Lincoln Electric SVM114-C service manual Operation, Welding Capability

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B-2

OPERATION

B-2

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SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION

BEFORE OPERATING MACHINE

GENERAL DESCRIPTION

The LN-25™ is a lightweight portable semiautomatic wire feeder designed for “across-the-arc” operation without a control cable on most any DC welding power source. Simply connect the LN-25™ to the electrode cable, clip it to Work and it is ready to weld, using up to 30 lb. coils or spools.

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WARNING

ELECTRIC SHOCK can kill.

•Do not touch electrically live part or electrode with skin or wet clothing.

•Insulate yourself from work and ground.

•Always wear dry insulating gloves.

FUMES AND GASSES can be dangerous.

•Keep your head out of fumes.

•Use ventilation or exhaust to remove fumes from breath- ing zone.

WELDING SPARKS can cause fire or explosion.

•Keep flammable material away.

ARC RAYS can burn.

•Wear eye, ear and body pro- tection.

The wire drive, controls and wire reel are fully enclosed in a rugged molded plastic case providing a compact and versatile welding package ideally suited to “on-the-go” field welding applications in virtually any environment.

RECOMMENDED PROCESSES AND EQUIPMENT

When combined with the drive roll kits and accessories available for use with the LN-25™, a versatile portable welding system can be provided to meet the specific needs of Innershield, submerged arc or gas metal arc welding applications within the wire feed capabilities of the LN-25™.

The LN-25™ provides constant wire feed speed for use with constant voltage (CV) power sources, and arc-sensing wire feed speed for use with constant current (CC) (formerly variable voltage) power sources. Wire speed is presettable on a dual-range calibrated dial.

The power sources recommended for use with the LN- 25™ include the DC-250™, -400™, -600™, CV-400™ and R3S type transformer machines, and the SAM- 400™, -650™ engine welders, as well as the SA- 200™, -250™ or SAE-300™, -400™ with CV Adapter and Pulse Power 500™ with K460-1 LN-25™ Kit.

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WELDING CAPABILITY

The LN-25™ will handle up to 500 Amp 60% duty cycle welding currents. However, when equipped with

aK443-1,-2, or-3 (depending on code number) Contactor, the LN-25™ will handle up to 300 Amp 60% duty cycle.

