Lincoln Electric SVM154-A service manual GUN Adapters for 10 Series, GUN and Cable Assemblies

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ACCESSORIES

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GUN ADAPTERS (FOR 10 SERIES

WIRE DRIVE) Adapts 10 Series heads for desired gun connection:

K1500-1for standard Lincoln Innershield gun con- nection, or with Fast-Made™ guns with K489-2 Fast- Mate Adapter Kit. Also for Magnum 200/300/400 with K466-1 connection kit, or Magnum 550 with K613-1.

K1500-2for Magnum 200/300/400 gun with K466- 10 connection kit. (Also Tweco 4). Factory provided with the LN-10.

K1500-3for Magnum 550 gun with K613-7 connec- tion. (Also Tweco 5).

GUN AND CABLE ASSEMBLIES

The following Lincoln gun and cable assemblies are compatible with 10 Series Wire Feed heads with appropriate K1500 Gun Adapter:

K126 (Requires K1500-1) Innershield gun and cable assemblies are rated at 350 amps, 60% duty cycle. (Consult sales specifications for appropriate models)

K115 (Requires K1500-1) Innershield gun and cable assemblies are rated at 450 amps, 60% duty cycle. (Consult sales specifications for appropriate models)

K470 (With K466-9 requires K1500-2) Magnum 300 GMAW gun and cable assemblies are rated 300 amps, 60% duty cycle. (Consult sales specifications for appropriate models)

K471 (With K466-9 requires K1500-2) Magnum 400 GMAW gun and cable assemblies are rated 400 amps, 60% duty cycle. (Consult sales specifications for appropriate models)

K497 (With K466-9 requires K1500-2) Magnum 200 GMAW gun and cable assemblies are rated 200 amps, 60% duty cycle. (Consult sales specifications for appropriate models)

K541 (With K466-9 requires K1500-2) Magnum 400 Short Neck GMAW gun and cable assemblies are rated 400 amps, 60% duty cycle. (Consult sales specifications for appropriate models)

K598 (With K613-7 requires K1500-3) Magnum 550 GMAW gun and cable assemblies are rated 550 amps, 60% duty cycle. (Consult sales specifications for appropriate models)

The following Lincoln gun and cable assemblies are equipped with a Fast-Mate™ connector. They can be used with 10 Series wire feed models by installing a K489-2 Fast-Mate™ adapter kit and a K1500-1 Lincoln Gun adapter.

K684 Magnum "Super Cool" FM water cooled GMAW gun and cable assemblies are rated 450 amps, 100% duty cycle (CO2). (Consult sales specifi- cations for appropriate models)

K498 Magnum 200 FM GMAW gun and cable assemblies are rated for 200 amps 60% duty cycle. (Consult sales specifications for appropriate models)

K534 Magnum 250L FM GMAW gun and cable assemblies are rated for 250 amps, 30% duty cycle. (Consult sales specifications for appropriate models)

K478 Magnum 300 FM GMAW gun and cable assemblies are rated for 300 amps, 60% duty cycle. (Consult sales specifications for appropriate models)

K479 Magnum 400 FM GMAW gun and cable assemblies are rated for 400 amps, 60% duty cycle. (Consult sales specifications for appropriate models)

K1558-1 REMOTE SWITCH INTERFACE MODULE

The Module provides for user interface connection of an external switch (flow switch, etc.) which must be closed to enable the feeder welding operation. Also, the Module provides for interface connection of exter- nal equipment (fume extractor, etc.) to the Module’s isolated relay contacts which actuate when the feeder welding gas solenoid is activated (representing weld- ing operation in process).

K1561-1 ROBOTICS INTERFACE MODULE

The module plugs directly into the LN-10 control board and provides an interface to a properly equipped Fanuc robot. When installed and properly configured, the K1561-1 Robotics Interface Module allows com- plete control of the welding process from the robot controller.

The Lincoln Electric Company’s Automation Center should be contacted for questions regarding installa- tion or operation of the Robotics Interface Module.

