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Lincoln Electric SVM127-A service manual Operation, Safety Instructions

Models: SVM127-A

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B-2

OPERATION	B-2

SAFETY INSTRUCTIONS

Read and understand this entire section of operating instructions operating the machine.

WARNING

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such as output terminals or internal wiring.

•Insulate yourself from the work and ground.

•Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

•Keep your head out of fumes.

•Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

LN-9 Wire Feeder

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Lincoln Electric SVM127-A service manual Operation, Safety Instructions

Contents

LN-9 Wire Feeder Safety LN-9 Wire FeederARC Rays can burn Electric Shock can killFumes 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 Technical Specifications LN-9 InstallationWidth Height Mounting the Wire Feed Unit Installing the LN-9F Roll and 4-ROLL ModelsAttaching the Wire Reel Stand Mounting the UnitElectrical Connections LN-9N, S and LN-9F Power Input Cable AssemblyLN-9S Wire Feed Unit 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 Direct Work Lead Connection Machine GroundingWork Cable 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 OperationGeneral Description DC Constant Voltage Power SourcesRecommended 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 SpoolsWhen Using the Extension Assembly models LN-9NE and LN-9SE Electrode Feeding and Brake AdjustmentLoading a 15 to 30 LB. Spool 12 Diameter Figure B.6 Loading a 50 or 60 LB. Coil Electrode Feeding Pulse Power 500, DC650 PRO Adjust the Power SourceSAM Voltage Control Response Adjust the LN-9 ControlsStarting Characteristics Select AccelerationSecurity of Weld Procedure Settings Procedure AT END of CoilMaking a Weld Table of Contents Accessories Wire Reel Stands and Mountings Optional Equipment and AccessoriesPower Input Cable Assemblies K196, K595, K596 Auxiliary Equipment Contacts50-60 LB. Wire Reel Assembly for Customer Mounting K299 Attaching the Wire Reel StandsWire Reel Door KIT M-11514 Spindle for READI-REELS and 2 I.D. Spools K162-H60% Duty GUN and Cable AssembliesTable C.1 LN-9 GUN and Cable Assemblies Process Model Electrode RatingDual Procedure KIT K319 Wire Feeder AccessoriesBurnback Delay KIT K202 Pulse Power Filter Conversion KIT K442-1Continuous Flux Feed Tank K320 Swivel Platform K178-1Undercarriage K163 K320 Flux Tank LoadingMagnetic Separator K58 Mechanized Travel Power Pack K161-CABLE LengthPower Extended Wire Drive K392 Mechanized Hand Travel Unit K110Cored Electrode Table C.2 Drive Roll and Guide Tube KitsKit Roll Solid Steel Electrode Aluminum ElectrodeTable of Contents Maintenance Routine Maintenance Safety PrecautionsPeriodic 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 electricityObserve Safety Guidelines Troubleshooting GuideDetailed 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 ActionDescription T1 Transformer TestMaterials 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 Digital Meter and Meter PC Board Removal ReplacementMeter 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