Lincoln Electric SVM132-A service manual Function Problems

Page 55

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F-5

 

TROUBLESHOOTING AND REPAIR

F-5

 

 

 

 

 

 

 

 

 

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

FUNCTION PROBLEMS (Continued)

 

 

 

 

 

 

 

 

The wire feeds when the gun trig-

1.

Check the welding cables for

1.

The 1CR relay, located on the

 

ger is activated but there is no arc

 

loose or faulty connections.

 

power board, may be faulty.

 

voltage.

 

 

 

 

Check or replace. Note: The

 

 

 

 

2.

Put a jumper wire from #2 to #4

 

relay may operate but the indi-

 

 

 

 

 

on the power source terminal

 

vidual contacts may not be func-

 

 

 

 

strip. (machines with 14 pin

 

tioning properly.

 

 

 

 

 

amphenols pin C to pin D). If the

 

 

 

 

 

 

 

arc voltage is not present at the

2.

If a burnback kit is installed,

 

 

 

 

 

output terminals, the power

 

remove and install the jumper

 

 

 

 

 

source is faulty. If the arc volt-

 

plug. If the problem is solved,

 

 

 

 

 

age IS present, the problem is in

 

the burnback kit is faulty.

 

 

 

 

 

the wire feeder or control cable.

 

 

 

 

 

 

 

 

3.

Check the #2 and #4 leads in the

 

 

 

3.

Check the continuity of leads #2

 

LN-8 wiring harness for loose or

 

 

 

 

and #4 through the control cable.

 

faulty connections. See wiring

 

 

 

 

 

Replace if “open”.

 

diagram.

 

 

 

 

4. The welding gun may be faulty.

 

 

 

 

 

 

 

Check or replace.

 

 

 

 

 

 

 

 

 

The wire continues to feed with the

1.

Disconnect the gun trigger cable.

1.

The 1CR relay may be stuck

 

gun trigger open, and the wire is

 

If the problem is solved, the gun

 

closed. Perform the 1CR Relay

electrically “hot”. The interlock

 

trigger or cable is faulty. Repair

 

Test.

 

switch is in the “off” position.

 

or replace.

 

 

 

 

 

 

 

 

2.

Check the relay board. Replace

 

 

 

 

 

 

if faulty.

 

 

 

 

 

 

 

With the interlock switch (S2) in the

1.

Check leads #529 and #528 for

1.

The 2CR reed switch may be

 

“ON” postion, the wire feed stops

 

loose or faulty connections

 

faulty. Check to see if it closes

when the gun trigger is released.

 

between the 2CR reed switch

 

when welding.

 

 

 

 

 

and the control board and motor

 

 

 

 

 

 

 

thermal circuit breaker. See

2.

Check the interlock switch (S2)

 

 

 

 

wiring diagram.

 

for proper operation.

 

 

 

 

 

 

3.

Check the continuity (zero ohms)

 

 

 

 

 

 

of leads #523 and #536 between

 

 

 

 

 

 

the interlock switch (S2) and the

 

 

 

 

 

 

relay board. See wiring diagram.

 

 

 

 

 

4.

The relay board 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 1-800-833-9353.

