Lincoln Electric 11937 Service Manual
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Lincoln Electric 11937 Service Manual

Lincoln Electric 11937 Service Manual

Wire feeder welder (180 models)
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WIRE FEEDER WELDER (180 MODELS)
For use with machines having Code Numbers:
11937, 11938, 11939, 11940
SERVICE MANUAL
SVM248-A
| Issue D ate 13-Jan
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

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Summary of Contents for Lincoln Electric 11937

  • Page 1 Some variances may exist when troubleshooting/repairing later code numbers. WIRE FEEDER WELDER (180 MODELS) For use with machines having Code Numbers: 11937, 11938, 11939, 11940 SERVICE MANUAL SVM248-A | Issue D ate 13-Jan © Lincoln Global, Inc. All Rights Reserved.
  • Page 2 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 3 SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 4.a. Use a shield with the proper filter and cover 3.a. The electrode and work (or ground) circuits plates to protect your eyes from sparks and are electrically “hot” when the welder is on. the rays of the arc when welding or observing Do not touch these “hot”...
  • Page 4 EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter.
  • Page 5 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommen- dations.
  • Page 6 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area. process used properly operating If this is not possible, cover them to prevent regulators designed for the gas and the welding sparks from starting a fire.
  • Page 7 NOTES WIRE FEEDER WELDERS (180 MODEL)
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN INDEX Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-vi Installation,.Operation,.Accessories,.Maintenance .

  • Page 9: Table Of Contents

    TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 General Description .
  • Page 10 THEORY OF OPERATION FIGURE E.2 - GENERAL DESCRIPTION WIRE TRIGGER VOLTAGE SPEED RECEPTACLE CONTROL CONTROL CONTROL BOARD SOLENOID CIRCUIT LINE BREAKER SWITCH INPUT RECEPTACLE WIRE MOTOR FEED MOTOR VOLTAGE FEEDBACK & MOTOR POWER CHOKE OUTPUT MAIN MAIN TRANSFORMER TERMINALS BRIDGE GENERAL DESCRIPTION The 180 AMP COMPACT WIRE WELDERS that are covered by this manual are Constant Voltage (CV)

  • Page 11: Theory Of Operation

    THEORY OF OPERATION FIGURE E.3 - INPUT LINE VOLTAGE, FAN MOTOR & MAIN TRANSFORMER NOT FOUND IN 125A MACHINE MOTOR SOLENOID CONTROL TRIGGER BOARD RECEPTACLE CIRCUIT INPUT BREAKER RECEPTACLE WIRE SPEED CONTROL WIRE FEED LINE MOTOR SWITCH WIRE DRIVE MOTOR & SOLENOID VOLTAGE NOT FOUND IN 125A MACHINE...

  • Page 12: Output Control, Rectification & Voltage Feedback

    THEORY OF OPERATION FIGURE E.4 - OUTPUT CONTROL, RECTIFICATION & VOLTAGE FEEDBACK NOT FOUND IN 125A MACHINE MOTOR SOLENOID CONTROL TRIGGER BOARD RECEPTACLE CIRCUIT INPUT BREAKER RECEPTACLE WIRE SPEED CONTROL WIRE FEED LINE MOTOR SWITCH WIRE DRIVE MOTOR & SOLENOID VOLTAGE NOT FOUND IN 125A MACHINE VOLTAGE...

  • Page 13: Trigger, Gas Solenoid And Wire Drive

    THEORY OF OPERATION FIGURE E.5 - TRIGGER, GAS SOLENOID AND WIRE DRIVE NOT FOUND IN 125A MACHINE MOTOR SOLENOID CONTROL TRIGGER BOARD RECEPTACLE CIRCUIT INPUT BREAKER RECEPTACLE WIRE SPEED CONTROL WIRE FEED LINE MOTOR SWITCH WIRE DRIVE MOTOR & SOLENOID VOLTAGE NOT FOUND IN 125A MACHINE VOLTAGE...

