Lincoln Electric SVM179-B service manual Electric Shock can kill ARC Rays can burn

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ii

 

 

 

 

 

 

SAFETY

 

 

 

 

 

 

 

ii

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRIC SHOCK can kill.

 

 

 

 

 

ARC RAYS can burn.

 

3.a. The electrode and work (or ground) circuits

 

 

 

 

 

4.a. Use a shield with the proper filter and cover

 

are electrically “hot” when the welder is on.

 

 

 

 

 

 

 

 

 

 

 

 

plates to protect your eyes from sparks and

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Do not touch these “hot” parts with your bare

 

 

 

 

 

 

the rays of the arc when welding or observing

 

skin or wet clothing. Wear dry, hole-free

 

 

 

 

 

 

open arc welding. Headshield and filter lens

 

gloves to insulate hands.

 

 

 

 

 

 

 

 

should conform to ANSI Z87. I standards.

3.b. Insulate yourself from work and ground using dry insulation.

 

4.b. Use suitable clothing made from durable flame-resistant

Make certain the insulation is large enough to cover your full

 

 

 

 

material to protect your skin and that of your helpers from

area of physical contact with work and ground.

 

 

 

 

the arc rays.

 

 

 

 

 

 

In addition to the normal safety precautions, if welding

 

4.c. Protect other nearby personnel with suitable, non-flammable

must be performed under electrically hazardous

 

 

 

 

screening and/or warn them not to watch the arc nor expose

conditions (in damp locations or while wearing wet

 

 

 

 

themselves to the arc rays or to hot spatter or metal.

clothing; on metal structures such as floors, gratings or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

scaffolds; when in cramped positions such as sitting,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FUMES AND GASES

 

kneeling or lying, if there is a high risk of unavoidable or

 

 

 

 

 

 

 

accidental contact with the workpiece or ground) use

 

 

 

 

 

 

can be dangerous.

 

the following equipment:

 

 

 

 

 

 

 

 

 

 

 

• Semiautomatic DC Constant Voltage (Wire) Welder.

 

 

 

 

 

 

5.a. Welding may

produce

fumes and gases

• DC Manual (Stick) Welder.

 

 

 

 

 

 

 

 

 

hazardous to health. Avoid breathing these

 

 

 

 

 

 

 

 

 

• AC Welder with Reduced Voltage Control.

 

 

 

 

 

 

fumes and gases.When welding, keep

 

 

 

 

 

 

 

 

 

 

 

 

 

 

your head out of the fume. Use enough

3.c. In semiautomatic or automatic wire welding, the electrode,

 

 

 

 

 

 

ventilation and/or exhaust at the arc to keep

 

 

 

 

fumes

and

gases

away from

the breathing

zone. When

electrode

reel,

welding head, nozzle

or

semiautomatic

 

 

 

 

 

 

 

 

welding

with

electrodes

which

require

special

welding gun are also electrically “hot”.

 

 

 

 

 

 

 

 

 

 

 

 

ventilation such as stainless or hard facing (see

 

 

 

 

 

 

 

 

 

 

 

 

3.d. Always be

sure

the

work

cable

makes

a

good electrical

 

 

 

 

instructions on

container

or MSDS) or

on

lead or

 

 

 

 

cadmium

plated

steel and

other metals

or

coatings

connection

with

the

metal

being

welded. The connection

 

 

 

 

 

 

 

 

which produce highly toxic fumes, keep exposure as

should be as close as possible to the area being welded.

 

 

 

 

 

 

 

 

low as possible and within applicable OSHA PEL and

 

 

 

 

 

 

 

 

 

 

 

 

3.e. Ground the work or metal to be welded to a good electrical

 

 

 

 

ACGIH TLV limits using local exhaust or mechanical ven-

 

 

 

 

tilation. In confined spaces or in some circumstances,

(earth) ground.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

outdoors, a respirator may be required. Additional pre-

 

 

 

 

 

 

 

 

 

 

 

 

3.f. Maintain the electrode holder, work clamp, welding cable and

 

 

 

 

cautions are also required when welding on galvanized

 

 

 

 

steel.

 

 

 

 

 

 

 

 

welding machine in good, safe operating condition. Replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

damaged insulation.

 

 

 

 

 

 

5. b. The operation of welding fume control equipment is affected

 

 

 

 

 

 

 

 

 

3.g. Never dip the electrode in water for cooling.

 

 

 

 

 

by various factors including proper use and positioning of the

 

 

 

 

 

equipment, maintenance of the equipment and the specific

 

 

 

 

 

 

 

 

 

 

 

 

3.h. Never simultaneously touch electrically

“hot” parts of

 

 

 

 

welding procedure and application involved. Worker expo-

 

 

 

 

sure level should be checked upon installation and periodi-

electrode holders connected to two welders because voltage

 

 

 

 

 

 

 

 

cally thereafter to be certain it is within applicable OSHA PEL

between the two can be the total of the open circuit voltage

 

 

 

 

 

 

 

 

and ACGIH TLV limits.

 

 

 

 

 

of both welders.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3.i. When working above floor level, use a safety belt to protect

 

5.c. Do not weld in locations near chlorinated hydrocarbon vapors

 

 

 

 

coming from degreasing, cleaning or spraying operations.

yourself from a fall should you get a shock.

