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Lincoln Electric SVM143-A manual

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Table of contents for the manual

  • Page 1

    DH- 10 Heads & Controls Boom Mount or Bench M odels OPERA TOR’S MANUAL SVM143-A March, 1999 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPA[...]

  • Page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINE po wered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or ven[...]

  • Page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the[...]

  • Page 4

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CYLINDER ma y explode if damaged. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the applicat[...]

  • Page 5

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour[...]

  • Page 6

    v v DH-10 MASTE R T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications — DH-10 Complete Units [...]

  • Page 7

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SECTION A-1 INST ALLA TION DH-10 SECTION A-1 T ABLE OF CONTENTS -INST ALLA TION SECTION- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical [...]

  • Page 8

    A-2 INST ALLA TION DH-10 A-2 TECHNICAL SPECIFICA TIONS – DH-10 Complete Units or Contr ols & Heads WIRE DRIVE HEADS (BOOM MOUNT)• SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO Wire Size Wire Size Speed Solid Cored Speed Solid Cored K1497-1 ¤ DH-10 35 - 500 IPM .025 - 3/32 in. .030 - .120 in. 50 - 750 IPM .025 - 1/16 in. .030 - 5/64 in. Doub[...]

  • Page 9

    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 A-3 INST ALLA TION DH-10 A-3 GENERAL DESCRIPTION The DH-10 is a modular line of 42 VAC input dual head 4-roll wire feeders. A single control with dual procedure presettability of[...]

  • Page 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 A-4 INST ALLA TION DH-10 A-4 SAFETY PRECA UTIONS INST ALLA TION OF THE DH-10 BOOM MOUNT WIRE FEEDER COMPONENTS Mounting the DH Double Header Wire Drive Unit (K1497-1 or -2) Mount[...]

  • Page 11

    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 A-5 INST ALLA TION DH-10 A-5 Connecting Wire Drive Unit to Control Bo x One head to control cable assembly is required for each head being used; however, only one electrode cable[...]

  • Page 12

    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 A-6 INST ALLA TION DH-10 A-6 To remove feedplate: a. Loosen the clamping collar screw using a 3/16 in. Allen wrench. The clamping collar screw is accessed from the bottom of the [...]

  • Page 13

    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 Single Drive 4-Roll Kits (KP655 and KP656) 1. Turn OFF welding power source. 2. Release both quick release levers by sliding the levers sideways into the open positions. 3. Remov[...]

  • Page 14

    A-8 INST ALLA TION DH-10 A-8 Gun Cable Connection with Standar d 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 Roll Kits in this section. 2. Lay the cable out straight. Insert the connector on the welding conductor cable into the brass conduct[...]

  • Page 15

    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 A-9 INST ALLA TION DH-10 A-9 GMA W Shielding Gas The customer must provide a cylinder of shielding gas, a pressure regulator, a flow control valve, and a hose from the flow valve[...]

  • Page 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 A-10 INST ALLA TION DH-10 A-10 K1503 Consists of a 9-conductor control cable with a 14-pin plug and 2/0 (67 mm 2 ) electrode cable with Twist-Mate™ connector. It is rated at 50[...]

  • Page 17

    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 A-11 INST ALLA TION DH-10 A-11 Magnum conduit to go between the reel cover and the feedplate. Gun Adapters (For DH Wire Drive Heads) Adapts DH heads for desired gun connection K4[...]

  • Page 18

    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 A-12 INST ALLA TION DH-10 A-12[...]

  • Page 19

    SECTION B-1 OPERA TION SECTION B-1 DH-10 T ABLE OF CONTENTS -OPERA TION SECTION- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 20

    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 For K1497-2 (DH-10 Boom) or K1499-2 (DH-10 Bench) with Left Head 35-500 IPM (0.89-12.7 m/m) & Right Head 55-825 IPM (1.40-21.0 m/m) Low Speed Ratio set S2 DIP switch as follo[...]

