Lincoln Electric SVM154-A Service Manual Download Page 67

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Summary of Contents for SVM154-A

Page 1: ...h LN 10 Control Boom Mount Code 10442 10 Series Wire Drive Boom Mount Code 10443 10444 10763 10764 LN 10 Boom Package Code 10445 10765 Synergic 7F Drive Code 10190 10191 LN 10 Bench Model Code 10440 1...

Page 2: ...OCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Stand...

Page 3: ...de holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch elect...

Page 4: ...mber that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available...

Page 5: ...laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes...

Page 6: ...nance Section D Theory of Operation Section E Troubleshooting and Repair Section F How to Use Troubleshooting Guide F 2 PC Board Troubleshooting Procedures F 3 Troubleshooting Guide F 5 Test Procedure...

Page 7: ...Drive Roll and Wire Guides A 6 Synergic 7F Wire Drive 4 Roll Kits KP655 KP656 A 6 10 Series Wire Drive Roll Kit Installation KP1505 and KP1507 A 6 Gun and Cable Assemblies with Standard Connection A 7...

Page 8: ...4 mm 373 6 mm 27 94 mm 11 3 Kg K1563 2 10 Series Hi Speed Boom Mount 40 C 40 C to to K679 1 Synergic 7F 11 5 7 16 8 06 16 5 Lbs 20 C 40 C Std Drive Boom Mount 285 8mm 181 9 mm 204 7mm 7 5 Kg K679 2 Sy...

Page 9: ...cored wire for Outershield GMA or Innershield processes The wire type and size range for the wire drive used and gear ratio change selected are given in the Specifications Recommended power sources ar...

Page 10: ...trol cable assembly is required The Head to Control cable assemblies are available in two types K1498 L Includes a control cable with 14 pin ms style connectors on each end and a 3 0 weld cable rated...

Page 11: ...rom the gearbox To remove feedplate a Loosen the clamping collar screw using a 3 16 Allen wrench The clamping collar screw is accessed from the bottom of the feedplate It is the screw which is perpen...

Page 12: ...e tube in the rear hole near the incoming drive roll Slide the tube in until it almost touches the roll Tighten in place 10 Install the remaining guide tube in the front hole Be certain that the prope...

Page 13: ...th the LN 10 Gun Cable Connection with Standard Connection 1 Check that the drive rolls and guide tubes are proper for the electrode size and type being used If necessary change them per Wire Drive Ro...

Page 14: ...the event the water line fittings on your water cooled gun are incompatible with the female quick connects on the front of the K682 2 Kit male quick connects are provided with the kit for installation...

Page 15: ...the 9 socket plug of the control cable to the mating receptacle on the bottom of the LN 10 control box 4 Slip the current sensor cover off enough to expose the input connector stud Connect the electr...

Page 16: ...mote control The 4 pin plug of the remote control connects to the mating receptacle on the bottom of the LN 10 Control box The K1450 L Extension cable is used to extend the 16 ft 5m cable attached to...

Page 17: ...ltmeter B 8 Acceleration Selection B 8 Security Modes B 8 Maximum and Minimum Limits Setting Modes B 9 Dual Procedure Remote Control K1449 1 B 10 Wire Reel Loading Readi Reels Spools or Coils B 10 To...

Page 18: ...ne using a pair of 8 pole DIP switches located inside the LN 10 control box Setup DIP Switch Access 1 Shut off the input power to the LN 10 control by turning off the power at the welding power source...

Page 19: ...00 DC 650 PRO DC 1000 Pulse Power 500 V300 PRO Requires optional K1520 1 115V 42V Transformer Kit Pwr Sources S1 ON S1 1 2 3 4 5 6 7 8 Pwr Sources S1 ON S1 1 2 3 4 5 6 7 8 Pwr Sources S1 ON S1 1 2 3 4...

Page 20: ...off current interlock function 4 Reopening Trigger stops wire feed and initiates burnback time then gas postflow time S2 switch 2 ON 4 Step without current interlock operation 1 Closing Trigger initia...

