Section TOC | Lincoln Electric SVM127-A guide

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F-46

F-46

TROUBLESHOOTING & REPAIR

OUT OF VOLTAGE RANGE SHUT DOWN TEST (continued)

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8.If the ACTUAL voltage reading is zero, the sensing leads may be faulty. Check the con- tinuity (zero ohms) of leads #21 and #67. Lead #21 must have continuity to the work- piece, and #67 must have continuity to the electrode. Also check the 1/8 amp fuse on the voltage PC board.

9.Check the polarity switches in the LN-9 and the Lincoln power source and their associat- ed leads. Set the switches to the same polarity as the electrode. See the Wiring Diagram.

10.If the ACTUAL voltage reading is different from the SET voltage reading, the power source may not be capable of producing the required arc voltage, the control cable may be faulty or misconnected, or the LN-9 volt- age PC board may be faulty.

11.After all tests are complete, remove input power to the wire feeder and remove the jumper you placed on the "BYPASS" pins on the voltage PC board. Reattach the left case side cover assembly.

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LN-9 Wire Feeder

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Lincoln Electric SVM127-A service manual Section TOC

Contents

LN-9 Wire Feeder Safety LN-9 Wire Feeder Fumes and Gases can be dangerous Electric Shock can killARC Rays can burn Cylinder may explode if damaged Iii Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Width Height InstallationTechnical Specifications LN-9 Installing the LN-9F Roll and 4-ROLL Models Attaching the Wire Reel StandMounting the Wire Feed Unit Mounting the Unit Power Input Cable Assembly LN-9S Wire Feed UnitElectrical Connections LN-9N, S and LN-9F Routing the Electrode Figure A.2 Strain Relief Clamp Figure A.4 LN-9F Control BOX Bottom View Connecting the Power Input Cable Assembly to Power Sources Figure A.5 for DC-250, DC-400 and CV-400, CV-500 l Can kill Figure A.6 Connection of LN-9 to DC-600 Power Sources Figure A.7 Connection of LN-9 to DC-1000 Power Sources Installation Machine Grounding Work Cable ConnectionDirect Work Lead Connection Table A.1 Work Cable Sizes Connecting the GUN Cable to the Wire Feeder Figure A.9 GUN Cable Connections LN-9 Wire Feeder Table of Contents Operation Section Safety Instructions Operation Recommended Processes and Equipment DC Constant Voltage Power SourcesGeneral Description Controls and Settings Figure B.1 Wire Feeder Controls for LN-9N, NE, S, SE Figure B.2 Wire Feeder Controls for LN-9F LN-9F Control BOX Bottom View Circuit Protection and Automatic Shutdown Avoiding Grounding Lead Protector GLP Shutdown Automatic Shutdown Drive Roll Installation and Pressure Setting Figure B.3 2 Roll Wire Feed Mechanism Setting the Idler Roll Spring Pressure 2-ROLL Wire Drives Setting the Idler Roll Pressure 4-ROLL Wire Drives Operation Figure B.4 Installing Drive Rolls on a 4-ROLL Feeder Wire Loading Loading and Feeding READI-REELS or Spools Loading a 15 to 30 LB. Spool 12 Diameter Electrode Feeding and Brake AdjustmentWhen Using the Extension Assembly models LN-9NE and LN-9SE Figure B.6 Loading a 50 or 60 LB. Coil Electrode Feeding SAM Adjust the Power SourcePulse Power 500, DC650 PRO Adjust the LN-9 Controls Starting CharacteristicsVoltage Control Response Select Acceleration Making a Weld Procedure AT END of CoilSecurity of Weld Procedure Settings Table of Contents Accessories Optional Equipment and Accessories Power Input Cable Assemblies K196, K595, K596Wire Reel Stands and Mountings Auxiliary Equipment Contacts Attaching the Wire Reel Stands Wire Reel Door KIT M-1151450-60 LB. Wire Reel Assembly for Customer Mounting K299 Spindle for READI-REELS and 2 I.D. Spools K162-H GUN and Cable Assemblies Table C.1 LN-9 GUN and Cable Assemblies60% Duty Process Model Electrode Rating Wire Feeder Accessories