  • Page 21

    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 B-3 OPERA TION B-3 DH-10 SINGLE HEADS: For K1563-1 (LN-10 Boom) with 35-500 IPM (0.89- 12.7 m/m) Low Speed Ratio set S2 DIP Switches as follows: For K1563-1 (LN-10 Boom) with 50-[...]

  • Page 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 Pulse Power 500: V300 PRO: Other Power Source Independent: Set the DIP switches as shown for all other power sources which can be controlled with a 10K Ω poten- tiometer circui[...]

  • Page 23

    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 B-5 OPERA TION B-5 S1 switch 7 ON = 4-Step without current interlock operation: 1. Closing Trigger initiates gas flow. 2. Opening Trigger initiates gas preflow timer fol- lowed b[...]

  • Page 24

    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 B-6 OPERA TION B-6 Dual procedure settings, including; trigger mode, cold feed speed, Run-in and weld speed and voltage, timers and acceleration are automatically saved for each [...]

  • Page 25

    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 B-7 OPERA TION B-7 Display Contr ol Keys Timer Select key - enables operator to choose burnback, spot or gas timers, as indicated by the appropriate light. Pressing the key cause[...]

  • Page 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 B-8 OPERA TION B-8 To change acceleration hold the Gas Purge Key closed, then press the Control key. The top (Voltage) display shows “Acc” indicating acceleration setting, 1 [...]

  • Page 27

    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 B-9 OPERA TION B-9 Check to be sure the Retaining Spring has fully returned to the locking position and has SECURELY locked the Readi-Reel Cage in place. Retaining Spring must re[...]

  • Page 28

    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 B-10 OPERA TION B-10 FEEDING ELECTR ODE AND BRAKE ADJUSTMENT 1. Turn the Reel or spool until the free end of the electrode is accessible. 2. While tightly holding the electrode, [...]

  • Page 29

    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 B-11 OPERA TION B-11 4. Use Control Select and encoder knobs to set desired Weld feed speed and voltage then Run-in speed and voltage to optimize arc starting. (Set for each proc[...]

  • Page 30

    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 B-12 OPERA TION B-12 GR OUNDING LEAD PR O TECT OR The frame of the DH-10 Control is grounded to the frame of the power source by a lead in the control cable. An overload protecto[...]

  • Page 31

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SECTION C-1 A CCESSORIES SECTION C-1 DH-10 T ABLE OF CONTENTS -A CCESSORIES SECTION- Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C General . . . . .[...]

  • Page 32

    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 KP1505 Series DRIVE ROLL AND GUIDE TUBE KITS KP1507 Series DRIVE ROLL AND GUIDE TUBE KITS KP655 Series DRIVE ROLL AND GUIDE TUBE KITS KP656 Series DRIVE ROLL AND GUIDE TUBE KITS [...]

  • Page 33

    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 DRIVE ROLL AND GUIDE TUBE KITS Table C.2 gives a listing of all of the Drive Roll and Guide Tube Kits that are available for the DH-10 Dual Head Wire Feeder. TABLE C.2 — DRIVE [...]

  • Page 34

    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 C-4 A CCESSORIES C-4 K1450-“L” - Extension cables are available in lengths “L” of 12, 16 or 25 ft (3.6, 4.9 or 7.6 m) to match the control to Feeder cable length used. K1[...]

  • Page 35

    C-5 A CCESSORIES C-5 Readi-Reel Adapters K363P - Adapts Lincoln Readi-Reel coils of electrode 30 lb (14 kg) and 22 lb (10 kg) to a 2 in. (51 mm) spin- dle. Durable molded plastic one piece construction. Designed for easy loading; adapter remains on spin- dle for quick changeover. K438 - Adapts Lincoln Readi-Reel coils of electrode 50 to 60 lb. (22.[...]

  • Page 36

    C-6 A CCESSORIES C-6 K1556-1 LIGHT DUTY CASTER KIT This 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 insulated lift hook is required. This kit provides an easily installed, heavy duty insulated li[...]

  • Page 37

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SECTION D-1 MAINTENANCE SECTION D-1 DH-10 T ABLE OF CONTENTS -MAINTENANCE SECTION- Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D Safety Precautions . [...]

