Operation, Operating Instructions | Lincoln Electric SVM138-A

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B-2

OPERATION	B-2

OPERATING INSTRUCTIONS

Read and understand this entire section of operating instructions operating the machine.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such as output terminals or internal wiring.

•Insulate yourself from the work and ground.

•Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

•Keep your head out of fumes.

•Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

LN-9 GMA Wire Feeder

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Lincoln Electric SVM138-A service manual Operation, Operating Instructions, Safety Precautions

Contents

LN-9 GMA Wire Feeder Safety Depends on You Safety LN-9 GMA Wire Feeder Electric Shock can kill ARC Rays can burnFumes and Gases can be dangerous Cylinder may explode if damaged Iii Précautions DE Sûreté Master Table of Contents Master Table of Contents cont’d Vii LN-9 GMA Wire Feeder Table of Contents Installation SectionInstallation Section A-1 Installation Technical SpecificationsWidth Height Installing the LN-9 GMA Roll and 4-ROLL Models Attaching the Wire Reel StandMounting the Wire Feed Unit Mounting the Unit Power Input Cable Assembly Electrical Connections LN-9 GMA and LN-9F GMARouting the Electrode Connecting the Power Input Cable Assembly to Power Sources Bottom View 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 Machine Grounding Work Cable ConnectionDirect Work Lead Connection Table A.1 Work Cable Sizes Connecting the GUN Cable to the Wire Feeder For GMA GUN CablesThumb- screw Hooking UP GMA Shielding GAS Cylinder may explode if damaged Table of Contents Operation Section Safety Precautions OperationOperating Instructions General Description Recommended Processes and EquipmentK424 LN-9 GMA 2-ROLL and K568-1 LN-9 GMA 4-ROLL K436 LN-9F GMA 2-ROLL and K583-1 LN-9F 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 Power Supply Fuse Circuit Protection and Automatic ShutdownAvoiding Grounding Lead Protector GLP Shutdown Circuit Breaker Automatic Shutdown Drive Roll Installation Changing Drive Rolls for 2-ROLL Wire Feeders Guide Tube Detail Changing Drive Rolls for 4-ROLL Wire Feeders Large Wire Loading Figure B.7a Threaded Locking Collar Loading a 50-60 LB .7-27.2 KG. Coil Using K1504-1 Coil Reel Feeding Electrode and Brake Adjustment Adjustable Wire Reel Brake Loading a 50 or 60 LB. Coil Feeding Electrode and Brake Adjustment Idle Roll Pressure Setting Roll Wire Feeders Adjust the Power Source Adjust the LN-9 GMA ControlsPulse Power 500, DC650 PRO DC-250, DC-400, or DC-600 Starting Characteristics RUN-IN FeatureVoltage Control Response Select Acceleration Procedure AT END of Coil Security of Weld Procedure SettingsMaking a Weld LN-9 GMA Wire Feeder Table of Contents Accessories Section Accessories Optional Equipment and AccessoriesPower Input Cable Assemblies K196, K595, K596 Wire Reel Stands and Mountings Attaching the Wire Reel Stands Wire Reel Door KIT50-60 LB. Wire Reel Assembly for Customer Mounting K299 Spindle for READI-REELS and 2 I.D. Spools K162-H Universal Wire Reel Stand K1524-1 Wire Feeder Accessories Burnback Timer KIT K419GUN and Cable Assemblies Table C.1 LN-9 GMA GUN and Cable Assemblies GMA Timer KIT K418 Dual Process KIT K317 For Wire FeedersDual Procedure KIT K319 Pulse Power Filter Conversion KIT K442-1 Swivel Platform K178-1 Undercarriage K163Continuous Flux Feed Tank K320 K320 Flux Tank Loading K58 Magnetic Separator Table C.2 Drive Roll and Guide Tube Kits Kit Roll Solid Steel ElectrodeCored Electrode Aluminum 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 Figure E.2 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 Power Board Printed Circuit Board FunctionsControl Board LN-9 GMA 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 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 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 32A Lead Lead Wire Drive Motor Test Wire Drive Motor Test Electric Shock can kill Hall Effect Module Test and Alignment Hall Effect Module Feedback Test Procedure Hall Effect Module Test and Alignment Test Hall Effect Module Alignment Test Procedure Figure F.8 Hall Effect Module Location Voltmeter Accuracy Test Voltmeter Accuracy Test Figure F.9 Voltmeter Connection Point Return Return to Master TOC Meter Circuit Accuracy Test Meter Circuit Accuracy Test Figure F.10 Meter PC Board Locations and Cover Figure F.11 Meter PC Board Test Points Test Meter PC Board Wire Feed Speed Test Meter PC Board Voltage Accuracy Test Meter PC Board Wire Feed Speed Accuracy 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.12 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 Replacement ProcedureDigital Meter and Meter PC Board Removal Meter 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.17 Primary Lead #31 AT R1 Resistor 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 Drive Motor Removal and Replacement Figure F.22 TOP Motor Plate Screws Nuts and Washers 4-ROLL Feeders Mylar Insulator Glastic Mounting Board Bolts Reassembly Figure F.25 Drive Motor Removal from Gear BOX Retest the LN-9 GMA wire feeder Retest After Repair LN-9 GMA Wire Feeder Section G LN-9 GMA Wire Feeder Electrical Diagrams Wiring Diagram-LN-9 GMALN-9 GMA Wiring Diagram-LN-9F GMA DEC Voltage Board Schematic LN9, LN9F, LN9GMA, LN9FGMA Power PC Board Schematic SHT. no Trigger PC Board Schematic 17950 M PM Control Schematic Circuit Meter Board Schematic 21146 Operating Schematic 525 B