Troubleshooting & Repair | Lincoln Electric SVM138-A manual

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F-6				F-6
	TROUBLESHOOTING & REPAIR
	Observe Safety Guidelines			TROUBLESHOOTING GUIDE
	detailed in the beginning of this manual.

	PROBLEMS	POSSIBLE AREAS OF		RECOMMENDED
	(SYMPTOMS)	MISADJUSTMENT(S)		COURSE OF ACTION

			FUNCTION PROBLEMS
	The wire feed “coasts” when the	1.	Make sure the gun trigger is not	1. The relay 1CR may be faulty.
	gun trigger is released.		“sticking.”	Replace.

	The gas solenoid does not activate	1.	If a K418 GMA Timer Kit or a	1. With the gun trigger closed,
	when the gun trigger is closed. The		K419 Burnback Timer Kit is	check for 115VAC at the power
	wire feeds and arc voltage is pre-		installed, disconnect it and	PC board terminals #7A to
	sent.		replace it with the jumper plug.	#32A.
			If the problem is resolved, the	a. If the 115VAC is present,
			K418 or K419 is faulty.	a. If the 115VAC is present,
			K418 or K419 is faulty.	the solenoid may be faulty.
				the solenoid may be faulty.
				Replace.
				b. If the 115VAC is NOT pre-
				sent at terminals #7 and
				#32, the relay CR1 on the
				power PC board may be
				faulty. Replace.

	The gas solenoid stays open after	1.	The gas solenoid may be stuck	1. With the gun trigger NOT
	the gun trigger switch is released.		in the open position.	closed, check for 115VAC at the
				power PC board terminals #7 to
				#32A.
				a. If the 115VAC is present,
				the relay CR1 may be
				defective.
				b. If the 115VAC is NOT pre-
				sent, the gas solenoid may
				be defective.

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 GMA Wire Feeder

Image 70

Lincoln Electric SVM138-A service manual Troubleshooting & Repair

Contents

LN-9 GMA Wire Feeder Safety Depends on You Safety LN-9 GMA 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 Master Table of Contents cont’d Vii LN-9 GMA Wire Feeder Installation Table of ContentsInstallation Section Section A-1 Technical Specifications InstallationWidth Height Mounting the Wire Feed Unit Installing the LN-9 GMA Roll and 4-ROLL ModelsAttaching the Wire Reel Stand Mounting the Unit Electrical Connections LN-9 GMA and LN-9F GMA Power Input Cable AssemblyRouting 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 Direct Work Lead Connection Machine GroundingWork Cable Connection Table A.1 Work Cable Sizes For GMA GUN Cables Connecting the GUN Cable to the Wire FeederThumb- screw Hooking UP GMA Shielding GAS Cylinder may explode if damaged Table of Contents Operation Section Operation Safety PrecautionsOperating Instructions K424 LN-9 GMA 2-ROLL and K568-1 LN-9 GMA 4-ROLL General DescriptionRecommended Processes and Equipment 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 Avoiding Grounding Lead Protector GLP Shutdown Power Supply FuseCircuit Protection and Automatic 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 Pulse Power 500, DC650 PRO Adjust the Power SourceAdjust the LN-9 GMA Controls DC-250, DC-400, or DC-600 Voltage Control Response Starting CharacteristicsRUN-IN Feature Select Acceleration Security of Weld Procedure Settings Procedure AT END of CoilMaking a Weld LN-9 GMA Wire Feeder Table of Contents Accessories Section Power Input Cable Assemblies K196, K595, K596 AccessoriesOptional Equipment and Accessories Wire Reel Stands and Mountings 50-60 LB. Wire Reel Assembly for Customer Mounting K299 Attaching the Wire Reel StandsWire Reel Door KIT Spindle for READI-REELS and 2 I.D. Spools K162-H Universal Wire Reel Stand K1524-1 GUN and Cable Assemblies Wire Feeder AccessoriesBurnback Timer KIT K419 Table C.1 LN-9 GMA GUN and Cable Assemblies Dual Procedure KIT K319 GMA Timer KIT K418Dual Process KIT K317 For Wire Feeders Pulse Power Filter Conversion KIT K442-1 Continuous Flux Feed Tank K320 Swivel Platform K178-1Undercarriage K163 K320 Flux Tank Loading K58 Magnetic Separator Cored Electrode Table C.2 Drive Roll and Guide Tube KitsKit Roll Solid Steel Electrode Aluminum Electrode LN-9 GMA Wire Feeder Table of Contents Maintenance Section Routine Maintenance MaintenancePeriodic Maintenance Proper Speed Sensor Module Mounting GUN and Cable Maintenance3D-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 Printed Circuit Board Functions Power BoardControl 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 Observe Safety Guidelines Troubleshooting GuideDetailed 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 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 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 Digital Meter and Meter PC Board Removal ReplacementProcedure 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 Wiring Diagram-LN-9 GMA Electrical DiagramsLN-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