  • Page 38

    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 SAFETY PRECA UTIONS Observe all additional Safety Guidelines detailed throughout this manual. D-2 MAINTENANCE D-2 DH-10 of teeth so they can be reversed for additional life. Driv[...]

  • Page 39

    D-3 MAINTENANCE D-3 PERIODIC MAINTENANCE Wire Drive Motor and Gearbo x Every year inspect the gearbox and coat the gear teeth with a moly-disulfide filled grease. Do not use graphite grease. Every six months check the motor brushes. Replace them if they are less than 1/4 in. long. Gun and Cable Maintenance See appropriate Operator’s Manual. PR OC[...]

  • Page 40

    D-4 MAINTENANCE D-4 DH-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 41

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SECTION E-1 THEOR Y OF OPERA TION DH-10 SECTION E-1 T ABLE OF CONTENTS -THEOR Y OF OPERA TION SECTION- Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E Gener[...]

  • Page 42

    E-2 THEOR Y OF OPERA TION DH-10 E-2 GENERAL DESCRIPTION The DH-10 is a 42 VAC, dual head, 4-roll wire feeder. A single control for each head is utilized, with dual procedure presettablility of wire feed speed and arc voltage. The DH-10 models have controls providing keypad or remote selectability of wire drive head and either one or two procedures [...]

  • Page 43

    E-3 THEOR Y OF OPERA TION DH-10 E-3 INPUT RECEPT A CLE, CONTROL BO ARD , AND OPERA T OR CONTR OLS The 42 VAC input voltage is applied to the DH-10 through a 9-pin amphenol type receptacle. The remote control and trigger leads are also accessed through this 9-pin receptacle. The 42 VAC is rectified by a full wave bridge and sent to the control board[...]

  • Page 44

    E-4 THEOR Y OF OPERA TION DH-10 E-4 WIRE FEED HEADS AND RECEPT A CLES The leads to the drive motor, gas solenoid, and the tach (hall effect device) are brought into the control box via the wire drive receptacles. These two 14-pin receptacles also house the gun trigger leads, the elec- trode voltage sense lead, and the leads for the option- al remot[...]

  • Page 45

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-1 TR OUBLESHOO TING AND REP AIR F-1 DH-10 T ABLE OF CONTENTS -TR OUBLESHOO TING AND REP AIR SECTION- Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F How to Use[...]

  • Page 46

    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 DH-10 F-2 TR OUBLESHOO TING AND REP AIR F-2 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step proce[...]

  • Page 47

    F-3 TR OUBLESHOO TING AND REP AIR F-3 ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts. ------------------------------------------------- Sometimes machine failures appear to be due to PC board failures. These pr[...]

  • Page 48

    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 F-4 TR OUBLESHOO TING AND REP AIR F-4 4. Test the machine to determine if the fail- ure symptom has been corrected by the replacement PC board. NOTE : It is desirable to have a s[...]

  • Page 49

    F-5 TR OUBLESHOO TING AND REP AIR F-5 DH-10 TR OUBLESHOO TING GUIDE Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION Neither drive motor turns when the gun triggers are activated. The dis- plays are lit and the correct input voltage (42 VAC) is appli[...]

  • Page 50

    F-6 TR OUBLESHOO TING AND REP AIR F-6 DH-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION No control of wire feed speed on both sides. Both motors run, both solenoids operate and arc voltage is present. The WFS can be preset on both sides. The wir[...]

  • Page 51

    F-7 TR OUBLESHOO TING AND REP AIR F-7 DH-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION The wire feed speed does not change when welding current is established. The voltmeter does not function properly. The welding may vary from normal performan[...]

  • Page 52

    F-8 TR OUBLESHOO TING AND REP AIR F-8 DH-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION The “Cold Feed Forward” and/or the “Cold Feed Reverse” buttons do not function properly. Both motors operate properly in other modes. The “Gas Purg[...]