Page 21: ...limits S2 switch 5 OFF Maximum Limits Setting mode OFF As shipped Minimum Limits Setting Mode Selection The LN 10 control is set up for allowing a minimum weld WFS and arc voltage setting for each pro...

Page 22: ...o the state they were in when power was removed The operator may overwrite any or all of these settings following power up recall Operation Keys Procedure Lights Indicate which procedure A or B is sel...

Page 23: ...flow and burnback timers are also functional in spot mode See Display Control Keys in this section Display Control Keys Timer Select key enables operator to choose burnback spot or gas timers as indic...

Page 24: ...e electrode If actual voltage drops below 8 0 volts for over 0 8 sec when the trigger is closed Loss of Voltage Sense Shutdown will occur See Loss of Voltage Sense Shutdown in this section The last we...

Page 25: ...f the power at the power source 8 Open the control box door 9 Put DIP switch S2 switch 5 in the OFF position and DIP switch S2 switch 6 in the ON position 10 Close the control box door 11 Turn on the...

Page 26: ...of the Readi Reel inside cage wires on the slot in the retaining spring tab 7 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded...

Page 27: ...or spool until the free end of the electrode is accessible 2 While tightly holding the electrode cut off the bent end and straighten the first 6 150 mm Cut off the first 1 25 mm If the electrode is n...

Page 28: ...encoder knobs to set desired Weld feed speed and voltage then Run in speed and voltage to optimize arc starting Set for each proce dure if using front panel remote control or optional dual procedure s...

Page 29: ...time the protec tion circuitry turns off the power source wire feed and gas solenoid and then displays H30 on the WFS display with blank Voltage display This indicates the wire drive motor is overload...

Page 30: ...ey on the keypad or close the trigger See Grounding Lead Protector in this section Cld Displayed on Voltage display when Cold Feed Forward or Cold Feed Reverse Key is pressed or Cold Feed Trigger mode...

Page 31: ...C 2 LN 10 Wire Feeder Accessories C 2 Drive Roll and Guide Tube Kits C 3 Input Cable Assemblies C 4 Spindle Adapters C 4 Gun Adapters For 10 Series Wire Drive C 5 Gun and Cable Assemblies C 5 Miscella...

Page 32: ...MAW GUN AND CABLE ASSEMBLY K497 MAGNUM 200 GMAW GUN AND CABLE ASSEMBLY K541 MAGNUM 400 SHORT NECK GMAW GUN AND CABLE ASSEMBLY K598 MAGNUM 550 GMAW GUN AND CABLE ASSEMBLY K684 MAGNUM SUPER COOL FM WATE...

Page 33: ...P1505 045C KP655 035C 0 045 1 2 mm KP1505 045C KP655 052C 0 052 1 4 mm KP1505 052C KP655 052C 1 16 1 6 mm KP1505 1 16C KP655 1 16 0 068 0 072 1 7 1 8 mm KP1505 068 KP655 3 32 5 64 2 0 mm KP1505 5 64 K...

Page 34: ...5 m 25 ft 7 6 m 33 ft 10 m 50 ft 15 m and 100 ft 30 m K1502 Consists of a 9 conductor control cable with a 14 pin plug and a 3 0 85 mm2 electrode cable with stud terminal It is rated at 600 amps 60 d...

Page 35: ...and cable assemblies are equipped with a Fast Mate connector They can be used with 10 Series wire feed models by installing a K489 2 Fast Mate adapter kit and a K1500 1 Lincoln Gun adapter K684 Magnum...

Page 36: ...s option provides 4 casters and all required hard ware to mount it to the Power Feed 10 This option is compatible with the K1557 1 Swivel Mount K1555 1 INSULATED LIFT HOOK For applications where an in...

Page 37: ...Tubes D 2 Wire Reel Mounting Readi Reels and 10 to 30 lb 4 5 to 14 kg Spools D 2 Avoiding Wire Feeding Problems D 2 Periodic Maintenance D 2 Wire Drive Motor and Gearbox D 2 Gun and Cable Maintenance...