Burnback Delay KIT K202Dual Procedure KIT K319 Pulse Power Filter Conversion KIT K442-1 Swivel Platform K178-1 Undercarriage K163Continuous Flux Feed Tank K320 K320 Flux Tank Loading Mechanized Travel Power Pack K161-CABLE Length Power Extended Wire Drive K392Magnetic Separator K58 Mechanized Hand Travel Unit K110 Table C.2 Drive Roll and Guide Tube Kits Kit Roll Solid Steel ElectrodeCored Electrode Aluminum Electrode Table of Contents Maintenance Periodic Maintenance Safety PrecautionsRoutine Maintenance GUN and Cable Maintenance Figure D.1 LN-9 Connectors Figure D.3 General Component Locations Table of Contents Theory of Operation Section Power Input Circuits Theory of Operation Trigger and Shutdown Circuit Figure E.3 Trigger and Shutdown Circuit ARC VOLTAGE, Wire Speed Control and Metering Figure E.4 ARC VOLTAGE, Wire Speed Control and Metering Printed Circuit Board Functions LN-9 Wire Feeder Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures PC Board can be damaged by static electricity Detailed in the beginning of this manual Troubleshooting GuideObserve Safety Guidelines Function Problems Trigger Troubleshooting & Repair Troubleshooting Guide Troubleshooting & Repair Trigger Interlock Function Problems Perform the T1 Transformer Perform the T2 Transformer Troubleshooting & Repair Perform Out of Voltage Range Feeding Problems Welding Problems Troubleshooting & Repair Meter Function Problems Bypass Starting Problems Troubleshooting & Repair Problems Possible Areas Symptoms Misadjustments Course of Action Materials Needed T1 Transformer TestDescription Test Procedure T1 Transformer Test Figure F.2 Secondary Leads #601 and #602 AT Lead Splices T2 Transformer Test Figure F.3 Protection Circuit Troubleshooting Nameplate T2 Transformer Test Circuit Breaker Lead Lead Wire Drive Motor and Tach Feedback Test Wire Drive Motor and Tach Feedback Test Apply 115 VAC power Tach Feedback Test Procedure Figure F.7 Leads #525, #510, #555 on Control PC Board Voltmeter Accuracy Test Voltmeter Accuracy Test Figure F.8 Voltmeter Connection Point Return Return to Section TOC Meter Circuit Accuracy Test Meter Circuit Accuracy Test Figure F.9 Meter PC Board Locations and Cover Figure F.10 Meter PC Board Test Points Test Meter PC Board Accuracy. All Models Test Meter PC Board Accuracy. For LN9-H Test Meter PC Board Accuracy. Metric Models Only Metric Model Metric Range SET M/MIN Reading Test Voltmeter Wire Speed Accuracy Test Wire Speed Accuracy Test Check for the proper drive roll revolutions per minute OUT of Voltage Range Shut Down Test OUT of Voltage Range Shut Down Test Figure F.11 Voltage PC Board with Jumpers Section TOC General Power Supply Tests General Power Supply Tests Also perform the T1 Transformer Test General Power Supply Checks Digital Meter and Meter PC Board Removal Replacement Meter PC Board Removal ReplacementDigital Meter and Meter PC Board Removal Digital Meter Removal Procedure Replacement Procedure Reed Switch CR2 Removal and Replacement Reed Switch CR2 Removal and Replacement Replacement T1 Transformer Removal and Replacement T1 Transformer Removal and Replacement Figure F.16 Primary Lead #31 AT R1 Resistor Lead NUT and Screw Control PC Board 1CR Relay Phillips Screws Terminal Tach PC Board Removal and Replacement Tach PC Board Removal and Replacement Figure F.21 Tach Assembly Cover Screws Phillips Screw Disc NUT Tach PC Board Reassembly Figure F.24 Tach Component Assembly Drive Motor Removal and Replacement Drive Motor Removal and Replacement Figure F.25 TOP Motor Plate Screws Nuts and Washers 4-ROLL Feeders Mylar Insulator Glastic Mounting Board Bolts Mounting Screws Insulators Gear BOX Assembly Retest the LN-9 wire feeder Retest After Repair LN-9 Wire Feeder Electrical Diagram Section LN-9 Wire Feeder Electrical Diagrams LN-9 Operating Schematic Meter Board L6687 Schematic 21145 Trigger Board M13861 Schematic 20031 Tachometer Schematic 19852