  • Page 53

    F-9 TR OUBLESHOO TING AND REP AIR F-9 DH-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION The “Timer”, "Control” and/or “Trigger” buttons do not function correctly. One of the encoder control knobs functions but the other one does n[...]

  • Page 54

    F-10 TR OUBLESHOO TING AND REP AIR F-10 DH-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION The DH-10 is dead. The displays and LEDs on the keypad are off The green and red LEDs on the control board are not lit. The displays and LEDs on the key- p[...]

  • Page 55

    F-11 TR OUBLESHOO TING AND REP AIR F-11 DH-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION The wire feeds for a few seconds and stops. The voltage display reads less than 8 VDC while the wire is feeding. The dual procedure switch is not functioni[...]

  • Page 56

    F-12 TR OUBLESHOO TING AND REP AIR F-12 DH-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION An “Er” message is displayed when the DH-10 is powered up. A “GLP” message is displayed. When the gun trigger is activated the wire feeds and arc v[...]

  • Page 57

    F-13 TR OUBLESHOO TING AND REP AIR F-13 DH-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION The preset arc voltage does not match the actual voltage. The preset WFS does not match the actual WFS. 1. Make sure the power source is set for remote vol[...]

  • Page 58

    F-14 TR OUBLESHOO TING AND REP AIR F-14 DH-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION The wire is feeding rough or not feeding, but the drive rolls are turning. The contact tip seizes in the gun liner. 1. Check for mechanical restric- tions [...]

  • Page 59

    F-15 TR OUBLESHOO TING AND REP AIR F-15 DH-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION The welding arc is variable or “hunting”. Poor arc striking with sticking or “blast-offs”. The bead may be nar- row, ropey and have porosity. 1. Th[...]

  • Page 60

    F-16 NO TES DH-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 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 Retu[...]

  • Page 61

    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 WIRE DRIVE MO T OR TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in [...]

  • Page 62

    F-18 TR OUBLESHOO TING AND REP AIR F-18 DH-10 5. If the correct voltages are NOT present at the armature motor leads, check the associated leads and plugs for loose or faulty connections. See the Wiring Diagram. If the leads and connections are OK, the control board may be faulty. 6. If the correct voltages are present at the motor armature leads a[...]

  • Page 63

    F-19 TR OUBLESHOO TING AND REP AIR F-19 T A CH ADJUSTMENT AND FEEDBA CK TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory war- ranty. For your safety and to avoi[...]

  • Page 64

    F-20 TR OUBLESHOO TING AND REP AIR F-20 DH-10 the control board or associated leads or plugs may be faulty. See the Wiring Diagram. 6. Activate the gun trigger. Make sure the motor is running. Check for the pres- ence of approximately 5.0 VDC from blue lead #555 (+) to black lead #500 (-). The 5.0 VDC represents the correct feedback voltage from th[...]

  • Page 65

    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 F-21 TR OUBLESHOO TING AND REP AIR F-21 DH-10 3. Using the 9/16 in. wrench loosen the locking nut. 4. Gently screw the hall effect module into the mounting plate until it just to[...]

  • Page 66

    F-22 NO TES DH-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 67

    F-23 TR OUBLESHOO TING AND REP AIR F-23 KEYP AD RESIST ANCE TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory war- ranty. For your safety and to avoid electrical[...]

  • Page 68

    F-24 TR OUBLESHOO TING AND REP AIR F-24 DH-10 6. Check the keypad resistances referenc- ing Figure F.3 and Table F.1 . 7 . The resistances are checked at plug J10 on the keypad. See Figure F.3. 8. If any of the resistances are not correct, the keypad may be faulty. 9. When test is complete, carefully install the display board and connect plugs J10 [...]

  • Page 69

    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 MAXIMUM TEST POINTS ALLOWABLE RESISTANCE FROM PIN TO PIN KEY PRESSED (TYPICAL RESISTANCE) 1J10 2J10 CONTROL 100 OHMS (50 OHMS TYPICAL) 1J10 3J10 TIMER 100 OHMS (50 OHMS TYPICAL) [...]

