GUN and Cable Maintenance | Lincoln Electric SVM127-A instruction

D-3

D-3

MAINTENANCE

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GUN AND CABLE MAINTENANCE

For instructions on periodic maintenance for the weld- ing gun and cables, refer to the manual for your specif- ic model of welding gun. Also see IM-294.

GUN CABLE CONNECTOR REQUIREMENTS TO PERMIT PROPER CONNECTION TO LINCOLN LN-9 AND LN-9F WIRE FEEDER

	“A” Diameter Hole
	to be Concentric to
Wire Size	.749/.747 Dia.
	Within .008 F.I.M.
7/64 & .120"	.152 (#24 Drill)
.068 Thru 3/32"	.125 (1/8 Drill)
1/16 or .062"	.078 (5/64 Drill)
.045 & .052"	.062 (1/16 Drill)
.030 & .035"	.055 (#54 Drill)

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The following Figures D.1 and D.2 should serve as a guide to determine if a particular gun or switch can be connected to the LN-9 and LN-9F models.

FIGURE D.1 – LN-9 CONNECTORS

LN-9 CONNECTOR FOR 1/16-120” (1.6-3.0 MM) WIRE)

LN-9 CABLE CONNECTOR FOR .030-.052” (0.8-1.3 mm)

WIRE (FOR ALL OTHER DIMENSIONS, SEE DIAGRAM

ABOVE).

NOTE: Connector part with .7459/.747 (19.0/18.9) diameter should be made from brass if it is to be part of the welding current carrying circuit.

All dimensions in inches and (millimeters).

FIGURE D.2 – SWITCH REQUIREMENTS

1/2 Amp AC 24 Volts — Inductive 1/2 Amp DC 24 Volts — Inductive

LN-9 Wire Feeder

Image 51

Lincoln Electric SVM127-A service manual GUN and Cable Maintenance, Figure D.1 LN-9 Connectors

Contents

LN-9 Wire Feeder LN-9 Wire Feeder Safety Electric Shock can kill ARC Rays can burnFumes and Gases can be dangerous Iii Cylinder may explode if damaged Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications LN-9Width Height Mounting the Unit Installing the LN-9F Roll and 4-ROLL ModelsAttaching the Wire Reel Stand Mounting the Wire Feed Unit Routing the Electrode Power Input Cable AssemblyLN-9S Wire Feed Unit Electrical Connections LN-9N, S and LN-9F Figure 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 Sources 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 Table A.1 Work Cable Sizes Machine GroundingWork Cable Connection Direct Work Lead Connection Figure A.9 GUN Cable Connections Connecting the GUN Cable to the Wire Feeder LN-9 Wire Feeder Table of Contents Operation Section Operation Safety Instructions DC Constant Voltage Power Sources General DescriptionRecommended Processes and Equipment 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-9F Avoiding Grounding Lead Protector GLP Shutdown Circuit Protection and Automatic Shutdown Automatic Shutdown Figure B.3 2 Roll Wire Feed Mechanism Drive Roll Installation and Pressure Setting 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 Loading and Feeding READI-REELS or Spools Wire Loading Electrode 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 Select Acceleration Adjust the LN-9 ControlsStarting Characteristics Voltage Control Response Procedure AT END of Coil Security of Weld Procedure SettingsMaking a Weld Table of Contents Accessories Auxiliary Equipment Contacts Optional Equipment and AccessoriesPower Input Cable Assemblies K196, K595, K596 Wire Reel Stands and Mountings Spindle for READI-REELS and 2 I.D. Spools K162-H Attaching the Wire Reel StandsWire Reel Door KIT M-11514 50-60 LB. Wire Reel Assembly for Customer Mounting K299 Process Model Electrode Rating GUN and Cable AssembliesTable C.1 LN-9 GUN and Cable Assemblies 60% Duty Pulse Power Filter Conversion KIT K442-1 Wire Feeder AccessoriesBurnback Delay KIT K202 Dual Procedure KIT K319 K320 Flux Tank Loading Swivel Platform K178-1Undercarriage K163 Continuous Flux Feed Tank K320 Mechanized Hand Travel Unit K110 Mechanized Travel Power Pack K161-CABLE LengthPower Extended Wire Drive K392 Magnetic Separator K58 Aluminum Electrode Table C.2 Drive Roll and Guide Tube KitsKit Roll Solid Steel Electrode Cored Electrode Table of Contents Maintenance Safety Precautions Routine MaintenancePeriodic Maintenance Figure D.1 LN-9 Connectors GUN and Cable Maintenance Figure D.3 General Component Locations Table of Contents Theory of Operation Section Theory of Operation Power Input Circuits Figure E.3 Trigger and Shutdown Circuit Trigger and Shutdown Circuit Figure E.4 ARC VOLTAGE, Wire Speed Control and Metering ARC VOLTAGE, Wire Speed Control and Metering Printed Circuit Board Functions LN-9 Wire Feeder Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & Repair PC Board can be damaged by static electricity PC Board Troubleshooting Procedures Troubleshooting 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 Symptoms Misadjustments Course of Action Problems Possible Areas T1 Transformer Test DescriptionMaterials Needed T1 Transformer Test Test Procedure Figure F.2 Secondary Leads #601 and #602 AT Lead Splices T2 Transformer Test T2 Transformer Test Figure F.3 Protection Circuit Troubleshooting Nameplate Circuit 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 Procedure Voltmeter Accuracy Test Figure F.8 Voltmeter Connection Point Voltmeter Accuracy Test Return Return to Section TOC Meter Circuit Accuracy Test Figure F.9 Meter PC Board Locations and Cover Meter Circuit Accuracy Test Figure F.10 Meter PC Board Test Points Test Meter PC Board Accuracy. For LN9-H Test Meter PC Board Accuracy. All Models Metric Model Metric Range SET M/MIN Reading Test Voltmeter Test Meter PC Board Accuracy. Metric Models Only Wire Speed Accuracy Test Check for the proper drive roll revolutions per minute Wire Speed Accuracy Test OUT of Voltage Range Shut Down Test Figure F.11 Voltage PC Board with Jumpers OUT of Voltage Range Shut Down Test Section TOC General Power Supply Tests Also perform the T1 Transformer Test General Power Supply Tests General Power Supply Checks Digital Meter and Meter PC Board Removal Replacement Replacement Digital Meter and Meter PC Board RemovalMeter PC Board Removal Replacement Procedure Digital Meter Removal Procedure Reed Switch CR2 Removal and Replacement Replacement Reed Switch CR2 Removal and Replacement T1 Transformer Removal and Replacement Figure F.16 Primary Lead #31 AT R1 Resistor T1 Transformer Removal and Replacement Lead 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 Replacement Phillips Screw Disc NUT Tach PC Board Figure F.24 Tach Component Assembly Reassembly Drive Motor Removal and Replacement Figure F.25 TOP Motor Plate Screws Drive Motor Removal and Replacement Nuts 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 feeder LN-9 Wire Feeder Electrical Diagram Section LN-9 Wire Feeder LN-9 Electrical Diagrams Operating Schematic 21145 Meter Board L6687 Schematic 20031 Trigger Board M13861 Schematic 19852 Tachometer Schematic