Page 38: ...es After feeding every coil of wire inspect the drive roll section Clean it as necessary Do not use a solvent for cleaning the idle roll because it may wash the lubricant out of the bearing The driver...

Page 39: ...embly 2 Door Feedplate Assembly 3 Motor Gear Box Assembly 4 Wire Drive Assembly 5 Spindle Assembly 6 Reel Stand Base Assembly 7 Current Sensing Reed Switch Energizer Assembly Return to Section TOC Ret...

Page 40: ...General Description E 2 Input Receptacle Control Board and Operator Controls E 3 Wire Feed Head and Receptacle E 4 Protection and Shutdown E 5 Wire Feed Overload Protection E 5 Grounding Lead Protect...

Page 41: ...low burnback and spot weld can all be preset Arc starting can be optimized for each procedure with 5 selectable wire feed acceleration rates A gas purge key is provided as well as cold feed forward an...

Page 42: ...ormation with the user command signals and generates the appro priate signals to control wire feed speed arc voltage and gas flow The current sensing switch and ground lead protector are connected to...

Page 43: ...power source The con trol board receives tach feedback information and adjusts the motor armature voltage to match the pre set wire feed speed FIGURE E 3 LN 10 WIRE FEED HEAD AND RECEPTACLE CONTROL B...

Page 44: ...erload protector prevents welding current from damaging this lead if the electrode circuit touch es the wire feeder frame while the electrode is electri cally hot If such a grounding lead fault occurs...

Page 45: ...E 6 NOTES LN 10 E 6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 46: ...and Feedback Test F 19 Keypad Resistance Test F 23 Encoder PC Board Test F 27 Gas Solenoid Test F 29 Component Replacement Procedures F 31 Display PC Board Removal and Replacement F 31 Gas Solenoid Re...

Page 47: ...er listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at th...

Page 48: ...pment Do not touch electrically hot parts Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which coul...

Page 49: ...F 4 NOTES F 4 LN 10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 50: ...nnector J5 on the control board 1 Check the connections between the drive motor and the control board See the Wiring Diagram 1 Check the tach leads between the tach hall effect device and the control...

Page 51: ...g voltage and current 4 Make certain the welding gun and cable are in good operating condition 1 Check the continuity zero ohms of leads 2 and 4 between the input cable recep tacle and plug J8 on the...

Page 52: ...work piece 1 Check the current sensing reed switch for proper operation A While not welding the volt age at pins 3J1 to 4J1 should be approximately 12 VDC The reed switch should be open If the 12 VDC...

Page 53: ...n the keypad and the display board for loose connections 1 Check the connectors and wires between the display board and the control board for loose or faulty connections J11 and J3 2 Check the connect...

Page 54: ...and the control board for loose or faulty connections J11 and J3 3 Check the connector J10 between the Keypad and the dis play board for loose connections 1 The unit maybe in a mode that utilizes only...

Page 55: ...board for loose or faulty connec tions 1 Make sure the LN 10 is con nected properly to the power source 2 Make sure 42 VAC is being applied to the LN 10 at the input receptacle terminals A and B 1 Ma...

Page 56: ...heck the resistance between pins E M of the 14 pin Amphenol connector on the wire drive while the dual proce dure switch is opened and closed The resistance must change from an open to almost no resis...

Page 57: ...e set tings will be removed 1 The Ground Lead Protector cir cuit has activated due to exces sive current flow in the wire feeder frame This can be caused be the electrode coming in contact with the wi...

Page 58: ...ctual WFS The K1449 1 remote control is not functioning when the Procedure LED is in the REMOTE position 1 Make sure the gas supply is adequate and connected cor rectly to the LN 10 1 Make sure the po...

Page 59: ...e Wire Drive Head Selection 1 The tip may be overheated because of prolonged or excessive high current and or duty cycle 1 If the drive rolls are turning erratically perform the Wire Drive Motor Test...