  • Page 70

    F-26 NO TES DH-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 71

    F-27 TR OUBLESHOO TING AND REP AIR F-27 ENCODER PC BO ARD TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory war- ranty. For your safety and to avoid electrical s[...]

  • Page 72

    F-28 TR OUBLESHOO TING AND REP AIR F-28 DH-10 7. While slowly rotating the Volts control check for a “pulsing” 0 to 5 VDC signal from 8J2 (lead #516) to 6J2 (lead #517). If the 5 VDC supply IS present at the encoder board and the pulsing signal is NOT, the Volts encoder board may be faulty. Also check the lead and plug connections between the e[...]

  • Page 73

    F-29 TR OUBLESHOO TING AND REP AIR F-29 GAS SOLENOID TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory war- ranty. For your safety and to avoid electrical shock,[...]

  • Page 74

    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 F-30 TR OUBLESHOO TING AND REP AIR F-30 DH-10 6. If the 10 VDC is missing or low, check the leads and connections between the solenoid and the control board. See the Wiring Diagr[...]

  • Page 75

    F-31 TR OUBLESHOO TING AND REP AIR F-31 DISPLA Y PC BO ARD REMO V AL AND REPLA CEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory war- ranty. For your safety an[...]

  • Page 76

    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 F-32 TR OUBLESHOO TING AND REP AIR F-32 DH-10 REPLA CEMENT PROCEDURE 1. Install plug J10 into the new display board. 2. Mount the display board onto the six mounting pins. 3. Ins[...]

  • Page 77

    F-33 TR OUBLESHOO TING AND REP AIR F-33 GAS SOLENOID REMO V AL AND REPLA CEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory war- ranty. For your safety and to a[...]

  • Page 78

    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 F-34 TR OUBLESHOO TING AND REP AIR F-34 DH-10 7. Remove the solenoid assembly from the DH-10 unit. 8. Using the Phillips head screwdriver remove the two screws holding the soleno[...]

  • Page 79

    F-35 TR OUBLESHOO TING AND REP AIR F-35 ENCODER PC BO ARD REMO V AL AND REPLA CEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory war- ranty. For your safety and[...]

  • Page 80

    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 F-36 TR OUBLESHOO TING AND REP AIR F-36 DH-10 6. Carefully remove the PC board from the front panel. 7. Remove the harness plug from the encoder PC board. 8. Install the harness [...]

  • Page 81

    F-37 TR OUBLESHOO TING AND REP AIR F-37 Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in dan- ger to the technician or machine operator and will invalidate your factory war- ranty. For your safety and to avoid electrical shock, please observe al[...]

  • Page 82

    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 F-38 TR OUBLESHOO TING AND REP AIR F-38 DH-10 7. Disconnect the motor armature leads. 8. Remove any necessary cable ties. 9. Using the 3/4 in. wrench remove the electrode cable f[...]

  • Page 83

    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 F-39 TR OUBLESHOO TING AND REP AIR F-39 DH-10 T O REMO VE THE WIRE DRIVE ASSEMBL Y FROM THE GEAR BO X: 16. Using the 3/16 in. Allen wrench loosen the two Allen screws located at [...]

  • Page 84

    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 F-40 TR OUBLESHOO TING AND REP AIR F-40 DH-10 8. Place the entire assembly into the DH-10 unit. Align the mounting holes with wire feeder base. 9. Secure the assembly to the wire[...]

  • Page 85

    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 F-41 TR OUBLESHOO TING AND REP AIR F-41 DH-10 Check the Feeder selection and Procedure keys for proper operation. 1. Press the Trigger key. The LEDs should toggle through the var[...]

  • Page 86

    F-42 NO TES DH-10 F-42 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 87

    SVM ERR OR REPOR TING FORM W e need to know if there are errors in our man uals. We also v alue any suggestions as to addi- tional tests or procedures that would mak e this SVM a better tool f or y ou. If you disco v er ne w or diff erent “Problems or Symptoms” that are not cov ered in the three col- umn troubleshooting chart, please share this[...]