LN-10

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Contents SVM154-A ISAFETYi Fumes and Gases SafetyIii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section InstallationGeneral Description Technical Specifications LN-10 Head & ControlRecommended Processes and Equipment Safety PrecautionsInstallation of the LN-10 Boom Mount Wire Feeder Components Mounting the 10 Series Wire DriveMounting the LN-10 Control Box Mounting Synergic 7F Wire Drive Unit K679-1 orConnecting Wire Drive Unit to Control Box Electrode Routing Wire Drive Speed Range SelectionControl Speed Range Setting Series Wire Drive Ratio SelectionSynergic 7F Wire Drive 4-Roll Kits KP655 and KP656 Wire Feed Drive Roll KitsProcedure to Install Drive Roll and Wire Guides Series Wire Drive Roll Kit Installation KP1505 and KP1507Innershield Guns GUN and Cable Assemblies with Standard ConnectionGUN and Cable Assemblies with FAST-MATE Connection Gmaw GunsBuildup of Shielding GAS may harm health or kill 8INSTALLATIONA-8Series Wire Drive Water Connections for Water Cooled Guns Cylinder may explode if damagedInput Cable LN-10 Control to Power Source Electrical InstallationMaterials Required for boom to bench conversion Optional Features InstallationBoom and Bench Conversions Materials Required for bench to boom conversionOperation Table of Contents Operation SectionSetup DIP Switch Access LN-10 Control DIP Switch SetupSetting the DIP Switches Wire Drive Head SelectionWelding Power Source Selection S2 switch 1 on = m/min Step Trigger Mode Operation SelectionSecurity Mode Selection Metric/English Wire Feed Speed Display SelectionS2 switch 4 OFF = Robotics mode OFF As shipped Maximum Limits Setting Mode SelectionS2 switch 4 on = Robotics mode on S2 switch 6 on Minimum Limits Setting mode onKeypad and Display Description Power-Down SaveProcedure Lights Indicate which Keypad and Display OperationTrigger Mode Selection Display Control Keys Digital Memory Voltmeter Control Control Select key enables operator toMaximum and Minimum Limits Setting Modes Wire Reel Loading READI-REELS Spools or Coils Dual Procedure RemoteFigure B.2 Making a Weld Procedure for Setting Angle of FeedplateGAS Guard Regulator Setting DH-10 Wire Reel ChangingWire Feed Overload Protection Grounding Lead ProtectorDisplay Prompt or Error Explanation of Prompting Error MessagesTable of Contents Accessories Section AccessoriesGeneral Table C.1 LN-10 Wire Feeder AccessoriesAluminum Electrode For use with Binzel Guns Only Wire Size Solid Steel ElectrodeCored Electrode Aluminum ElectrodeInput Cable Assemblies K683-1 Dual Procedure SwitchK683-3 Dual Procedure Switch K1449-1 Dual ProcedureK1561-1 Robotics Interface Module K1558-1 Remote Switch Interface ModuleGUN Adapters for 10 Series GUN and Cable AssembliesK1555-1 Insulated Lift Hook K1557-1 Swivel MountK1556-1 Light Duty Caster KIT Table of Contents Maintenance Section MaintenancePeriodic Maintenance MaintenanceAvoiding Wire Feeding Problems Safety Precautions Routine MaintenanceFigure D.1 Major Component Locations Theory of Operation Table of Contents Theory of Operation SectionControl Board Input RECEPTACLE, Control Board and Operator Controls Figure E.3 LN-10 Wire Feed Head and Receptacle Wire Feed Head ReceptacleTheory of Operation Protection and Shutdown Wire Feed Overload Loss of Voltage Sense Protection ShutdownLN-10 Table of Contents Troubleshooting and Repair Section Troubleshooting and RepairReturn to Return to Master TOC HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures LN-10 Function Problems Troubleshooting GuideFunction Problems Power Source Selection Function Problems Mode Selection Perform the Encoder Board Test Troubleshooting and Repair Mum and minimum limit set Perform the Gas Solenoid Test Feeding Problems Welding Problems LN-10 Materials Needed Test ProceduresWire Drive Motor Test Test DescriptionTest Procedure Wire Drive Motor TestMaterials Needed Tach Adjustment and Feedback TestTach Adjustment and Feedback Test 20TROUBLESHOOTING and REPAIRF-20Tach Adjustment Procedure LN-10 Keypad Resistance Test Keypad Resistance Test 24TROUBLESHOOTING and REPAIRF-24Control Ohms 50 Ohms Typical LN-10 Encoder PC Board Test Figure F.4 Encoder PC Board Test Encoder PC Board TestGAS Solenoid Test GAS Solenoid Test 30TROUBLESHOOTING and REPAIRF-30Display PC Board Removal and Replacement Component Replacement ProceduresReplacement Procedure 32TROUBLESHOOTING and REPAIRF-32Display PC Board Removal and Replacement Removal ProcedureGAS Solenoid Removal and Replacement GAS Solenoid Removal and Replacement 34TROUBLESHOOTING and REPAIRF-34Encoder PC Board Removal and Replacement Figure F.8 Encoder PC Board Removal and Replacement Encoder PC Board Removal and ReplacementWire Drive Motor and Gear BOX Removal and Replacement Figure F.9 Wire Feed Assembly Removal Wire Drive Motor and Gear BOX Removal and ReplacementTo Remove the Drive Motor from the Gear BOX To Remove the Wire Drive Assembly from the Gear BOXReplacement Procedures Current Sensing Reed Switch Removal and Replacement Current Sensing Reed Switch Plug Retest After Repair Check Wire Feed Speed RangeElectrical Diagrams Section Wiring Diagram LN-10 Control Electrical DiagramsElectrode Cable From Current Sensor Wiring Diagram LN-10 Wire DriveSchematic Control PC Board #1 Circuitry Tach Schematic Control PC Board #23168 G PC Board ASSEMBLY-CONTROL5VA Schematic Display PC BoardBoard 22066 Schematic Encoder PC BoardEncoder PC Board ASSEMBLY-ENCODERSVM Error Reporting Form