 

 

 

 

 

 

 

 

 

 

The heat and rays of the arc can react with solvent vapors to

 

 

 

 

 

 

 

 

 

 

 

 

3.j. Also see Items 6.c. and 8.

 

 

 

 

 

 

 

 

form phosgene, a highly toxic gas, and other irritating prod-

 

 

 

 

 

 

 

 

ucts.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.d. Shielding gases used for arc welding can displace air and

 

 

 

 

 

 

 

 

 

 

 

 

cause injury or death. Always use enough ventilation,

 

 

 

 

 

 

 

 

 

 

 

 

especially in confined areas, to insure breathing air is safe.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.e. Read and understand the manufacturer’s instructions for this

 

 

 

 

 

 

 

 

 

 

 

 

equipment and the consumables to be used, including the

 

 

 

 

 

 

 

 

 

 

 

 

material safety data sheet (MSDS) and follow your

 

 

 

 

 

 

 

 

 

 

 

 

employer’s safety practices. MSDS forms are available from

 

 

 

 

 

 

 

 

 

 

 

 

your

welding distributor

or

from

the

manufacturer.

 

 

 

 

 

 

 

 

 

5.f. Also see item 1.b.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LN-25™ PRO

Image 3
Contents LN-25PRO Wire Feeder LN-25 PRO SafetyElectric Shock can kill ARC Rays can burn Welding Cutting For ElectricallyIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation ELECTRIC SHOCK can Kill Safety PrecautionsHigh Frequency Protection LocationChanging the GUN Receiver Bushing Wire Drive ConfigurationCable Connections Shielding GAS ConnectionWire Guides Procedure to Install Drive RollsPressure ARM Adjustment Loading Spools of WireGUN Connection Power Source to LN-25 PRO Cable Connection Diagrams Across the ARC SET-UPSDescription Figure A.7 Table of Contents Operation Section Operation Safety PrecautionsGeneral Description Wire Feed Speed Knob DescriptionAnalog Voltmeter Figure B.2 Wire Feed Speed, CC Operation See Figure B.2 orTable B.2 VV CC Wire Speed Setting Figure B-3 Constant Current VS Constant Voltage Wire WeldingThermal LED, Motor Overload See Figure B.1 PIN GUN Trigger Connector See Figure B.1Wire Feed Speed Range Switch K2613-5 and K2613-7 only Work Sense LeadFigure B.4 Internal ControlsCold Feed Pushbutton Step Trigger Interlock SwitchCV/CC Switch Internal Controls DescriptionPreflow Timer Optional PREFLOW, Burnback Postflow Timer KIT K2330-2Figure B.5 Rear ControlsScfh POWER-UP SequenceGAS Purge Pushbutton Flow MeterLN-25 PRO Table of Contents Accessories Section Drive Roll Kits AccessoriesFactory Installed Equipment Wire TypeAccessories Accessories K435 Spindle Adapter, for mounting Installation of the K590-6 Water Cooling KIT Table of Contents Maintenance Section Calibration Specification MaintenanceRoutine Maintenance Periodic MaintenanceWire Feed Speed CoverBoard Figure D.3. Major Component Location Control Board 1TABLE of CONTENTS-THEORY of Operation Section E-1Figure E.2 General Description Theory of OperationTRIGGER CIRCUIT Input PowerFigure E.4 Feedback & Control Circuits Feedback and Control CIR- CuitsFigure E.5 Optional Circuits & Digital Display Board Optional CircuitsLN-25 PRO Table of Contents Troubleshooting & Repair HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board Troubleshooting Procedures Fault Code Description Possible Adjustment Motor Solenoid Test Problems Symptoms Possible Areas MisadjustmentsRecommended Course of Action LN-25 PRO Case Removal Procedure Test DescriptionMaterials Needed Figure F.1 Case Removal ProcedureGAS Solenoid Test GAS Solenoid Control BOX Control BOX Cover Contactor Test Control BOX Contactor Drive Motor and Tach Feedback Test Case Control BOX Assembly Motor Overload Test Figure F.5 Control BOX Assembly Contactor Removal and Replacement Procedure Figure F.6 Control BOX Removal ProcedureFigure F.7 Buss BAR and Mounting Block Replacement ProcedureLN-25 PRO Front Panel Removal and Replacement Procedure Front Panel Troubleshooting & Repair Gas Hose Control BOX Wire Drive Panel Drive Gear Cover LN-25 PRO PC Board Removal and Replacement Procedure Figure F.11 Control PC Board Location PC BOARD Removal and Replacement ProcedureGAS Solenoid Removal and Replacement Procedure GAS Solenoid GAS Hose Control BOX Lock NUT Operation Verification SET UPRetest After Repair Retest a machineLN-25 PRO Table of Contents Diagram Section Wiring Diagram LN-25 PRO WiriNG DiaGram lN-25 prO CODEs 11507, 11508 G5681-1 Wiring DIAGRAM- LN-25 PRO Analog WiriNG DiaGram lN-25 prO CODEs 11746, 11747 G5681-3 G5683 LN-25 PRO Wire FeederLN-25 PRO Wire Feeder ElECTriCal DiaGrams G5683-1 Pushbutton LN-25 PRO Analog G5683-2G5683 G5683-3 Circuitryconfidential Equipmenttype Xres RXD Work 624 4783-1C0 Flexiblepowerfeede R 50V OF05 Circuitryconfidential S27505-1B0 R2 CW