T2 Transformer | Lincoln Electric SVM138-A instruction

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F-12							F-12
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE					Observe Safety Guidelines
			detailed in the beginning of this manual.

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

	FUNCTION PROBLEMS
Circuit breaker (3 amp) repeatedly	1. Check or replace gun trigger			1.	Disconnect lead #500 from the
trips when the gun trigger is acti-	and leads.		Make sure the trig-		trigger PC board. If the breaker
vated.	ger leads are not shorted to the				still trips when the gun trigger is
	electrode or work cables.				activated, the trigger PC board
					may be faulty. Replace
				2.	Disconnect any accessory that
					may be connected to terminals
					#7 and #32A. See the Wiring
					Diagram. If the problem is
					resolved, the accessory may be
					faulty. Replace.
				3.	Perform the Wire Drive Motor
					Test.
				4.	The power PC board may be
					faulty. Replace.

Circuit breaker (3 amp) trips when	1. Disconnect any kits that may be			1.	Disconnect lead #620 from the
power is applied to the LN-9 GMA.	incorporated in the LN-9 GMA				trigger PC	board.	See the
Gun trigger is NOT activated.	(K418, K419, etc.). Be sure to				Wiring Diagram. If the problem
	install	any	necessary jumper		is resolved, the trigger PC
	plugs.	If	the problem is re-		board may be faulty. Replace.
	solved, the fault may be in the			2.	Perform the	T2 Transformer
	disconnected kit.			2.	Perform the	T2 Transformer
	disconnected kit.				Test.
					Test.
				3.	Check the harness leads #32A,
					#31, and #531 for shorts or
					grounds.	See	the Wiring
					Diagram.
				4.	The power PC board may be
					faulty. Replace.

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 76

Lincoln Electric SVM138-A service manual T2 Transformer

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 Table of Contents Installation SectionInstallation Section A-1 Technical Specifications InstallationWidth Height Installing the LN-9 GMA Roll and 4-ROLL Models Attaching the Wire Reel StandMounting the Wire Feed Unit 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 Machine Grounding Work Cable ConnectionDirect Work Lead 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 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 Security of Weld Procedure Settings Procedure AT END of CoilMaking 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 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 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 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