Page 60: ...the set screw in the connector block is in place and tightened against the liner bushing 4 Weld procedures and or para meters incorrect for process being performed 5 The power source may be faulty 1...

Page 61: ...F 16 NOTES LN 10 F 16 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 62: ...he test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 WEL...

Page 63: ...0 unit 2 Using the 5 16 in nut driver remove the wire drive cover 3 Locate the motor armature leads for the motor to be tested one black lead and one white lead Do not discon nect the leads See Figure...

Page 64: ...throughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troub...

Page 65: ...Using the 5 16 in nut driver remove the wire drive cover 3 Locate the three hall effect leads blue red and black See Figure F 2 4 Apply the correct input power 42 VAC to the LN 10 5 Check for approxi...

Page 66: ...TACH ADJUSTMENT PROCEDURE Proper positioning of the module is critical to the proper operation the LN 10 wire feed er If the device is not screwed in far enough the motor speed could be unstable or ru...

Page 67: ...F 22 NOTES LN 10 F 22 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 68: ...roughout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical trouble...

Page 69: ...ST PROCEDURE 1 Remove input power to the LN 10 unit 2 Using the 5 16 in nut driver remove the two screws from the top of the con trol panel See Figure F 3 3 Carefully lower the control panel 4 Remove...

Page 70: ...00 OHMS 50 OHMS TYPICAL 1J10 8J10 COLD FEED REVERSE 100 OHMS 50 OHMS TYPICAL 1J10 9J10 GAS PURGE 100 OHMS 50 OHMS TYPICAL F 25 TROUBLESHOOTING AND REPAIR F 25 LN 10 NOTE There should not be continuity...

Page 71: ...F 26 NOTES LN 10 F 26 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 72: ...out this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshoot...

Page 73: ...input power to the LN 10 unit 10 Reassemble the control panel TEST PROCEDURE 1 Remove input power to the LN 10 unit 2 Using the 5 16 in nut driver remove the two screws from the top of the con trol p...

Page 74: ...reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you p...

Page 75: ...onnect all disconnected leads 10 Install the wire drive cover TEST PROCEDURE 1 Remove input power to the LN 10 unit 2 Using the 5 16 in nut driver remove the wire drive cover 3 Locate the gas solenoid...

Page 76: ...hout this manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshoo...

Page 77: ...el 4 Locate and remove plug J11 from the display board Observe static electricity precautions See Figure F 6 5 Carefully pry the display board from the six mounting pins Note that the keypad is still...

Page 78: ...manual If for any reason you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assi...

Page 79: ...e gas solenoid assembly and remove the input gas lines using pliers See Figure F 7 4 Label and remove the two leads con nected to the solenoid 5 Remove the rubber hose and clamp from the gas solenoid...

Page 80: ...nderstand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 8...

Page 81: ...two screws from the top of the control panel 3 Lower the control panel 4 Using the 5 64 in Allen wrench remove the control knob spacer and felt washer from the encoder board that is to be removed See...

Page 82: ...le to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The procedure wi...

Page 83: ...t 2 Remove the electrode wire from the wire drive 3 Using the 5 16 in nut driver remove the wire drive cover 4 Disconnect the 67 lead at the quick connect See Figure F 9 5 Disconnect the gas hose from...

Page 84: ...e F 10 13 Using the 5 16 in wrench remove the motor mounting screws located inside the gear box 14 Using the flat head screwdriver remove the two screws mounting the top of the motor to the gear box 1...

Page 85: ...ved cable ties 16 Install the wire drive cover REPLACEMENT PROCEDURES 1 Carefully slide the wire drive assembly and gear box together 2 Tighten the two Allen type screws at the bottom of the wire driv...

Page 86: ...you do not understand the test procedures or are unable to per form the test repairs safely contact the Lincoln Electric service department for technical troubleshooting assistance before you proceed...

