Lincoln Electric SVM138-A - Manual

Lincoln Electric SVM138-A

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Table of Contents:

  • Page 2 – SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
  • Page 3 – ii; ELECTRIC SHOCK can kill.
  • Page 4 – iii
  • Page 5 – iv; PRÉCAUTIONS DE SÛRETÉ
  • Page 6 – MASTER TABLE OF CONTENTS; Page; RETURN TO MAIN INDEX
  • Page 8 – NOTES; vii
  • Page 9 – TABLE OF CONTENTS; Installation
  • Page 10 – INSTALLATION; TECHNICAL SPECIFICATIONS; Recommended; LENGTH; LN-9F GMA Control Box
  • Page 11 – Accessories; MOUNTING THE WIRE FEED UNIT; Diagrams section of this manu-
  • Page 12 – ROUTING THE ELECTRODE; Accessories section for information about; POWER INPUT CABLE ASSEMBLY; Figure A.2. Remove the screws holding the; FIGURE A.1 – INPUT CONTROL CABLE AND
  • Page 13 – FIGURE A.2 – STRAIN RELIEF CLAMP; Bolt the electrode lead from the power source to the; BOTTOM VIEW
  • Page 15 – • Turn off input power to the welding; ELECTRIC SHOCK
  • Page 18 – FIGURE A.7 – CONNECTION OF LN-9 GMA TO PULSE POWER 500 POWER SOURCES
  • Page 19 – FIGURE A.8 – CONNECTION OF LN-9 GMA TO V300 POWER SOURCES; TO WORK
  • Page 20 – MACHINE GROUNDING; TABLE A.1 – WORK CABLE SIZES; DIRECT WORK LEAD CONNECTION; Circuit
  • Page 21 – Accessories section; FOR GMA GUN CABLES:; FIGURE A.9 – GUN CABLE CONNECTIONS
  • Page 22 – FIGURE A.10 – SHIELDING GAS HOOKUP
  • Page 23 – Operation
  • Page 24 – OPERATION
  • Page 25 – GENERAL DESCRIPTION
  • Page 26 – The Idealarc
  • Page 27 – CONTROLS AND SETTINGS; a) When you are not welding, the trigger will function
  • Page 28 – FIGURE B.3 – WIRE FEEDER CONTROLS FOR LN-9 GMA
  • Page 29 – FIGURE B.4 – WIRE FEEDER CONTROLS FOR LN-9F GMA
  • Page 31 – AUTOMATIC SHUTDOWN
  • Page 32 – DRIVE ROLL INSTALLATION; NOTE: Although an LN-9 GMA model is shown in; Idle Roll
  • Page 33 – GUIDE TUBE DETAIL; FIGURE B.5 – INSTALLING DRIVE ROLLS ON A 2-ROLL FEEDER
  • Page 35 – GUIDE TUBE DETAIL; FIGURE B.6 – INSTALLING DRIVE ROLLS ON A 4-ROLL FEEDER
  • Page 36 – WIRE LOADING
  • Page 37 – FEEDING ELECTRODE AND BRAKE ADJUSTMENT
  • Page 38 – a) Be sure the coil is placed so that the spring loaded; CAUTION
  • Page 39 – Inch the electrode through the gun.
  • Page 40 – IDLE ROLL PRESSURE SETTING; PRESSURE
  • Page 42 – SELECT ACCELERATION
  • Page 43 – MAKING A WELD; PROCEDURE AT END OF COIL; Lay the cable out straight.
  • Page 46 – AUXILIARY EQUIPMENT CONTACTS; • K196 Input Cable Assemblies - For power sources; WIRE REEL STANDS AND MOUNTINGS; MOUNTING STAND; ACCESSORIES
  • Page 49 – WIRE FEEDER ACCESSORIES; GUN AND CABLE ASSEMBLIES; TABLE C.1 – LN-9 GMA GUN AND CABLE ASSEMBLIES; Innershield
  • Page 50 – Provides the following functions:
  • Page 51 – K320 FLUX TANK LOADING
  • Page 52 – K58 MAGNETIC SEPARATOR; The magnetic separator is used with all
  • Page 55 – Maintenance
  • Page 56 – SAFETY PRECAUTIONS; ROUTINE MAINTENANCE; DRIVE ROLLS AND GUIDE TUBES; Operation Section for drive roll installation; PERIODIC MAINTENANCE; CONTROL BOX; MAINTENANCE
  • Page 57 – GUN AND CABLE MAINTENANCE; FIGURE D.1 – SPEED SENSOR MODULE LOCATION
