Lincoln Electric SVM138-A manual

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

Section F-1

Section F-1

TABLE OF CONTENTS

TROUBLESHOOTING & REPAIR SECTION

Troubleshooting & Repair Section	Section F
How to Use Troubleshooting Guide	F-2
PC Board Troubleshooting Procedures	F-3
Troubleshooting Guide	F-4 - F-23
Test Procedures
T1 Transformer Test	F-24
T2 Transformer Test	F-27
Wire Drive Motor Test	F-31
Hall Effect Test and Alignment	F-34
Voltmeter Accuracy Test	F-38
Meter Circuit Accuracy Test	F-41
Wire Speed Accuracy Test	F-46
Out of Voltage Range Shut Down Test	F-48
General Power Supply Tests	F-51
Replacement Procedures
Digital Meter and Meter PC Board Removal and Replacement	F-54
Reed Switch (CR2) Removal and Replacement	F-57
T1 Transformer Removal and Replacement	F-59
Drive Motor Removal and Replacement	F-64
Retest After Repair	F-69

NOTE

This Troubleshooting section is specific to the LN-9 GMA. However, much of this information may apply to the LN-9 F GMA model with slight adaptation. Refer to LN-9F GMA Wiring Diagram.

LN-9 GMA Wire Feeder

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Lincoln Electric SVM138-A service manual Table of Contents Troubleshooting & Repair Section

Contents

Safety Depends on You LN-9 GMA Wire Feeder LN-9 GMA Wire Feeder Safety Fumes and Gases can be dangerous Electric Shock can killARC Rays can burn 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 Installation Section Table of ContentsInstallation Section A-1 Width Height InstallationTechnical Specifications Attaching the Wire Reel Stand Installing the LN-9 GMA Roll and 4-ROLL ModelsMounting the Wire Feed Unit Mounting the Unit Routing the Electrode Power Input Cable AssemblyElectrical Connections LN-9 GMA and LN-9F GMA 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 Work Cable Connection Machine GroundingDirect Work Lead Connection Table A.1 Work Cable Sizes Thumb- screw Connecting the GUN Cable to the Wire FeederFor GMA GUN Cables Cylinder may explode if damaged Hooking UP GMA Shielding GAS Table of Contents Operation Section Operating Instructions Safety PrecautionsOperation Recommended Processes and Equipment General DescriptionK424 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 Circuit Protection and Automatic Shutdown Power Supply FuseAvoiding Grounding Lead Protector GLP Shutdown Circuit Breaker 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 Adjust the LN-9 GMA Controls Adjust the Power SourcePulse Power 500, DC650 PRO DC-250, DC-400, or DC-600 RUN-IN Feature Starting CharacteristicsVoltage Control Response Select Acceleration Making a Weld Procedure AT END of CoilSecurity of Weld Procedure Settings LN-9 GMA Wire Feeder Table of Contents Accessories Section Optional Equipment and Accessories AccessoriesPower Input Cable Assemblies K196, K595, K596 Wire Reel Stands and Mountings Wire Reel Door KIT 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 Universal Wire Reel Stand K1524-1 Burnback Timer KIT K419 Wire Feeder AccessoriesGUN and Cable Assemblies Table C.1 LN-9 GMA GUN and Cable Assemblies Dual Process KIT K317 For Wire Feeders GMA Timer KIT K418Dual Procedure KIT K319 Pulse Power Filter Conversion KIT K442-1 Undercarriage K163 Swivel Platform K178-1Continuous Flux Feed Tank K320 K320 Flux Tank Loading K58 Magnetic Separator Kit Roll Solid Steel Electrode Table C.2 Drive Roll and Guide Tube KitsCored Electrode Aluminum Electrode LN-9 GMA Wire Feeder Table of Contents Maintenance Section Periodic Maintenance MaintenanceRoutine Maintenance 3D-3 GUN and Cable MaintenanceProper Speed Sensor Module Mounting 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 Control Board Power BoardPrinted Circuit Board Functions 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 Detailed in the beginning of this manual Troubleshooting GuideObserve Safety Guidelines 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 Materials Needed T1 Transformer TestDescription 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 Procedure ReplacementDigital Meter and Meter PC Board Removal 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 LN-9 GMA Electrical DiagramsWiring Diagram-LN-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