LN-25™

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Contents Semiautomatic Wire Feeder Safety California Proposition 65 WarningsCan be dangerous Electric Shock can killFumes and Gases Iii Welding and Cutting Sparks can Cause fire or explosionCylinder may explode if damaged Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionWire Feed Speed InstallationTechnical Specifications LN-25 CurrentrentSafety Precautions Power Source ConnectionWith CV Adapter INVERTEC, CV300 and Other Newer Lincoln Power SourcesGUN Cable Connection to Feeder For GMA GUN and Cables Electrode Cable Connection Wire Feed Drive Roll and Guide Tube Kits Weld Cable Connection Work Cable ConnectionLN-25 Operation Section Read and Understand Entire Section Before Operating Machine OperationWelding Capability Wire Speed Dial and Range Switch Electrode Polarity SwitchWire Feed Mode Switch LN-25 Instruments ControlsAWG GAS Post PRE-FLOW Timers OptionalWork Clip Lead Remote ARC Voltage Control OptionalMounting 22 to 30 LB READI-REELCOILS Sequence of OperationLoading Electrode Mounting 10 to 30 LB SpoolsGrooves READI-REEL Inside Cage Wires Loading Wire DriveIdle Roll Pressure Setting 6OPERATIONB-6Setting ARC Sensing Wire Feed Speed CC Mode Presetting Wire Feed SpeedSetting Constant Wire Feed Speed CV Mode Minimum Arc VoltsFigure B.4 VV CC Wire Speed Setting Making a WeldCylinder may explode if damaged Procedure AT END of CoilWelding Motor Overload Shutdown Circuit Protection and Automatic ShutdownOvervoltage Shutdown Accessories Section Accessories Section CHow to use Table C.1 AccessoriesLN-25 Option Chart Table C.1GAS Solenoid KIT K430-2 for Codes Optional AccessoriesK434-1 GAS Flow Timer KIT Remote Output Control Options and Control Cable Assemblies K433 Power Source Remote BOXK432 Remote Control Cable Assembly LN-25 Contactor KIT K443-1 for CodesK624-1 42V Remote Output Control Module K439 Remote Extension Cable AssemblyK625, K626, K627 Remote Control Cable Assembly K444, K444-1 or K444-2 Remote Voltage Control KITStyle a Connector Must be Insulated in this AreaTo GUN Switch Connect Leads to Pins a and C DIA. HoleMaintenance Section Adjusting Speed Sensor Module MaintenanceRoutine Maintenance Calibration of LN-25 Wire Speed Dial LN-25 Figure E.1 Theory of Operation Block Diagram Theory of Operation SectionGeneral Description Input Power CircuitTheory of Operation Control Circuit OperationFeedback and Control Circuits Trigger CircuitGAS Solenoid Optional CircuitsContactor Later ModelsProtective Devices Circuits Control PC Board FusesLN-25 Troubleshooting and Repair Section 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting GuideTroubleshooting and Repair PC Board Troubleshooting ProceduresFeeding Problems Feeding Problems Hall Effect Materials Needed GAS Solenoid Valve and Solenoid PC Board TestTest Description For Codes below 10500 onlyCase Door Test ProcedureScrew Wire Reel Retaining Collar GAS Solenoid ValveFigure F.2 Solenoid Leads Troubleshooting and Repair 624A 621 J11 GAS Solenoid Valve and Solenoid PC Board Test512 PC Board for K430 GAS Solenoid KITLN-25 GAS Solenoid Valve and Control PC Board Test For Codes Above 10500 onlyFor Codes Above 10500 only Figure F.5 Control BOX Cover RemovalSolenoid Leads Figure F.6. Solenoid LeadsFigure F.7. Applied Voltage Polarity Control PC Board Solenoid Circuitry TestG3425 667 555 691 621 500 512 690LN-25 Hall Effect Module Test 539 G1757 Hall Effect Module TestG2196 539 541 500 Figure F.11 Control PC Board Codes Above LN-25 Wire Drive Motor Test Drive Motor Lead IN-LINE Connector Hall Effect Module Contactor & Contactor PC Board Test Contactor Test Procedure Contactor & Contactor PC Board TestS20963 Contactor Coil Leads667 28TROUBLESHOOTING and Repair F-28Contactor PC Board Test J14 LN-25 Contactor PC Board Replacement Tools RequiredContactor PC Board Replacement Repair Procedure33TROUBLESHOOTING and Repair F-33 Figure F.17 Control PC Board Replacement Control PC Board Replacement Figure F.21. Control PC Board Codes 9812 and belowFigure F.22. Plug Locations for L12253- Control Board J14Figure F.24. Control Board Replacement PC Board Screw Contactor Replacement For Codes below40TROUBLESHOOTING and Repair F-40 Contactor ReplacementFor Codes Above Figure F.26 Phillips Head Screwdriver Wrench Pliers GAS Solenoid Valve AND/OR Solenoid PC Board if Present ReplacementPurge Switch Leads Solenoid Plug J11 GAS SolenoidFigure F.29. Solenoid Assembly Wiring Codes 9812 and below Figure F.31. GAS Solenoid Assembly for Earlier Codes Phillips Head Screwdriver Wrench Slot Head Screwdriver Hall Effect Module 48TROUBLESHOOTING and Repair F-48Drive Motor and Gearbox Replacement and Access to Mylar Insulation Electrode CableG1757 Figure F.34. Drive Motor Replacement Retest After Repair LN-25 Electrical Diagrams Table of Contents Electrical Diagrams SectionWiring Diagram Above Code 11140 G4679 Optional 42 Volt Remote Output ControlWiring Diagram Code 10556 Thru 10500 L10925 Wiring Diagram Code 10100 Thru 10500 L9644 Wiring Diagram below Code 9900 L7545 Schematic Complete Machine Codes Above 11140 G5366 LN-25 Across the ARC ModelSchematic Complete Machine below Code 9900 only G1833 Schematic Control PC BD Above Code 11140 G4616-5 Schematic Control PC BD Code 10556 Thru 10558 G3424-3 Schematic Control PC BD Code 10100 Thru 10500 G2194 L12253-3 PC Board Assembly Control Abovr Code 11140 L12253-3L12253 PC Board Assembly Control Code 10556 Thru 10558 G3425-3 G3425PC Board Assembly Control Code 10100 Thru 10500 G2196-1 PC Board Assembly Control below Code 9900 G1757-6 LN-25 ControlSchematic Contactor PC BD Above Code 10500 M10965 ContactorSchematic Contactor PC BD Code 10100 Thru 10500 M17621 Electrical Diagrams Electrical Diagrams PC Board Assembly Contactor Above Code 10500 L10863-1 L10863PC Board Assembly Contactor Code 10100 Thru 10500 L9670-1 PC Board Assembly Contactor below Code 9900 L9185-2