  • Page 88

    ELECTRICAL DIA GRAMS G-1 G-1 DH-10 Return to Master TOC Retur n to Master TOC Return to Master TOC Retur n to Master TOC Electrical Diagrams Section...........................................................................................Section G Wiring Diagram (Control) (L10218)....................................................................[...]

  • Page 89

    G-2 ELECTRICAL DIA GRAMS DH-10 Wiring Diagram (Contr ol) (L10218) TO SOLENOID TO DUAL PROCEDURE SWITCH TO SOLENOID TO DUAL PROCEDURE SWITCH TO MOTOR TACHOMETER TO MOTOR RIGHT WIRE DRIVE RECEPTACLE 561(L) 512(L) TO MOTOR 6 5 3 11 10 9 8 J13 560(R) L 539(R) J 560(L) TO DUAL PROCEDURE SWITCH 12 1 8 6 519R U(R) R(R) B(R) 512(R) B A 522(L) U(L) 552 4 9 [...]

  • Page 90

    ELECTRICAL DIA GRAMS G-3 G-3 DH-10 Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Return to Master TOC Wiring Diagram (Wire Drive) (M17871) NO TE: This diagram is f or ref erence only . It may not be accurate f or all machines cov ered by this [...]

  • Page 91

    G-4 ELECTRICAL DIA GRAMS DH-10 G-4 Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Return to Master TOC Contr ol Board Sc hematic (Sheet 1) (G3040-1) 3040-1 G 5-2-97 NO TE: Lincoln Electric assumes no responsibility f or liab lilities resulting [...]

  • Page 92

    G-5 ELECTRICAL DIA GRAMS DH-10 Contr ol Boar d Schematic (Sheet 2) (G3040-2) X7 13 10 11 DPG1 505 505 3.32K R92 GUN 2 PROC A C31 500 4.75K R98 D49 GUN 1 2.21K R171 X16 1 6 7 1.00K R90 2.21K R91 J6 5 X16 13 10 11 3.92K R93 2.21K R186 J6 12 512 500 512 D19 505 BLACK BLUE RED 520L 519L 519R DUAL PROCEDURE DUAL PROCEDURE PROC B PROC A PROC B C30 4.7 35[...]

  • Page 93

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Return to Master TOC G-6 ELECTRICAL DIA GRAMS SQU ARE W A VE TIG 275 Displa y Board Sc hematic L10138) L10138 5-2-97 G-6 NO TE: Lincoln Electric assumes no responsibility f or liab lilities resulti[...]

  • Page 94

    ELECTRICAL DIA GRAMS G-7 G-7 DH-10 Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Return to Master TOC Encoder Boar d Schematic (S22066) 4-7-95 S22066 NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board le v[...]

  • Page 95

    ELECTRICAL DIA GRAMS G-8 DH-10 Contr ol Boar d Lay out (G3041-2) 2-20-98M G ITEM REQ'D. REQ'D. ITEM 3041-2 DESCRIPTION PART NO. DESCRIPTION PART NO. CAPACITORS = MFD/VOLTS RESISTORS = OHMS, 1/4 WATT UNLESS OTHERWISE SPECIFIED. INDUCTANCE = HENRYS N.A. N.B. N.A. N.A. N.A. N.B. N.B. N.B. N.B. N.B. N.B. .18 5.17 5.85 9.82 10.00 3.13 5.48 8.8[...]

  • Page 96

    ELECTRICAL DIA GRAMS G-9 G-9 Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Return to Master TOC DH-10 Displa y Boar d Lay out (L10139-1) L10139-1 D. H. DISPLAY ITEM REQ'D PART NO. IDENTIFICATION 5-2-97 L10139-1 NO TE: Lincoln Electric ass[...]

  • Page 97

    ELECTRICAL DIA GRAMS G-10 G-10 DH-10 Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Return to Master TOC Encoder Boar d Lay out (M17797-1) NO TE: Lincoln Electric assumes no responsibility for liab lilities resulting from board le vel troub les[...]

  • Page 98

    NO TES DH-10 Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur n to Master TOC Return to Master TOC Return to Master TOC[...]