Output System Troubleshooting - Lincoln Electric RANGER IM511-D Operator's Manual

OUTPUT SYSTEM
TROUBLE
A. No welder or power output.
B. Output control on welder not
functioning.
C. Output control or remote not
functioning.
D. Wire feeder does not work when
connected to welder amphenol.
CAUSE
1. Open lead in flashing or field circuit.
2. Faulty rotor.
3. Faulty stator field.
4. Faulty field rectifier D2.
5. Output contactor does not pull in.
6. Faulty P.C. Board.
1. Output control switch in wrong
position.
2. Output control switch defective.
3. Output control potentiometer
defective.
4. Faulty wiring.
5. Faulty P.C. Board
1. Output control switch in wrong
position.
2. Leads #75, #76, #77 broken at P.C.
Board or S4.
3. Leads #75A, #76A, #77A broken at
S4 or amphenol.
4. Remote control leads broken in
control cable.
5. Faulty wire feeder.
6. Faulty P.C. Board.
1. Wire feeder circuit breaker open or
faulty.
2. Broken #31, #32, or #42 lead at
amphenol.
3. No 115V or 42V output from stator.
4. Faulty wiring in control cable.
5. Faulty wire feeder.
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WHAT TO DO
1. Refer to wiring diagram and check
related leads.
(#7 & #9; #200, #201 and #219)
2. Lift brushes and check rotor
continuity between slip rings.
(Should be approx. 7.3Ω)
3. Disconnect lead #7 at D2 and
check for continuity between
leads #7 and #9.
4. Replace with known good one.
5. Refer to wiring diagram and check
related leads and contactor.
6. Replace P.C. Board with known
good one.
1. Place switch in "Output Control
at Welder".
2. Check and replace switch if faulty.
3. Check and replace potentiometer
if faulty.
4. Check for broken leads #75, #76,
and #77 from P.C. Board and
#75A, #76D, and #77D from
potentiometer to remote switch.
5. Replace P.C. Board with known
good one.
1. Place switch in "Remote" position.
2. Repair.
3. Repair.
4. Repair.
5. Replace wire feeder with known
good one.
6. Replace P.C. Board with known
good one.
1. Reset or replace.
2. Repair.
3. Check continuity on #31, #32, and
#42 at stator. Check buildup. If
O.K. , stator may be faulty.
Replace.
4. Repair or replace cable.
5. Replace P.C. Board with known
good one.