  • Page 14: Protective Devices And Circuits

    THEORY OF OPERATION PROTECTIVE DEVICES AND CIRCUITS THERMAL PROTECTION The Compact Wire Welders have a rated output duty cycle as defined in the Technical Specification page. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools to a rea- sonable operating temperature.
  • Page 15 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. . F-1 How to Use Troubleshooting Guide .

  • Page 16: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 17: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shield- ing bag. This will prevent further damage and allow CAUTION proper failure analysis.
  • Page 18 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. WIRE FEEDER WELDER (180 MODEL)
  • Page 19 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. WIRE FEEDER WELDER (180 MODEL)
  • Page 20 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. WIRE FEEDER WELDER (180 MODEL)
  • Page 21 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. WIRE FEEDER WELDER (180 MODEL)
  • Page 22 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. WIRE FEEDER WELDER (180 MODEL)
  • Page 23 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. WIRE FEEDER WELDER (180 MODEL)
  • Page 24 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. WIRE FEEDER WELDER (180 MODEL)

  • Page 25: Case Cover Removal And Replacement Procedure

    CASE COVER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 26 TROUBLESHOOTING AND REPAIR F-12 F-12 CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.1 – CASE COVER SCREWS 5/16” SCREWS PHILLIPS SCREWS PROCEDURE 4. Using a phillips screwdriver, remove the two 1. Disconnect power to the machine. screws from the case front. See Figure F.1. WARNING 5.

  • Page 27: Gas Solenoid Test

    GAS SOLENOID TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 28 TROUBLESHOOTING AND REPAIR F-14 F-14 GAS SOLENOID TEST (continued) FIGURE F.2 – GAS SOLENOID LOCATION & LEADS Gas Solenoid Leads PROCEDURE 6. If the 6.0 - 6.5 VDC is missing or is low, check 1. Remove input power to the machine. the leads and connections between the solen- 2.

  • Page 29: Wire Drive Motor Test

    WIRE DRIVE MOTOR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 30 TROUBLESHOOTING AND REPAIR F-16 F-16 WIRE DRIVE MOTOR TEST (continued) FIGURE F.3 – PLUGS P2 AND P3 PROCEDURE A. Turn the machine off between each test. NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. B. Carefully insert the meter probes into the lead side of plug P3.

  • Page 31: Main Transformer Test

    MAIN TRANSFORMER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 32 TROUBLESHOOTING AND REPAIR F-18 F-18 MAIN TRANSFORMER TEST (continued) FIGURE F.4 – VOLTAGE CONTROL SWITCH VOLTS AC PROCEDURE SECONDARY TEST PROCEDURE 1. Remove the input power to the machine. NOTE: Secondary voltages will vary proportion- ately with primary input voltage. For this 2.

  • Page 33: Fan Motor Test

    FAN MOTOR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 34 TROUBLESHOOTING AND REPAIR F-20 F-20 FAN MOTOR TEST (continued) FIGURE F.5 – CONTROL BOARD LEAD LOCATION(S) MOV2 MOV1 RETAIL BOARD L16300-1 PROCEDURE 5. There should be 230 VAC on the Fan leads at 1. Remove the input power to the machine. P2 pins 2 and 4 on the Control Board.

  • Page 35: Typical Output Voltage Waveform - Machine Loaded

    TROUBLESHOOTING AND REPAIR F-21 F-21 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED 0 volts 10 Volts 20ms This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 36: Abnormal Open Circuit Voltage Waveform

    TROUBLESHOOTING AND REPAIR F-22 F-22 ABNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 0 volts 10 Volts 20ms This is NOT the typical voltage wave- form. The output capacitor was dis- connected from the circuit. Note the increased ripple in the waveform. This condition simulates the faulty output filter capacitor.
  • Page 37 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 38 TROUBLESHOOTING AND REPAIR F-24 F-24 CONTROL BOARD REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.6 – CONTROL BOARD LOCATION CONTROL BOARD CONTROL PROCEDURE 5. Remove and replace the Control Board. 1. Remove the input power to the machine. 6. Connect all previously removed leads and WARNING plugs to the new Control Board.

