Troubleshooting & Repair | Lincoln Electric SVM138-A instruction

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F-17							F-17
	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

			WELDING PROBLEMS
	Poor arc striking with sticking or	1.	Make sure the welding parame-	1. Put the power source in
	"blast offs." The weld bead may		ters and techniques are correct	"Machine	Control"		and check
	also be ropey and display weld		for the welding procedure being	whether welding			performance
	porosity.		used.	improves.	If	the	problem is
		2.	Check the welding cables for	resolved, check or replace the
		2.	Check the welding cables for	control cable.		Or, the LN-9
			loose or faulty connections.	control cable.		Or, the LN-9
			loose or faulty connections.	GMA voltage PC board may be
				GMA voltage PC board may be
		3.	The gun cable may be faulty.	faulty.
			Check or replace.
		4.	The gun contact tip may be
			worn. Check or replace.
		5.	The welding power source may
			be faulty. Check or 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

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Lincoln Electric SVM138-A service manual Troubleshooting & Repair

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 Installation Section Table of ContentsInstallation Section A-1 Installation Technical SpecificationsWidth Height Attaching the Wire Reel Stand Installing the LN-9 GMA Roll and 4-ROLL ModelsMounting the Wire Feed Unit Mounting the 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 Work Cable Connection Machine GroundingDirect Work Lead Connection Table A.1 Work Cable Sizes 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 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 Procedure AT END of Coil Security of Weld Procedure SettingsMaking a Weld 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 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 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 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