Contactor Replacement, For Codes below | Lincoln Electric SVM114-C

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F-39

TROUBLESHOOTING AND REPAIR

F-39

CONTACTOR REPLACEMENT

(FOR CODES BELOW 10500)

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

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

TOOLS REQUIRED

Phillips Head Screwdriver

5/16" Nut Driver

11/16" Wrench

LN-25™

Image 77

Lincoln Electric SVM114-C service manual Contactor Replacement, For Codes below

Contents

Semiautomatic Wire Feeder California Proposition 65 Warnings Safety Can be dangerous Electric Shock can killFumes and Gases Iii Welding and Cutting Sparks can Cause fire or explosionCylinder may explode if damaged Sûreté Pour Soudage a L’Arc Précautions DE Sûreté Master Table of Contents for ALL Sections Installation Section Table of Contents Technical Specifications LN-25 InstallationWire Feed Speed Currentrent Power Source Connection Safety Precautions GUN Cable Connection to Feeder INVERTEC, CV300 and Other Newer Lincoln Power SourcesWith CV Adapter For GMA GUN and Cables Weld Cable Connection Wire Feed Drive Roll and Guide Tube KitsElectrode Cable Connection Work Cable Connection LN-25 Operation Section Read and Understand Entire Section Before Operating Machine OperationWelding Capability Wire Feed Mode Switch Electrode Polarity SwitchWire Speed Dial and Range Switch LN-25 Instruments Controls Work Clip Lead GAS Post PRE-FLOW Timers OptionalAWG Remote ARC Voltage Control Optional Loading Electrode Sequence of OperationMounting 22 to 30 LB READI-REELCOILS Mounting 10 to 30 LB Spools Idle Roll Pressure Setting Loading Wire DriveGrooves READI-REEL Inside Cage Wires 6OPERATIONB-6 Setting Constant Wire Feed Speed CV Mode Presetting Wire Feed SpeedSetting ARC Sensing Wire Feed Speed CC Mode Minimum Arc Volts Making a Weld Figure B.4 VV CC Wire Speed Setting Cylinder may explode if damaged Procedure AT END of CoilWelding Motor Overload Shutdown Circuit Protection and Automatic ShutdownOvervoltage Shutdown Accessories Section C Accessories Section LN-25 Option Chart AccessoriesHow to use Table C.1 Table C.1 GAS Solenoid KIT K430-2 for Codes Optional AccessoriesK434-1 GAS Flow Timer KIT K432 Remote Control Cable Assembly K433 Power Source Remote BOXRemote Output Control Options and Control Cable Assemblies LN-25 Contactor KIT K443-1 for Codes K625, K626, K627 Remote Control Cable Assembly K439 Remote Extension Cable AssemblyK624-1 42V Remote Output Control Module K444, K444-1 or K444-2 Remote Voltage Control KIT To GUN Switch Connect Leads to Pins a and C Connector Must be Insulated in this AreaStyle a DIA. Hole Maintenance Section Adjusting Speed Sensor Module MaintenanceRoutine Maintenance Calibration of LN-25 Wire Speed Dial LN-25 Theory of Operation Section Figure E.1 Theory of Operation Block Diagram Theory of Operation Input Power CircuitGeneral Description Control Circuit Operation Trigger Circuit Feedback and Control Circuits Contactor Optional CircuitsGAS Solenoid Later Models Control PC Board Fuses Protective Devices Circuits LN-25 Troubleshooting and Repair Section HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2 PC Board Troubleshooting Procedures Troubleshooting and Repair Feeding Problems Feeding Problems Hall Effect Test Description GAS Solenoid Valve and Solenoid PC Board TestMaterials Needed For Codes below 10500 only Screw Wire Reel Retaining Collar Test ProcedureCase Door GAS Solenoid Valve Figure F.2 Solenoid Leads Troubleshooting and Repair 512 GAS Solenoid Valve and Solenoid PC Board Test624A 621 J11 PC Board for K430 GAS Solenoid KIT LN-25 For Codes Above 10500 only GAS Solenoid Valve and Control PC Board Test Figure F.5 Control BOX Cover Removal For Codes Above 10500 only Figure F.6. Solenoid Leads Solenoid Leads Control PC Board Solenoid Circuitry Test Figure F.7. Applied Voltage Polarity 667 555 691 621 500 512 690 G3425 LN-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 & Contactor PC Board Test Contactor Test Procedure Contactor Coil Leads S20963 667 28TROUBLESHOOTING and Repair F-28Contactor PC Board Test J14 LN-25 Tools Required Contactor PC Board Replacement Repair Procedure Contactor PC Board Replacement 33TROUBLESHOOTING and Repair F-33 Figure F.17 Control PC Board Replacement Figure F.21. Control PC Board Codes 9812 and below Control PC Board Replacement J14 Figure F.22. Plug Locations for L12253- Control Board Figure F.24. Control Board Replacement PC Board Screw For Codes below Contactor Replacement Contactor Replacement 40TROUBLESHOOTING and Repair F-40 For Codes Above Figure F.26 Phillips Head Screwdriver Wrench Pliers Purge Switch Leads Solenoid Plug J11 Present ReplacementGAS Solenoid Valve AND/OR Solenoid PC Board if GAS Solenoid Figure 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 Drive Motor and Gearbox Replacement and Access to 48TROUBLESHOOTING and Repair F-48Hall Effect Module Mylar Insulation Electrode Cable G1757 Figure F.34. Drive Motor Replacement Retest After Repair LN-25 Table of Contents Electrical Diagrams Section Electrical Diagrams Optional 42 Volt Remote Output Control Wiring Diagram Above Code 11140 G4679 Wiring Diagram Code 10556 Thru 10500 L10925 Wiring Diagram Code 10100 Thru 10500 L9644 Wiring Diagram below Code 9900 L7545 LN-25 Across the ARC Model Schematic Complete Machine Codes Above 11140 G5366 Schematic 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 G3425 PC Board Assembly Control Code 10556 Thru 10558 G3425-3 PC Board Assembly Control Code 10100 Thru 10500 G2196-1 LN-25 Control PC Board Assembly Control below Code 9900 G1757-6 Contactor Schematic Contactor PC BD Above Code 10500 M10965 Schematic Contactor PC BD Code 10100 Thru 10500 M17621 Electrical Diagrams Electrical Diagrams L10863 PC Board Assembly Contactor Above Code 10500 L10863-1 PC Board Assembly Contactor Code 10100 Thru 10500 L9670-1 PC Board Assembly Contactor below Code 9900 L9185-2