Lincoln Electric SVM154-A service manual Recommended Processes and Equipment, Safety Precautions

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INSTALLATION

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All of these features are selected with a tactile-feel keypad, and are set independently using one of two rotating knob encoders, setting levels are displayed on one of two digital LED displays.

The 10 Series Wire Drive assemblies include a heavy duty head with externally changeable gear ratio and 4 driven roll drives housed together in a single combination mounting and connection box. Gun adapters are available to permit use with a variety of standard welding guns.

Available Models:

The LN-10 Wire Feeder system is available configured in both Bench and Boom models.

Bench Models consists of an LN-10 control and a 10 Series wire drive assembly premounted on a platform with a dual 2" O.D. spindle mounting.

Boom Models consist of an LN-10 control and a choice of wire drives designed to be mounted separately and joined by available head to control cable assemblies.

The head to control cable assemblies are available in two types; one control cable is required for each head:

K1498-”L” Includes a control cable with a 14-pin ms style connection on each end, and a 3/0 weld cable. Available in lengths “L” of 16, 20 or 25 ft. (4.9, 6.1 or 7.6 m)

K681-”L” Same as above but does not include weld cable available in lengths “L” of 12, 16 or 25 ft. (3.6, 4.9 or 7.6 m).

LN-10 Boom Packages (K1564-Series) are also avail- able which include:

•LN-10 Control Box

•10 Series Wire Drive

•Appropriate length Control and Weld Cables to connect Control to Wire Drive

•Accessories specific to the Boom package ordered

RECOMMENDED PROCESSES AND EQUIPMENT

The LN-10 Wire Feeder system is recommended for use with solid wire gas-metal-arc or CV Submerged arc processes, as well as cored wire for Outershield GMA or Innershield processes.

The wire type and size range for the wire drive used, and gear ratio change selected, are given in the Specifications.

Recommended power sources are Lincoln Electric Company constant voltage power sources with 42 VAC auxiliary power and a 14-pin connector recepta- cle. At the time of printing these include: CV 250, CV300-I, CV-300, CV400-I, CV-400, CV500-I, DC- 400, CV-655, Invertec V300-PRO and DC-650 PRO.

The DC-250, DC-600, DC-1000 and the Pulse Power 500 (CV mode only) may also be used with the LN-10 if the optional K1520-1 115V / 42V Transformer Kit is used.

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

•Turn the input power off at the power source disconnect switch before attempting to connect the input power to the LN-10 Control.

•Only qualified personnel should perform this installation.

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INSTALLATION OF THE LN-10 BOOM MOUNT WIRE FEEDER COMPONENTS

Mounting the 10 Series Wire Drive

Mount the 10 Series wire drive to the boom or struc- ture using the four 5/16-18 threaded mounting holes located on the bottom of the drive connection box. See Figure A.1 for the size and location of the mount- ing holes. The feed plate assembly is electrically "hot" when the gun trigger is pressed. Therefore, make certain the feed plate does not come in contact with the structure on which the unit is mounted.

The wire drive unit should be mounted so that the drive rolls are in a vertical plane so dirt will not collect in the drive roll area. Pivot the feed plate so it will point down at an angle so the wire feed gun cable will not be bent sharply as it comes from the unit. See “Procedure for setting angle of Feed Plate” in the OPERATION section of this 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 & ControlInstallation of the LN-10 Boom Mount Wire Feeder Components Safety PrecautionsMounting the 10 Series Wire Drive Recommended Processes and EquipmentMounting Synergic 7F Wire Drive Unit K679-1 or Connecting Wire Drive Unit to Control BoxMounting the LN-10 Control Box Control Speed Range Setting Wire Drive Speed Range SelectionSeries Wire Drive Ratio Selection Electrode RoutingProcedure to Install Drive Roll and Wire Guides Wire Feed Drive Roll KitsSeries Wire Drive Roll Kit Installation KP1505 and KP1507 Synergic 7F Wire Drive 4-Roll Kits KP655 and KP656GUN and Cable Assemblies with FAST-MATE Connection GUN and Cable Assemblies with Standard ConnectionGmaw Guns Innershield GunsSeries Wire Drive Water Connections for Water Cooled Guns 8INSTALLATIONA-8Cylinder may explode if damaged Buildup of Shielding GAS may harm health or killInput Cable LN-10 Control to Power Source Electrical InstallationBoom and Bench Conversions Optional Features InstallationMaterials Required for bench to boom conversion Materials Required for boom to bench conversionOperation Table of Contents Operation SectionSetting the DIP Switches LN-10 Control DIP Switch SetupWire Drive Head Selection Setup DIP Switch AccessWelding Power Source Selection Security Mode Selection Step Trigger Mode Operation SelectionMetric/English Wire Feed Speed Display Selection S2 switch 1 on = m/minS2 switch 4 on = Robotics mode on Maximum Limits Setting Mode SelectionS2 switch 6 on Minimum Limits Setting mode on S2 switch 4 OFF = Robotics mode OFF As shippedProcedure Lights Indicate which Power-Down SaveKeypad and Display Operation Keypad and Display DescriptionTrigger 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 Procedure for Setting Angle of Feedplate GAS Guard Regulator SettingMaking a Weld Wire Feed Overload Protection Wire Reel ChangingGrounding Lead Protector DH-10Display Prompt or Error Explanation of Prompting Error MessagesTable of Contents Accessories Section AccessoriesGeneral Table C.1 LN-10 Wire Feeder AccessoriesCored Electrode Wire Size Solid Steel ElectrodeAluminum Electrode Aluminum Electrode For use with Binzel Guns OnlyK683-3 Dual Procedure Switch K683-1 Dual Procedure SwitchK1449-1 Dual Procedure Input Cable AssembliesGUN Adapters for 10 Series K1558-1 Remote Switch Interface ModuleGUN and Cable Assemblies K1561-1 Robotics Interface ModuleK1557-1 Swivel Mount K1556-1 Light Duty Caster KITK1555-1 Insulated Lift Hook Table of Contents Maintenance Section MaintenanceAvoiding Wire Feeding Problems Safety Precautions MaintenanceRoutine Maintenance Periodic 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 Wire Drive Motor Test Test ProceduresTest Description Materials NeededTest 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 ProceduresDisplay PC Board Removal and Replacement 32TROUBLESHOOTING and REPAIRF-32Removal Procedure Replacement 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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