Diagram Spool GUN Interface Wiring Diagram Wiring Diagram Thermostat TMP FAN TS1 M20410-3 a COmpacT WirE WElDErS SchEmaTic cOmplETE machiNE m21240 C12 R1Feed R24