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Lincoln Electric SVM127-A service manual Figure A.4 LN-9F Control BOX Bottom View

Models: SVM127-A

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A-6

INSTALLATION

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7.If using welding currents over 450 amperes, con- nect a length of 1/0 cable between the brass block on the hand crank and the input strap located in the wire drive unit. Tape this cable to the extension assembly. Proper cable lengths are as follows:

22-1/2 ft. extension	26’	M5906-106
45 ft. extension	46’	M5906-104

8.A handle is provided and is mounted to the wire drive unit in the following manner:

Remove the two self-tapping screws that hold the hinge pin in captivity. Push the hinge pin out, leav- ing the covers intact. Place the handle into the slots provided. Push the hinge pin back into the assembly, making sure that the pin goes through the holes in the handle. Put the two self-tapping screws back into their respective positions and tighten.

9.If the extension is being used with a K306 Wire Reel Flux Tank Assembly, the hose attached to the bottom of the flux tank may have to be shortened.

This hose is 64 feet long and is the correct length for use with the 45 foot extension. If a 22-1/2 foot extension is used, cut off 22-1/2 feet of the flux hose to give the correct length of 41-1/2 feet. (The conductor cable of the extension assembly is 22- 1/2 feet long, tip to tip, and can be used to measure the length cut off.) If you tape the flux hose to the extension cables or the gun cable, be careful not to deform or collapse the flux hose.

CONNECTING THE POWER INPUT CABLE ASSEMBLY TO THE LN-9F CONTROL BOX

1.See Figure A.4. Connect the MS-type plug of the K196, K595, or K596 control cable to the mating MS-type connector on the bottom of the LN-9F con- trol box.

2.Bolt the electrode lead from the power source to the electrode lead to the wire feed unit using the nut and bolt supplied. Insulate the connection with elec- trical tape.

FIGURE A.4 – LN-9F CONTROL BOX

BOTTOM VIEW

CIRCUIT		GLP	4-PIN CONTROL CABLE
BREAKER		RESET	TACH FEEDBACK
			CONNECTOR

9-PIN MS-TYPE CONNECTOR	14-PIN MS-TYPE CONNECTOR
INPUT CABLE TO POWER SOURCE	CONTROL CABLE TO WIRE FEED HEAD

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LN-9 Wire Feeder

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Lincoln Electric SVM127-A service manual Figure A.4 LN-9F Control BOX Bottom View

Contents

LN-9 Wire Feeder Safety LN-9 Wire FeederElectric Shock can kill ARC Rays can burnFumes and Gases can be dangerous Cylinder may explode if damaged IiiPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications LN-9Width Height Installing the LN-9F Roll and 4-ROLL Models Attaching the Wire Reel StandMounting the Wire Feed Unit Mounting the UnitPower Input Cable Assembly LN-9S Wire Feed UnitElectrical Connections LN-9N, S and LN-9F Routing the ElectrodeFigure 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 lCan 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 SizesConnecting the GUN Cable to the Wire Feeder Figure A.9 GUN Cable ConnectionsLN-9 Wire Feeder Table of Contents Operation Section Safety Instructions OperationDC Constant Voltage Power Sources General DescriptionRecommended Processes and Equipment 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 ViewCircuit Protection and Automatic Shutdown Avoiding Grounding Lead Protector GLP ShutdownAutomatic Shutdown Drive Roll Installation and Pressure Setting Figure B.3 2 Roll Wire Feed MechanismSetting 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 SpoolsElectrode Feeding and Brake Adjustment When Using the Extension Assembly models LN-9NE and LN-9SELoading a 15 to 30 LB. Spool 12 Diameter Figure B.6 Loading a 50 or 60 LB. Coil Electrode Feeding Adjust the Power Source Pulse Power 500, DC650 PROSAM Adjust the LN-9 Controls Starting CharacteristicsVoltage Control Response Select AccelerationProcedure AT END of Coil Security of Weld Procedure SettingsMaking a Weld Table of Contents Accessories Optional Equipment and Accessories Power Input Cable Assemblies K196, K595, K596Wire Reel Stands and Mountings Auxiliary Equipment ContactsAttaching 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-HGUN and Cable Assemblies Table C.1 LN-9 GUN and Cable Assemblies60% Duty Process Model Electrode RatingWire Feeder Accessories Burnback Delay KIT K202Dual Procedure KIT K319 Pulse Power Filter Conversion KIT K442-1Swivel Platform K178-1 Undercarriage K163Continuous Flux Feed Tank K320 K320 Flux Tank LoadingMechanized Travel Power Pack K161-CABLE Length Power Extended Wire Drive K392Magnetic Separator K58 Mechanized Hand Travel Unit K110Table C.2 Drive Roll and Guide Tube Kits Kit Roll Solid Steel ElectrodeCored Electrode Aluminum ElectrodeTable of Contents Maintenance Safety Precautions Routine MaintenancePeriodic Maintenance GUN and Cable Maintenance Figure D.1 LN-9 ConnectorsFigure D.3 General Component Locations Table of Contents Theory of Operation Section Power Input Circuits Theory of OperationTrigger and Shutdown Circuit Figure E.3 Trigger and Shutdown CircuitARC VOLTAGE, Wire Speed Control and Metering Figure E.4 ARC VOLTAGE, Wire Speed Control and MeteringPrinted Circuit Board Functions LN-9 Wire Feeder Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures PC Board can be damaged by static electricityTroubleshooting Guide Observe Safety GuidelinesDetailed in the beginning of this manual 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 ActionT1 Transformer Test DescriptionMaterials Needed Test Procedure T1 Transformer TestFigure F.2 Secondary Leads #601 and #602 AT Lead Splices T2 Transformer Test Figure F.3 Protection Circuit Troubleshooting Nameplate T2 Transformer TestCircuit 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 BoardVoltmeter Accuracy Test Voltmeter Accuracy Test Figure F.8 Voltmeter Connection PointReturn Return to Section TOC Meter Circuit Accuracy Test Meter Circuit Accuracy Test Figure F.9 Meter PC Board Locations and CoverFigure F.10 Meter PC Board Test Points Test Meter PC Board Accuracy. All Models Test Meter PC Board Accuracy. For LN9-HTest Meter PC Board Accuracy. Metric Models Only Metric Model Metric Range SET M/MIN Reading Test VoltmeterWire Speed Accuracy Test Wire Speed Accuracy Test Check for the proper drive roll revolutions per minuteOUT of Voltage Range Shut Down Test OUT of Voltage Range Shut Down Test Figure F.11 Voltage PC Board with JumpersSection TOC General Power Supply Tests General Power Supply Tests Also perform the T1 Transformer TestGeneral Power Supply Checks Digital Meter and Meter PC Board Removal Replacement Replacement Digital Meter and Meter PC Board RemovalMeter PC Board Removal Digital Meter Removal Procedure Replacement ProcedureReed Switch CR2 Removal and Replacement Reed Switch CR2 Removal and Replacement ReplacementT1 Transformer Removal and Replacement T1 Transformer Removal and Replacement Figure F.16 Primary Lead #31 AT R1 ResistorLead 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 ScrewsPhillips Screw Disc NUT Tach PC Board Reassembly Figure F.24 Tach Component AssemblyDrive Motor Removal and Replacement Drive Motor Removal and Replacement Figure F.25 TOP Motor Plate ScrewsNuts 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 RepairLN-9 Wire Feeder Electrical Diagram Section LN-9 Wire Feeder Electrical Diagrams LN-9Operating Schematic Meter Board L6687 Schematic 21145Trigger Board M13861 Schematic 20031Tachometer Schematic 19852