E-4
TROUBLESHOOTING
WIRE FEED MODULE™
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility
for technical troubleshooting assistance before you proceed.
CAUTION
PC BOARD TROUBLESHOOTING GUIDE -
CONTROL P.C. BOARD
1. 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 run-
ning 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 follow-
ing voltages accessible at P.C. Board plug J3:
Lead Number
Voltage
610 - 600
120 + 13/-10 Volts DC
If these voltages are not present, check the wiring con-
nections 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”.
2. Procedures for Replacing P.C. Boards
Before replacing a P.C. Board which is suspected of being defec-
tive, 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 remedies the problem. If the
problem is remedied, reinstall the old P.C. Board to see
if the problem 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 looseness.
b) Check leads in the plug harness for loose or inter-
mittent 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 possible shorts, opens, or
grounds caused by:
a) Frayed or pinched lead insulation.
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.
3. 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.
4.
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 positive output
stud. The voltage should measure between 7 and
55 volts DC depending on the position of the CV
voltage control setting. Try adjusting the voltage
control to see if this voltage changes. If voltage 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.
