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Lincoln Electric SVM127-A service manual T1 Transformer Removal and Replacement

Models: SVM127-A

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F-55

F-55

TROUBLESHOOTING & REPAIR

T1 TRANSFORMER REMOVAL AND REPLACEMENT

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 elec- trical 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 troubleshoot- ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will help the technician remove the T1 Transformer for repair or replacement.

MATERIALS NEEDED

Soldering iron

Phillips head screw driver Slot head screw driver Needle nose pliers 5/16" wrench

11/32" wrench

LN-9 Wire Feeder

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Lincoln Electric SVM127-A service manual T1 Transformer Removal and Replacement

Contents

LN-9 Wire Feeder LN-9 Wire Feeder SafetyFumes and Gases can be dangerous Electric Shock can killARC Rays can burn Iii Cylinder may explode if damagedPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Width Height InstallationTechnical Specifications LN-9 Attaching the Wire Reel Stand Installing the LN-9F Roll and 4-ROLL ModelsMounting the Wire Feed Unit Mounting the UnitLN-9S Wire Feed Unit Power Input Cable AssemblyElectrical Connections LN-9N, S and LN-9F Routing the ElectrodeFigure A.2 Strain Relief Clamp Figure A.4 LN-9F Control BOX Bottom View Figure A.5 for DC-250, DC-400 and CV-400, CV-500 l Connecting the Power Input Cable Assembly to Power SourcesCan 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 Work Cable Connection Machine GroundingDirect Work Lead Connection Table A.1 Work Cable SizesFigure A.9 GUN Cable Connections Connecting the GUN Cable to the Wire FeederLN-9 Wire Feeder Table of Contents Operation Section Operation Safety InstructionsRecommended Processes and Equipment DC Constant Voltage Power SourcesGeneral Description Controls and Settings Figure B.1 Wire Feeder Controls for LN-9N, NE, S, SE LN-9F Control BOX Bottom View Figure B.2 Wire Feeder Controls for LN-9FAvoiding Grounding Lead Protector GLP Shutdown Circuit Protection and Automatic ShutdownAutomatic Shutdown Figure B.3 2 Roll Wire Feed Mechanism Drive Roll Installation and Pressure SettingSetting 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 Loading and Feeding READI-REELS or Spools Wire LoadingLoading 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 Starting Characteristics Adjust the LN-9 ControlsVoltage Control Response Select AccelerationMaking a Weld Procedure AT END of CoilSecurity of Weld Procedure Settings Table of Contents Accessories Power Input Cable Assemblies K196, K595, K596 Optional Equipment and AccessoriesWire Reel Stands and Mountings Auxiliary Equipment ContactsWire Reel Door KIT M-11514 Attaching the Wire Reel Stands50-60 LB. Wire Reel Assembly for Customer Mounting K299 Spindle for READI-REELS and 2 I.D. Spools K162-HTable C.1 LN-9 GUN and Cable Assemblies GUN and Cable Assemblies60% Duty Process Model Electrode RatingBurnback Delay KIT K202 Wire Feeder AccessoriesDual Procedure KIT K319 Pulse Power Filter Conversion KIT K442-1Undercarriage K163 Swivel Platform K178-1Continuous Flux Feed Tank K320 K320 Flux Tank LoadingPower Extended Wire Drive K392 Mechanized Travel Power Pack K161-CABLE LengthMagnetic Separator K58 Mechanized Hand Travel Unit K110Kit Roll Solid Steel Electrode Table C.2 Drive Roll and Guide Tube KitsCored Electrode Aluminum ElectrodeTable of Contents Maintenance Periodic Maintenance Safety PrecautionsRoutine Maintenance Figure D.1 LN-9 Connectors GUN and Cable MaintenanceFigure D.3 General Component Locations Table of Contents Theory of Operation Section Theory of Operation Power Input CircuitsFigure E.3 Trigger and Shutdown Circuit Trigger and Shutdown CircuitFigure E.4 ARC VOLTAGE, Wire Speed Control and Metering ARC VOLTAGE, Wire Speed Control and MeteringPrinted Circuit Board Functions LN-9 Wire Feeder Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board can be damaged by static electricity PC Board Troubleshooting ProceduresDetailed 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 Symptoms Misadjustments Course of Action Problems Possible AreasMaterials Needed T1 Transformer TestDescription T1 Transformer Test Test ProcedureFigure F.2 Secondary Leads #601 and #602 AT Lead Splices T2 Transformer Test T2 Transformer Test Figure F.3 Protection Circuit Troubleshooting NameplateCircuit Breaker Lead Lead Wire Drive Motor and Tach Feedback Test Wire Drive Motor and Tach Feedback Test Apply 115 VAC power Figure F.7 Leads #525, #510, #555 on Control PC Board Tach Feedback Test ProcedureVoltmeter Accuracy Test Figure F.8 Voltmeter Connection Point Voltmeter Accuracy TestReturn Return to Section TOC Meter Circuit Accuracy Test Figure F.9 Meter PC Board Locations and Cover Meter Circuit Accuracy TestFigure F.10 Meter PC Board Test Points Test Meter PC Board Accuracy. For LN9-H Test Meter PC Board Accuracy. All ModelsMetric Model Metric Range SET M/MIN Reading Test Voltmeter Test Meter PC Board Accuracy. Metric Models OnlyWire Speed Accuracy Test Check for the proper drive roll revolutions per minute Wire Speed Accuracy TestOUT of Voltage Range Shut Down Test Figure F.11 Voltage PC Board with Jumpers OUT of Voltage Range Shut Down TestSection TOC General Power Supply Tests Also perform the T1 Transformer Test General Power Supply TestsGeneral Power Supply Checks Digital Meter and Meter PC Board Removal Replacement Meter PC Board Removal ReplacementDigital Meter and Meter PC Board Removal Replacement Procedure Digital Meter Removal ProcedureReed Switch CR2 Removal and Replacement Replacement Reed Switch CR2 Removal and ReplacementT1 Transformer Removal and Replacement Figure F.16 Primary Lead #31 AT R1 Resistor T1 Transformer Removal and ReplacementLead NUT and Screw Control PC Board 1CR Relay Phillips Screws Terminal Tach PC Board Removal and Replacement Figure F.21 Tach Assembly Cover Screws Tach PC Board Removal and ReplacementPhillips Screw Disc NUT Tach PC Board Figure F.24 Tach Component Assembly ReassemblyDrive Motor Removal and Replacement Figure F.25 TOP Motor Plate Screws Drive Motor Removal and ReplacementNuts and Washers 4-ROLL Feeders Mylar Insulator Glastic Mounting Board Bolts Mounting Screws Insulators Gear BOX Assembly Retest After Repair Retest the LN-9 wire feederLN-9 Wire Feeder Electrical Diagram Section LN-9 Wire Feeder LN-9 Electrical DiagramsOperating Schematic 21145 Meter Board L6687 Schematic20031 Trigger Board M13861 Schematic19852 Tachometer Schematic