SVM154-A specifications

The Lincoln Electric SVM154-A is a powerful and versatile inverter-based welding machine designed for a wide range of applications. As a part of Lincoln Electric's esteemed portfolio, this model is particularly favored for its robust performance and cutting-edge technologies, making it ideal for both professional fabricators and hobbyists alike.

One of the standout features of the SVM154-A is its compact and lightweight design, which enhances portability without compromising power. Weighing significantly less than traditional welding machines, it allows welders to easily transport the equipment to various job sites. This feature is particularly beneficial in industries where mobility is essential.

Equipped with advanced inverter technology, the SVM154-A delivers a stable and smooth arc, providing consistent welding performance even in challenging conditions. The inverter design also contributes to energy efficiency, allowing users to save on operational costs while enjoying superior performance. The machine supports both MIG and TIG welding processes, which adds to its versatility. This adaptability makes it suitable for a range of materials including mild steel, stainless steel, and aluminum.

Another notable characteristic is its user-friendly interface. Designed with the welder in mind, the SVM154-A includes intuitive controls that simplify settings adjustments and operational processes. This ergonomic layout allows for ease of use, even for beginners, while still offering the adjustments that experienced welders appreciate for customizing their welds.

The SVM154-A also includes several safety features, such as thermal overload protection and a dynamic power control, ensuring safe operation while maintaining high productivity. Users benefit from features that protect both the machine and the operator, making it a reliable choice for long hours of work.

Moreover, Lincoln Electric's commitment to durability is evident in the SVM154-A's construction. Built with high-quality materials, this welding machine is designed to withstand the rigors of daily use, ensuring longevity and reliability over time.

In summary, the Lincoln Electric SVM154-A stands out for its portability, versatility, and user-centric design. With advanced inverter technology that promotes energy efficiency and a stability for various welding processes, it serves as a valuable tool for both professionals and hobbyists seeking to achieve high-quality welds across different applications. Its combination of advanced features, safety mechanisms, and rugged durability positions the SVM154-A as a top choice in the welding equipment market.
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