  • Page 58 – /2 Amp AC 24 Volts — Inductive; FIGURE D.2 – SWITCH REQUIREMENTS
  • Page 59 – FIGURE E.1 – LN-9 GMA BLOCK LOGIC DIAGRAM
  • Page 60 – POWER INPUT CIRCUITS; THEORY OF OPERATION; FIGURE E.2 – POWER INPUT CIRCUITS
  • Page 61 – FIGURE E.3 – TRIGGER AND SHUTDOWN CIRCUIT
  • Page 62 – FIGURE E.4 – ARC VOLTAGE, WIRE SPEED CONTROL AND METERING
  • Page 65 – NOTE
  • Page 66 – HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; The
  • Page 67 – PC BOARD TROUBLESHOOTING PROCEDURES
  • Page 68 – Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; FUNCTION PROBLEMS; Make sure 115VAC is being
  • Page 69 – The Ground Lead Protector; Trigger
  • Page 70 – Make sure the gun trigger is not
  • Page 71 – Make sure the interlock switch
  • Page 72 – Contact your local Lincoln
  • Page 73 – The control PC board may be
  • Page 74 – TRIGGER INTERLOCK FUNCTION PROBLEMS
  • Page 75 – The voltage PC board may be; T1 Transformer; The power PC board may be
  • Page 76 – Check or replace gun trigger; Wire Drive Motor; T2 Transformer; The power PC board may be
  • Page 78 – Make sure the power source; Out of Voltage; The voltage PC board may be
  • Page 79 – FEEDING PROBLEMS; Make certain the drive rolls and
  • Page 80 – WELDING PROBLEMS; Check the welding cables for
  • Page 82 – METER FUNCTION PROBLEMS; The arc is unstable or oscillating.
  • Page 84 – Meter Circuit
  • Page 85 – STARTING PROBLEMS
  • Page 86 – Put the Lincoln power source in
  • Page 87 – Put the Lincoln power source in
  • Page 88 – T1 TRANSFORMER TEST; DESCRIPTION; This procedure takes approximately 20 minutes to perform.
  • Page 89 – TEST PROCEDURE; Remove input power to the LN-9 GMA wire; Electric Shock can kill.; • With power applied,
  • Page 90 – With 115VAC applied to the primary leads
  • Page 92 – T2 TRANSFORMER TEST; FIGURE F.3 – “PROTECTION CIRCUIT TROUBLESHOOTING” NAMEPLATE; PROTECTION CIRCUIT
  • Page 93 – Locate the T2 transformer primary lead; R1 RESISTOR
  • Page 94 – FIGURE F.5 – T2 SECONDARY LEADS #621 AND #620 ON TRIGGER PC BOARD; LEAD
  • Page 95 – This procedure takes approximately 12 minutes to perform.
  • Page 96 – WIRE DRIVE MOTOR TEST; FIGURE F.6 – LEAD #539 AND #541 AT POWER PC BOARD TERMINAL STRIP
  • Page 97 – Hall Effect Module Test.
  • Page 98 – HALL EFFECT MODULE TEST AND ALIGNMENT; The Hall Effect Module Test takes approximately
  • Page 99 – Remove the input power to the LN-9 GMA
  • Page 100 – General Power Supply; With the gun trigger activated or the gun ter-
  • Page 101 – FIGURE F.8 – HALL EFFECT MODULE LOCATION
  • Page 102 – This procedure takes approximately 8 minutes to perform.
  • Page 103 – VOLTMETER ACCURACY TEST; FIGURE F.9 – VOLTMETER CONNECTION POINT; Installation section of this; Connect the test meter (see Materials; BRASS
  • Page 104 – • With power applied, there; Meter Circuit Accuracy Test.; If no further tests are required, remove the
  • Page 105 – This procedure takes approximately 17 minutes to perform.
  • Page 106 – METER CIRCUIT ACCURACY TEST; FIGURE F.10 – METER PC BOARD LOCATIONS AND COVER
  • Page 107 – Test for AC supply to the meter PC board.; FIGURE F.11 – METER PC BOARD TEST POINTS
