Lincoln Electric SVM154-A service manual 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 DriveConnecting Wire Drive Unit to Control Box Mounting Synergic 7F Wire Drive Unit K679-1 orMounting the LN-10 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 GAS Guard Regulator Setting Procedure for Setting Angle of FeedplateMaking a Weld 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 AssembliesK1556-1 Light Duty Caster KIT K1557-1 Swivel MountK1555-1 Insulated Lift Hook 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 Test Materials 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