  • Page 39: Rectifier Removal And Replacement Procedure

    RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 40 TROUBLESHOOTING AND REPAIR F-26 F-26 RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.7 – RECTIFIER MOUNTING BOLTS CONTROL 7/16” MOUNTING BOLTS LEADS PROCEDURE 1. Remove the input power to the machine. 2. Perform the Case Cover Removal Procedure. 5. Remove the rectifier. 6.

  • Page 41: Transformer & Choke Assembly Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 42 TROUBLESHOOTING AND REPAIR F-28 F-28 TRANSFORMER & CHOKE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.8 – LEADS TO VOLTAGE CONTROL SWITCH CONTROL LEADS TO VOLTAGE CONROL SWITCH TRANSFORMER AND CHOKE PROCEDURE 1. Remove the input power to the machine. 2.
  • Page 43 TROUBLESHOOTING AND REPAIR F-29 F-29 TRANSFORMER & CHOKE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.9 – THREAD FORMING SCREWS CONTROL THREAD FORMING SCREWS TRANSFORMER AND CHOKE 5. Label and remove the leads connected to the capacitor. 6. Unplug the thermostat leads. 7.
  • Page 44 NOTES F-30 F-30 WIRE FEEDER WELDER (180 MODEL)

  • Page 45: Wire Dive Motor Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 46 TROUBLESHOOTING AND REPAIR F-32 F-32 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.10 – PHILLIPS SCREWS CONTROL PHILLIPS MOUNTING SCREWS PROCEDURE 5. Label and disconnect the wire feed motors 1. Remove input power to the machine. armature leads. Remove gas hose. 2.
  • Page 47 TROUBLESHOOTING AND REPAIR F-33 F-33 WIRE DRIVE MOTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.11 – 1/4” MOUNTING BOLTS LOCATION 1/4” BOLTS 9. Install the four phillips screws and the two 7/16” bolts previously and torque to 23 - 27 inch/lbs.
  • Page 48 NOTES F-34 F-34 WIRE FEEDER WELDER (180 MODEL)
  • Page 49 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 50 TROUBLESHOOTING AND REPAIR F-36 F-36 FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.13 – FAN LOCATION FIGURE F.14 – FAN MOUNTING SCREWS CONTROL FAN MOUNTING SCREWS VIEWED FROM REAR OF MACHINE PROCEDURE 1. Remove the input power to the machine. 2.
  • Page 51 TROUBLESHOOTING AND REPAIR F-37 F-37 RETEST AFTER REPAIR (180 AMP UNIT) INPUT IDLE AMPS & WATTS Input Volts/Hertz Maximum Idle Amps Maximum Idle Watts 230/60 3.00 OPEN CIRCUIT VOLTAGE 30.5 - 34 VDC WIRE SPEED RANGE 30-500 in./min. (1.3-12.7 m/min) WIRE FEEDER WELDER (180 MODEL)
  • Page 52 Wiring Diagram - Code 11937, 11938, 11939, 11940 - (M24682) .......
  • Page 53 ELECTRICAL DIAGRAMS WIRING DIAGRAM - COMPLETE MACHINE - M24682 (CODES 11937, 11938, 11939, 11940) WIRING DIAGRAM WARNING Do not operate with covers removed. CONTROL P.C. BOARD Disconnect input power by unplugging power cord before servicing. MAGNUM 100SG Do not touch electrically live parts...
  • Page 54 ELECTRICAL DIAGRAMS MACHINE SCHEMATIC - M24683 RELEASED A.04 FROM X. ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: AIR FLOW Center Panel SELECTOR IS BACK TO FRONT SWITCH above Transformer and Rectifier RUNS CONTINUOUSLY WHEN ON/OFF SWITCH IS ON CONTROL BOARD SCHEMATIC L16300-1 11J3 G7533-1 12J3...
  • Page 55 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL BOARD (G7533-101) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. WIRE FEEDER WELDER (180 MODEL)
  • Page 56 ELECTRICAL DIAGRAMS SET UP INSTRUCTIONS - (M24783) RELEASED A.01 FROM X. ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: EQUIPMENT TYPE:...

This manual is also suitable for:

119381193911940

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