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Lincoln Electric SVM127-A service manual Troubleshooting & Repair

Models: SVM127-A

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F-17				F-17
	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

			WELDING PROBLEMS
	Poor arc striking with sticking or	1.	Make sure the welding parame-	1. Jumper the "BYPASS" terminals
	"blast offs." The weld bead may		ters and techniques are correct	on the voltage PC board.
	also be ropey and display weld		for the welding procedure being	2. Put the power source in
	porosity.		used.	2. Put the power source in
	porosity.		used.	"Machine Control" and check if
				"Machine Control" and check if
		2.	Check the welding cables for	welding performance improves.
			loose or faulty connections.	If the problem is resolved, check
		3.	The gun cable may be faulty.	or replace the control cable. Or,
		3.	The gun cable may be faulty.	the LN-9 voltage PC board may
			Check or replace.	the LN-9 voltage PC board may
			Check or replace.	be faulty.
				be faulty.
		4.	The gun contact tip may be
			worn. Check or replace.
		5.	The welding power source may
			be faulty. Check or 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

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Lincoln Electric SVM127-A service manual Troubleshooting & Repair

Contents

LN-9 Wire Feeder LN-9 Wire Feeder SafetyElectric Shock can kill ARC Rays can burnFumes and Gases can be dangerous Iii Cylinder may explode if damagedPrécautions 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 UnitRouting the Electrode Power Input Cable AssemblyLN-9S Wire Feed Unit Electrical Connections LN-9N, S and LN-9FFigure 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 Table A.1 Work Cable Sizes Machine GroundingWork Cable Connection Direct Work Lead ConnectionFigure A.9 GUN Cable Connections Connecting the GUN Cable to the Wire FeederLN-9 Wire Feeder Table of Contents Operation Section Operation Safety InstructionsDC 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-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 LoadingElectrode 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 ResponseProcedure 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 MountingsSpindle 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 K299Process Model Electrode Rating GUN and Cable AssembliesTable C.1 LN-9 GUN and Cable Assemblies 60% DutyPulse Power Filter Conversion KIT K442-1 Wire Feeder AccessoriesBurnback Delay KIT K202 Dual Procedure KIT K319K320 Flux Tank Loading Swivel Platform K178-1Undercarriage K163 Continuous Flux Feed Tank K320Mechanized Hand Travel Unit K110 Mechanized Travel Power Pack K161-CABLE LengthPower Extended Wire Drive K392 Magnetic Separator K58Aluminum Electrode Table C.2 Drive Roll and Guide Tube KitsKit Roll Solid Steel Electrode Cored ElectrodeTable of Contents Maintenance Safety Precautions Routine MaintenancePeriodic 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 ProceduresTroubleshooting 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 AreasT1 Transformer Test DescriptionMaterials Needed 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 Replacement Digital Meter and Meter PC Board RemovalMeter 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