Lincoln Electric SVM114-C service manual Feeding Problems

Page 42

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F-4

 

TROUBLESHOOTING AND REPAIR

F-4

 

 

 

 

 

Troubleshooting Guide – See Wiring Diagrams for location of specified

Observe Safety Guidelines

components. See Wiring Diagrams for troubleshooting of specific circuits.

detailed in the beginning of this manual.

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

 

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

FEEDING PROBLEMS

NOTE: Many options and possible option combinations are available for the LN-25™. In many cases, it is best to disconnect the options and test the LN-25™ in its “basic” form. In this manner, many possible faulty circuits can be isolated and/or eliminated from the troubleshooting procedure.

Major physical or electrical damage

1. Contact

Lincoln

Electric

 

is evident when the box cover is

Service Department 1-888-

 

removed.

935-3877.

 

 

 

 

 

 

When gun trigger is pulled, there is

1. Check to see if the drive rolls

1. With the gun trigger circuit

no wire feed.

are turning when the gun

activated and the mode switch

NOTE:On codes above 10100, the

trigger is pulled. If the drive

in the CV position, check for

rolls are turning, then check for

the presence of 2 to 23 VDC at

motor leads (541 & 539) are

a mechanical restriction in the

leads 539 to 541. This is the

in Control Board Connector

wire feed path.

 

nor mal range for ar mature

J4, pins 13 & 14.

2. If the drive rolls do not turn,

voltage, which is dependent on

 

the wire speed setting.

 

then check to ensure the power

 

 

 

source is on and an open

2. If the normal armature voltage

 

circuit voltage (OCV) is present

is present at leads 539 to 541,

 

at the weld terminals.

then the motor or motor

 

3. Make sure the LN-25™ work

brushes may be faulty. Check

 

or replace.

 

clip is connected to the work

 

 

 

piece or work terminal.

3. If the correct armature voltage

 

4. Ensure the LN-25™ polarity

is missing, then remove any

 

option plugs that may be

 

switch matches the electrode

 

connected to J3 on the control

 

polarity.

 

 

 

 

 

board. Install the jumper plug

 

 

 

 

 

5. Check if the jumper plug on the

into the J3 receptacle. If the

 

problem is solved, then the

 

control board or

contactor

 

option board may be faulty.

 

board (if used) is loose or

 

 

 

missing.

 

 

4. Check the wire speed control,

 

 

 

 

 

6. Make certain the power source

range switch and associated

 

wiring to the control board.

 

open circuit voltage is above 15

 

 

 

VDC but not more than 110

5. If the correct armature voltage

 

VDC.

 

 

 

 

 

is still not present at leads 539

 

 

 

 

 

7. Check if

the gun

trigger is

to 541, then the control board

 

may be faulty. Replace.

 

faulty. Repair or replace.

 

 

8.On “older” control boards, check the 1/8 amp fuse. If “blown”, the gun may be faulty.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

LN-25™

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Contents Semiautomatic Wire Feeder Safety California Proposition 65 WarningsElectric Shock can kill Fumes and GasesCan be dangerous Welding and Cutting Sparks can Cause fire or explosion Cylinder may explode if damagedIii 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 CablesElectrode Cable Connection Wire Feed Drive Roll and Guide Tube KitsWeld Cable Connection Work Cable ConnectionLN-25 Operation Section Operation Welding CapabilityRead and Understand Entire Section Before Operating Machine 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 WeldProcedure AT END of Coil WeldingCylinder may explode if damaged Circuit Protection and Automatic Shutdown Overvoltage ShutdownMotor Overload Shutdown Accessories Section Accessories Section CHow to use Table C.1 AccessoriesLN-25 Option Chart Table C.1Optional Accessories K434-1 GAS Flow Timer KITGAS Solenoid KIT K430-2 for Codes 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 Maintenance Routine MaintenanceAdjusting Speed Sensor Module 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 Hall Effect Module Test G2196 539 541 500539 G1757 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 Leads28TROUBLESHOOTING and Repair F-28 Contactor PC Board Test667 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 PC Board Assembly Control Abovr Code 11140 L12253-3 L12253L12253-3 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
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