Troubleshooting Procedures - Lincoln Electric WIRE FEED MODULE IM 513-B Operator's Manual

TROUBLESHOOTING PROCEDURES

A. P.C. Board Troubleshooting Procedures
Perform the following checks before replacing the
P.C. Board.
1. Remove the cover to the Wire Feed Module
box located on the right side of the machine.
With the engine running the green and red
LED on the P.C. Board must be glowing. If
not, check the following:
a) Check for loose connections in the P.C.
Board plugs, pay close attention to J3.
b) With machine running at high idle, check
the following voltages accessible at P.C.
Board plug J3:
Lead Number
610 - 600
If these voltages are not present, check the
wiring connections between the engine welder
and the Wire Feed Module. If wiring is good,
then refer to the "Quick Check Procedure for
Generator Only". If generator is operating
properly, refer to "Procedure for Replacing
P.C. Boards".
B. Procedures for Replacing P.C. Boards
Before replacing a P.C. Board which is suspected of
being defective, visually inspect the P.C. Board in
question for any electrical or mechanical damage to
any of its components and conductors on the back of
the board.
1. If there is no visible damage to the P.C.
Board, install a new one and see if this reme-
dies the problem. If the problem is remedied,
reinstall the old P.C. Board to see if the prob-
lem still exists. If it does no longer exist with
the old P.C. Board:
a) Check the P.C. Board harness connector
pins for corrosion, contamination, or loose-
ness.
b) Check leads in the plug harness for loose
or intermittent connection.
2. If P.C. Board is visibly damaged electrically,
before possibly subjecting the new P.C. Board
to the same cause of failure, check for possi-
ble shorts, opens, or grounds caused by:
a) Frayed or pinched lead insulation.
Voltage
120 + 13/-10 Volts DC
b) Poor lead termination, such as a poor
contact or a short to adjacent connection
or surface.
c) Shorted or open leads, or other external
leads.
d) Foreign matter or interference behind the
P.C. Boards.
3. If P.C. Board is visibly damaged mechanically,
inspect for cause then remedy before
installing a replacement P.C. Board.
If there is damage to the P.C. Board or if
replacing P.C. Board corrects problem, return
it to the local Lincoln Electric Field Service
Shop.
C. Output Voltage
Constant Voltage Mode -- The open circuit
voltage in CV mode is 7-55 volts DC. If any
other conditions exist, refer to the
Troubleshooting Chart.
D. Procedure for Checking the Cold Tip
Contactor (CR4)
1. If there is no output during the initial start
up of the machine, check to see if the
"Local/Remote" switch is in "LOCAL", if so,
switch to "REMOTE" and then back to
"LOCAL" and check for output voltage. If
switch is in "Remote" switch to the
"LOCAL" position and check for output
voltage.
2. Open side panel of wire feed module.
With machine running, verify the P.C.
Board is working by checking to see if the
green and red LED's are on. If LED's are
not on, see P.C. Board Troubleshooting
Procedures. If the LED's are on, check
the voltage between the top left stud of
the cold tip contactor (CR4) and the posi-
tive output stud. The voltage should mea-
sure between 7 and 55 volts DC depend-
ing on the position of the CV voltage con-
trol setting. Try adjusting the voltage con-
trol to see if this voltage changes. If volt-
age is present, go to step 3. If no voltage
is present, check for loose cable or wiring
connections. If voltage is still not present,
refer to Troubleshooting Chart.
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