Perform the T1 Transformer | Lincoln Electric SVM127-A guide

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F-11				F-11
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE			Observe Safety Guidelines
	detailed in the beginning of this manual.

PROBLEMS	POSSIBLE AREAS OF	RECOMMENDED
(SYMPTOMS)	MISADJUSTMENT(S)	COURSE OF ACTION

	FUNCTION PROBLEMS
The SET voltage is erratic or not	1. Check for loose or faulty con-	1.	Remove power to the LN-9 and
adjustable over the entire range of	nections on leads #634, #635		disconnect Plug J1 from the
control. The actual voltage is also	and #636 between the voltage		voltage PC board. Check the
erratic like the SET voltage.	control potentiometer (R3) and		resistance of the voltage control
	the voltage PC board.		potentiometer (R3).	When
			measured from the wiper (lead
			#635) to lead #634, the resis-
			tance should vary	smoothly
			from 0 to 10,000 ohms when the
			shaft is rotated.
		2.	The voltage PC board may be
			faulty. Replace.

The field fuse (F101), located on	1. Very rapid and repetitive gun	1.	Perform the T1 Transformer
the power PC board, repeatedly	triggering can possibly cause		Test.
fails.	the field fuse to fail.	2.	Perform the Wire Drive Motor
		2.	Perform the Wire Drive Motor
			Test.
		3.	Disconnect the meter board. If
			the problem is resolved, the
			meter board may be faulty.
		4.	The power PC board may be
			faulty. Replace.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

LN-9 Wire Feeder

Image 69

Lincoln Electric SVM127-A service manual Perform the T1 Transformer

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 Attaching the Wire Reel Stand Installing the LN-9F Roll and 4-ROLL ModelsMounting the Wire Feed Unit Mounting the Unit LN-9S Wire Feed Unit Power Input Cable AssemblyElectrical 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 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 Work Cable Connection Machine GroundingDirect Work Lead Connection Table A.1 Work Cable Sizes 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 Starting Characteristics Adjust the LN-9 ControlsVoltage Control Response Select Acceleration Procedure AT END of Coil Security of Weld Procedure SettingsMaking a Weld Table of Contents Accessories Power Input Cable Assemblies K196, K595, K596 Optional Equipment and AccessoriesWire Reel Stands and Mountings Auxiliary Equipment Contacts Wire 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-H Table C.1 LN-9 GUN and Cable Assemblies GUN and Cable Assemblies60% Duty Process Model Electrode Rating Burnback Delay KIT K202 Wire Feeder AccessoriesDual Procedure KIT K319 Pulse Power Filter Conversion KIT K442-1 Undercarriage K163 Swivel Platform K178-1Continuous Flux Feed Tank K320 K320 Flux Tank Loading Power Extended Wire Drive K392 Mechanized Travel Power Pack K161-CABLE LengthMagnetic Separator K58 Mechanized Hand Travel Unit K110 Kit Roll Solid Steel Electrode Table C.2 Drive Roll and Guide Tube KitsCored Electrode Aluminum 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