Page 87: ...er Note lead routing for reassembly See Figure F 11 5 Replace Reed Switch into the copper energizer and tighten locking screw Mount the assembly to the machine using 3 4 nuts 6 Plug in Reed Switch lea...

Page 88: ...cs must be replaced or if any electrical components are repaired or replaced the machine must be retested and meet the following standards Apply the correct input power 42 VAC to the LN 10 unit The fo...

Page 89: ...agrams Section Section G Wiring Diagram Control G 2 Wiring Diagram Wire Drive G 3 Control Board Schematic Sheet 1 G 4 Control Board Schematic Sheet 2 G 5 Control Board Layout G 6 Display Board Schemat...

Page 90: ...ED REV ROBOT COLD FEED FWD ROBOT BURN BACK ROBOT VOLTS ROBOT 21 67 4 2 75 76 500 542 81R 516 500 512B TO MOTOR TACHOMETER TO BRASS BLOCK VOLTAGE SENSE TO SOLENOID TO SOLENOID TO DUAL PROCEDURE SWITCH...

Page 91: ...PTACLE 539 10 11 1 B K 2 A W 8 2 9 B 541 512 SWITCH 522 RECEPTACLE TRIGGER AND C D DUAL PROCEDURE E HEAD ASSEMBLY SENSOR CURRENT FROM CABLE ELECTRODE J1 P1 P2 J5 J2 P4 J4 M18036 N A 541 539 522 N A CH...

Page 92: ...urn to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 4 LN 10 SCHEMATIC CONTROL PC BOARD 1 G 4 NOTE This diagram is for reference...

Page 93: ...OLTS WFS CFFR CFRR BBR 500 TRIGR GASR 500 500 512 500 512 SOLENOID 500 FAULT J6 6 D30 1 0 35V C50 488 DP 3 32K R169 3 32K R96 50V 0 1 C71 J7 1 X16 2 4 5 332 R170 44 2K R172 13 7K R167 D46 3 32K R160 D...

Page 94: ...5 8 S 1 5 0 0 0 2 5 O P T O C O U P L E R O C I 6 O C I 7 O C I 8 O C I 9 O C I 1 0 2 S 1 5 0 0 0 2 0 P H O T O F E T Q 1 Q 3 Q 5 3 T 1 2 7 0 4 6 8 2 N 4 4 0 1 Q 4 1 T 1 2 7 0 4 5 4 N C H A N N E L F...

Page 95: ...5 R17 X4 5 6 50V 0047 C7 1 2 500 475 R19 475 R12 475 R13 1 4W 7 29 96 NONE 022 50V E D TO KEYPAD A B J10 6 DISP4 2 1 4 9 5 10 7 6 8 3 COLD FEED FORWARD GAS PURGE FEEDER SCHEDULE SELECT J10 7 J10 8 J10...

Page 96: ...C 6 C 7 3 S 1 6 6 6 8 6 4 7 0 0 p F 5 0 C 8 C 1 1 2 S 1 3 4 9 0 2 5 4 7 3 5 D 1 D 2 2 T 1 2 1 9 9 1 1 N 4 0 0 4 D I S P 1 1 S 1 7 3 9 5 1 D I S P L AY D I S P 2 D I S P 3 D I S P 4 D I S P 5 7 S 1 7 3...

Page 97: ...E WITH PUBLISHED STANDARDS UNLESS OTHERWISE SPECIFIED TOLERANCE 22066 NONE EQUIP COMMON CONNECTION TYPE CLEVELAND OHIO U S A SUBJECT 11 8 94 POWER SUPPLY SOURCE POINT ELECTRICAL SYMBOLS PER E1537 CODE...

Page 98: ...he machine ELECTRICAL DIAGRAMS G 10 LN 10 PC BOARD ASSEMBLY ENCODER 04 1 85 04 2 30 0 0 ITEM REQ D PART NO DESCRIPTION CAPACITORS MFD VOLTS RESISTORS OHMS 17797 1 Ch ge Sht No 4 7 95 10 23 98F SYNERGI...

Page 99: ..._________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ______________...

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