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F-36

F-36

TROUBLESHOOTING & REPAIR

VOLTMETER ACCURACY TEST (continued)

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WARNING

ELECTRIC SHOCK can kill.

•With power applied, there are high voltages inside the wire feeder. Do not reach into the wire feeder or touch any internal part of the wire feeder while power is applied.

3.With the LN-9 gun trigger closed or the gun terminals jumpered together (see the Wiring Diagram), the test meter reading should match the LN-9 ACTUAL volts reading within +/- 0.5 volts. If it does not, check the integri- ty and placement of the voltage sensing leads #21 and #67. Perform the Meter Circuit

Accuracy Test.

4.Remove the test voltmeter and, while weld- ing, compare the SET volts and ACTUAL volts meter readings. Depending upon the arc volt- age characteristics of the welding process being used, the ACTUAL reading may vary somewhat around an average value. The average ACTUAL reading should match the SET reading within +/- 0.5 volts. If not, refer to the Meter Circuit Accuracy Test.

5.If no further tests are required, remove the jumper from the gun terminals (if used) and close the left case side cover assembly.

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LN-9 Wire Feeder

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Lincoln Electric SVM127-A service manual Return Return to Section TOC

Contents

LN-9 Wire Feeder Safety LN-9 Wire Feeder ARC Rays can burn Electric Shock can killFumes and Gases can be dangerous Cylinder may explode if damaged Iii Précautions 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 Unit Electrical Connections LN-9N, S and LN-9F Power Input Cable AssemblyLN-9S Wire Feed Unit Routing the Electrode Figure 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 l 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 Direct Work Lead Connection Machine GroundingWork Cable Connection Table A.1 Work Cable Sizes Connecting the GUN Cable to the Wire Feeder Figure A.9 GUN Cable Connections LN-9 Wire Feeder Table of Contents Operation Section Safety Instructions Operation General 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 View Circuit Protection and Automatic Shutdown Avoiding Grounding Lead Protector GLP Shutdown Automatic Shutdown Drive Roll Installation and Pressure Setting Figure B.3 2 Roll Wire Feed Mechanism 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 Wire Loading Loading and Feeding READI-REELS or Spools When 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 Acceleration Security 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 Contacts 50-60 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-H 60% Duty GUN and Cable AssembliesTable C.1 LN-9 GUN and Cable Assemblies Process Model Electrode Rating Dual Procedure KIT K319 Wire Feeder AccessoriesBurnback Delay KIT K202 Pulse Power Filter Conversion KIT K442-1 Continuous Flux Feed Tank K320 Swivel Platform K178-1Undercarriage K163 K320 Flux Tank Loading Magnetic Separator K58 Mechanized Travel Power Pack K161-CABLE LengthPower Extended Wire Drive K392 Mechanized Hand Travel Unit K110 Cored Electrode Table C.2 Drive Roll and Guide Tube KitsKit Roll Solid Steel Electrode Aluminum Electrode Table of Contents Maintenance Routine Maintenance Safety PrecautionsPeriodic Maintenance GUN and Cable Maintenance Figure D.1 LN-9 Connectors Figure D.3 General Component Locations Table of Contents Theory of Operation Section Power Input Circuits Theory of Operation Trigger and Shutdown Circuit Figure E.3 Trigger and Shutdown Circuit ARC VOLTAGE, Wire Speed Control and Metering Figure E.4 ARC VOLTAGE, Wire Speed Control and Metering Printed Circuit Board Functions LN-9 Wire Feeder Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting Guide PC Board Troubleshooting Procedures PC Board can be damaged by static electricity Observe 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 Action Description T1 Transformer TestMaterials Needed Test Procedure T1 Transformer Test Figure F.2 Secondary Leads #601 and #602 AT Lead Splices T2 Transformer Test Figure F.3 Protection Circuit Troubleshooting Nameplate T2 Transformer Test Circuit 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 Board Voltmeter Accuracy Test Voltmeter Accuracy Test Figure F.8 Voltmeter Connection Point Return Return to Section TOC Meter Circuit Accuracy Test Meter Circuit Accuracy Test Figure F.9 Meter PC Board Locations and Cover Figure F.10 Meter PC Board Test Points Test Meter PC Board Accuracy. All Models Test Meter PC Board Accuracy. For LN9-H Test Meter PC Board Accuracy. Metric Models Only Metric Model Metric Range SET M/MIN Reading Test Voltmeter Wire Speed Accuracy Test Wire Speed Accuracy Test Check for the proper drive roll revolutions per minute OUT of Voltage Range Shut Down Test OUT of Voltage Range Shut Down Test Figure F.11 Voltage PC Board with Jumpers Section TOC General Power Supply Tests General Power Supply Tests Also perform the T1 Transformer Test General 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 Procedure Reed Switch CR2 Removal and Replacement Reed Switch CR2 Removal and Replacement Replacement T1 Transformer Removal and Replacement T1 Transformer Removal and Replacement Figure F.16 Primary Lead #31 AT R1 Resistor Lead 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 Screws Phillips Screw Disc NUT Tach PC Board Reassembly Figure F.24 Tach Component Assembly Drive Motor Removal and Replacement Drive Motor Removal and Replacement Figure F.25 TOP Motor Plate Screws Nuts 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 Repair LN-9 Wire Feeder Electrical Diagram Section LN-9 Wire Feeder Electrical Diagrams LN-9 Operating Schematic Meter Board L6687 Schematic 21145 Trigger Board M13861 Schematic 20031 Tachometer Schematic 19852