  • Page 108 – With the meter in SET volts, adjust the voltage
  • Page 109 – Connect the + probe to lead called for in the table; METRIC MODEL; LO
  • Page 111 – WIRE SPEED ACCURACY TEST; Set the LN-9 GMA wire speed control for
  • Page 112 – This procedure takes approximately 18 minutes to perform.
  • Page 113 – OUT OF VOLTAGE RANGE SHUT DOWN TEST; FIGURE F.12 – VOLTAGE PC BOARD WITH JUMPERS
  • Page 114 – If the ACTUAL voltage reading is zero, the
  • Page 116 – GENERAL POWER SUPPLY TESTS
  • Page 117 – GENERAL POWER SUPPLY CHECKS
  • Page 119 – FIGURE F.13 – METER PANEL ASSEMBLY SCREWS; DIGITAL METER AND METER PC BOARD REMOVAL AND; Locate and remove the two screws on the top
  • Page 120 – FIGURE F.15 – METER PC BOARD REMOVAL; MOUNTING NUTS; REPLACEMENT PROCEDURE
  • Page 122 – PROCEDURE; REED SWITCH (CR2) REMOVAL AND REPLACEMENT; FIGURE F.16 – CR2 REED SWITCH LOCATION AND COMPONENTS; COPPER
  • Page 123 – This procedure takes approximately 25 minutes to perform.
  • Page 124 – Using the phillips head screwdriver remove the; T1 TRANSFORMER REMOVAL AND REPLACEMENT; FIGURE F.17 – PRIMARY LEAD #31 AT R1 RESISTOR
  • Page 126 – Remove the two phillips head screws from the; FIGURE F.20 – 1CR RELAY REMOVAL; NUT AND SCREW
  • Page 127 – REPLACEMENT; Figure
  • Page 128 – DRIVE MOTOR REMOVAL AND REPLACEMENT; This procedure takes approximately 40 minutes to perform.
  • Page 129 – FIGURE F.22 – TOP MOTOR PLATE SCREWS
  • Page 130 – Remove the three screws and lock washers; FIGURE F.23 – GLASTIC MOUNTING SCREWS
  • Page 131 – Lift the right side cover assembly and care-; FIGURE F.24 – MOTOR AND WIRE DRIVE REMOVAL
  • Page 132 – REASSEMBLY; Hall
  • Page 133 – RETEST AFTER REPAIR; OR; Voltmeter Accuracy Check
  • Page 137 – ELECTRICAL DIAGRAMS
  • Page 139 – Voltage Board Schematic
  • Page 140 – Power PC Board Schematic
  • Page 141 – Trigger PC Board Schematic
  • Page 142 – PM Control Schematic
  • Page 143 – Meter Board Schematic; M E T E R B O A R D S C H E M A T I C
  • Page 144 – Operating Schematic
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SVM138-A

June, 1998

Safety Depends on You

Lincoln arc welding equipment
is designed and built with safety
in mind. However, your overall
safety can be increased by
proper installation. . . and
thoughtful operation on your
part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.

SERVICE MANUAL

For use with machines having Code Numbers: 9100 and Above

LN-9 GMA Wire Feeder

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

World's Leader in Welding and Cutting Products

Premier Manufacturer of Industrial Motors

RETURN TO MAIN INDEX

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Summary

Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. O...

Page 3 - ii; ELECTRIC SHOCK can kill.

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY ii ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter l...

Page 4 - iii

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iii iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National ...

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