LN-8

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Contents LN-8 Semiautomatic Wire Feeder LN-8 SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation LN-8 with K378 Electrode DiameterLN-8 with K303 LN-8 with K377Table A.1 Work Lead Specifications Power Source ConnectionsLN-8N and LN-8NE LN-8S and LN-8SE and Converted LN-8N and LN-8NE Power Source Selection Switch Variable Voltage PC BoardTable A.2 LN-8 Power Source Connection Diagrams Power Source Connection DiagramsSection TOC Installation TOC Figure A.5 Connection of LN-8 to R3S-250 and R3S-325 9A-9Figure A.6 Connection of LN-8 to DC-600 10A-10Power Source To LN-8 Input Cable Plug Control Cable LN-8 for Same Polarity Operation Shock Can Kill LN-8 for Opposite Polarity Operation14A-14 Figure A.10 for Power Sources Other than Lincoln ElectricLN-8NE and LN-8SE Cable Clamp Conductor Electrode Wire Reel BasecontrolInput Cable Connections LN-8N and LN-8SScrew Connections to Wire FeederExtension Tube Connector LockingSELF-TAPPING Screw Hinge Handle Figure A.14 Wire Feeder Handle InstallationGeneral Handling ProceduresGUN and Cable Assemblies LN-8S and LN-8SE Continuous Flux Feed Submerged ARCOperation Gouging Sparks Safety InstructionsControls and Their Functions Constant Current ControlsCurrent Controls Voltage Constant Voltage ControlsAvoiding Ground Lead Protector GLP Activation Circuit ProtectionFigure B.3 Wire Feed Rolls and Guide Tube Installation Wire Feed Rolls and Guide TubesSetting for CV or CC Power Sources Welding with a Constant Voltage Power SourceSlots Coil Reel Mounting a 50 or 60 lb CoilK363-P READI-REEL Adapter Wire Reel Loading K1524-1 Universal Wire Reel StandAdapter READI-REELS a K438 READI-REEL Adapter Must be Used To Mount 10 to 44 lb 4.5 to 20 kg Spools12 in./300 mm Diameter or 14 lb 6 kg Innershield CoilsFeeding Electrode to the LN-8NE or LN-8SE with Extension Feeding Electrode to the LN-8N or LN-8SBrass Blocks Hand Crank ARM Slow Acceleration Starting Code 7926 and Above Flux Tank LoadingAccessories General Table C.1 LN-8 Wire Feeder AccessoriesK58 Magnetic Separator K161 Mechanized Travel Power PackK163 Undercarriage Requires K303, K377, or K378 K178 Mounting PlatformReel Mounting Accessories Constant Current Conversion Parts Welding Guns Welding GUN AccessoriesLN-8 Table of Contents Maintenance Section MaintenanceRoutine Maintenance Periodic Maintenance Theory of Operation Table of Contents Theory of Operation SectionGeneral Description Power Input CircuitsFigure E.2 GUN Trigger and 1CR Contact Control Circuits GUN Trigger and 1CR Relay Contact Control CircuitsFuse Field 5E-5 SCR OperationApplied Later CYCLE, the SCR Output Is Decreased LN-8 Troubleshooting and Repair Return to Return to Section TOC HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Troubleshooting & RepairProblems Symptoms Troubleshooting GuideFunction Problems Transformer Test Perform the 1CR Relay Test Feeding Problems Welding Problems LN-8 Electrical Sequence of Operation Figure F.1 LN-8 Electrical Sequence of Operation Test Description Trigger Transformer TestTrigger Transformer Test Internal Voltage Test Control Board ConnectorReceptacle Circuit Applied BreakerTable F.1 Voltage Test Points Internal Voltage Test1CR Relay Test 1CR Relay Test Table F.2 Relay Test Terminal Connections 1CR Relay TestDrive Motor Test Drive Motor Test 1CR Figure F.6 GUN Terminal Jumper LocationsTable F.3 Drive Motor Test Points To further check the drive motorPotentiometer Replacement Repair Procedure Circuit Breaker Replacement Retaining NUT Ground Lead Protector Switch Mount Flatwasher Lockwasher NUTGround Lead Protector Push Button Switch Replacement Ground Lead Protector Push Button Trigger Transformer Replacement Insulation Sheet Trigger Transformer NUT Relay PC Board Roundhead ScrewPC Board Replacement Control PC Board Variable Voltage PC Board Relay PC Board Figure F.10 PC Board LocationsRelay Board Removal Control PC Board Replacement Wire Drive Assembly and Component Replacement Blue TWO BlackWhite Green Ground Yellow#568 #567 ShuntGearbox Insulation Sheet Mounting Plate MotorTOC Retest After Repair Electrical Diagrams LN-8N, -8NE, -8S, and -8SE Wiring Diagram Source Power to Work Connection Schematic1CR Wire Feed Motor Field Operating SchematicControl Board L5767 Schematic Variable Voltage Board L5039 Schematic Control Control Board L5767 LayoutVariable Voltage Board L5039 Layout SVM Error Reporting Form
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