T1 Transformer Removal and Replacement | Lincoln Electric SVM138-A

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F-59

F-59

TROUBLESHOOTING & REPAIR

T1 TRANSFORMER REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.

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

DESCRIPTION

The following procedure will help the technician remove the T1 Transformer for repair or replacement.

MATERIALS NEEDED

Soldering iron

Phillips head screwdriver Slot head screwdriver Needle nose pliers 5/16" Wrench

11/32" Wrench

This procedure takes approximately 25 minutes to perform.

LN-9 GMA Wire Feeder

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Lincoln Electric SVM138-A service manual T1 Transformer Removal and Replacement

Contents

Safety Depends on You LN-9 GMA Wire Feeder LN-9 GMA 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 Master Table of Contents cont’d Vii LN-9 GMA Wire Feeder Section A-1 Table of ContentsInstallation Section Installation Installation Technical SpecificationsWidth Height Mounting the Unit Installing the LN-9 GMA Roll and 4-ROLL ModelsAttaching the Wire Reel Stand Mounting the Wire Feed Unit Power Input Cable Assembly Electrical Connections LN-9 GMA and LN-9F GMARouting the Electrode Bottom View Connecting the Power Input Cable Assembly to Power Sources Installation Can kill Figure A.5 Connection of LN-9 GMA to DC-600 Power Sources Figure A.6 Connection of LN-9 GMA to DC-1000 Power Sources To LN-9 GMA Input Cable Plug Figure A.8 Connection of LN-9 GMA to V300 Power Sources Table A.1 Work Cable Sizes Machine GroundingWork Cable Connection Direct Work Lead Connection Connecting the GUN Cable to the Wire Feeder For GMA GUN CablesThumb- screw Cylinder may explode if damaged Hooking UP GMA Shielding GAS Table of Contents Operation Section Safety Precautions OperationOperating Instructions K436 LN-9F GMA 2-ROLL and K583-1 LN-9F GMA 4-ROLL General DescriptionRecommended Processes and Equipment K424 LN-9 GMA 2-ROLL and K568-1 LN-9 GMA 4-ROLL DC Constant Voltage Power Sources Controls and Settings Figure B.3 Wire Feeder Controls for LN-9 GMA Figure B.4 Wire Feeder Controls for LN-9F GMA Circuit Breaker Power Supply FuseCircuit Protection and Automatic Shutdown Avoiding Grounding Lead Protector GLP Shutdown Automatic Shutdown Changing Drive Rolls for 2-ROLL Wire Feeders Drive Roll Installation Guide Tube Detail Changing Drive Rolls for 4-ROLL Wire Feeders Large Figure B.7a Threaded Locking Collar Wire Loading Feeding Electrode and Brake Adjustment Loading a 50-60 LB .7-27.2 KG. Coil Using K1504-1 Coil Reel Loading a 50 or 60 LB. Coil Adjustable Wire Reel Brake Feeding Electrode and Brake Adjustment Roll Wire Feeders Idle Roll Pressure Setting DC-250, DC-400, or DC-600 Adjust the Power SourceAdjust the LN-9 GMA Controls Pulse Power 500, DC650 PRO Select Acceleration Starting CharacteristicsRUN-IN Feature Voltage Control Response Procedure AT END of Coil Security of Weld Procedure SettingsMaking a Weld LN-9 GMA Wire Feeder Table of Contents Accessories Section Wire Reel Stands and Mountings AccessoriesOptional Equipment and Accessories Power Input Cable Assemblies K196, K595, K596 Spindle for READI-REELS and 2 I.D. Spools K162-H Attaching the Wire Reel StandsWire Reel Door KIT 50-60 LB. Wire Reel Assembly for Customer Mounting K299 Universal Wire Reel Stand K1524-1 Table C.1 LN-9 GMA GUN and Cable Assemblies Wire Feeder AccessoriesBurnback Timer KIT K419 GUN and Cable Assemblies Pulse Power Filter Conversion KIT K442-1 GMA Timer KIT K418Dual Process KIT K317 For Wire Feeders Dual Procedure KIT K319 K320 Flux Tank Loading Swivel Platform K178-1Undercarriage K163 Continuous Flux Feed Tank K320 K58 Magnetic Separator Aluminum Electrode Table C.2 Drive Roll and Guide Tube KitsKit Roll Solid Steel Electrode Cored Electrode LN-9 GMA Wire Feeder Table of Contents Maintenance Section Maintenance Routine MaintenancePeriodic Maintenance GUN and Cable Maintenance Proper Speed Sensor Module Mounting3D-3 Figure D.2 LN-9 GMA Connectors Table of Contents Theory of Operation Section Theory of Operation Figure E.2 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 Power Board Printed Circuit Board FunctionsControl Board LN-9 GMA 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 Trigger Troubleshooting & Repair Troubleshooting & Repair Troubleshooting Guide Troubleshooting & Repair Interlock Function Problems Test T2 Transformer Troubleshooting & Repair Range Shutdown Test Feeding Problems Welding Problems Troubleshooting & Repair Meter Function Problems Hall Effect Bypass Starting Problems Troubleshooting & Repair Starting Problems 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 32A Lead Lead Wire Drive Motor Test Wire Drive Motor Test Electric Shock can kill Hall Effect Module Test and Alignment Hall Effect Module Test and Alignment Hall Effect Module Feedback Test Procedure Test Figure F.8 Hall Effect Module Location Hall Effect Module Alignment Test Procedure Voltmeter Accuracy Test Figure F.9 Voltmeter Connection Point Voltmeter Accuracy Test Return Return to Master TOC Meter Circuit Accuracy Test Figure F.10 Meter PC Board Locations and Cover Meter Circuit Accuracy Test Figure F.11 Meter PC Board Test Points Test Meter PC Board Voltage Accuracy Test Meter PC Board Wire Feed Speed Metric Model Metric Range SET M/MIN Reading Test Voltmeter Test Meter PC Board Wire Feed Speed Accuracy 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.12 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 Meter PC Board Removal ReplacementProcedure Digital Meter and Meter 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.17 Primary Lead #31 AT R1 Resistor T1 Transformer Removal and Replacement Figure F.18 Leads #526 and #527 AT Power PC Board NUT and Screw Control PC Board 1CR Relay Phillips Screws T1 Transformer Mounting Screws Terminal Strip Drive Motor Removal and Replacement Figure F.22 TOP Motor Plate Screws Drive Motor Removal and Replacement Nuts and Washers 4-ROLL Feeders Mylar Insulator Glastic Mounting Board Bolts Figure F.25 Drive Motor Removal from Gear BOX Reassembly Retest After Repair Retest the LN-9 GMA wire feeder LN-9 GMA Wire Feeder Section G LN-9 GMA Wire Feeder Electrical Diagrams Wiring Diagram-LN-9 GMALN-9 GMA DEC Wiring Diagram-LN-9F GMA LN9, LN9F, LN9GMA, LN9FGMA Voltage Board Schematic SHT. no Power PC Board Schematic 17950 M Trigger PC Board Schematic Circuit PM Control Schematic 21146 Meter Board Schematic 525 B Operating Schematic