Lincoln Electric SVM154-A manual

LN- 10 Heads & Controls Boom Mount or Bench M odels SER VICE MANUAL SVM154-A September, 2002 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 REPAI[...]

i SAFETY i W ARNING FOR ENGINE powered 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 vent the engine exhaust fumes outdoors. ____________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. Nation[...]

iv SAFETY iv PRÉCAUTIONS 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 Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ?[...]

v v LN-10 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Operation . . . . . . . . . . . . . . . . . . . . .[...]

SECTION A-1 INST ALLA TION LN-10 SECTION A-1 T ABLE OF CONTENTS -INST ALLA TION SECTION- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications — LN-10 Head and Control . . . . . . . . . . . . . . . . . . . . . [...]

A-2 INST ALLA TION LN-10 A-2 WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO HIGH SPEED RATIO Speed Wire Size Speed Wire Size Solid Cored Solid Cored K1563-1 10 Series 35-500 IPM .025 - 3/32 in. .035 - .120 in .50 - 750 IPM .025 - 1/16 in. .035 - 5/64 in. Std Drive Boom Mount (0.89-12.7 M/M) (0.6 - 2.4 mm) (0.9 - 3.0 mm) (1.2[...]

A-3 INST ALLA TION LN-10 A-3 All of these features are selected with a tactile-feel keypad, and are set independently using one of two rotating knob encoders, setting levels are displayed on one of two digital LED displays. The 10 Series Wire Drive assemblies include a heavy duty head with externally changeable gear ratio and 4 driven roll drives h[...]

A-4 INST ALLA TION LN-10 A-4 FIGURE A.1 Mounting Synergic 7F Wire Drive Unit (K679-1 or -2) Mount the wire feed unit by means of the insulated mounting bracket attached to the bottom of the gearbox. Reference L9777 (included with Drive unit) to find the size and location of the mounting holes. The gearbox assembly is electrically “hot” when the[...]

A-5 INST ALLA TION LN-10 A-5 Electrode Routing The electrode supply may be either from reels, Readi- Reels, spools, or bulk packaged drums or reels. Observe the following precautions: a) The electrode must be routed to the wire drive unit so that the bends in the wire are at a minimum, and also that the force required to pull the wire from the reel[...]

A-6 INST ALLA TION LN-10 A-6 WIRE FEED DRIVE ROLL KITS NOTE: The maximum rated solid and cored wire sizes for each wire drive head and selected drive ratio is shown on the SPECIFICATIONS in the front of this section. The electrode sizes that can be fed with each roll and guide tube are stenciled on each part. Check the kit for proper components. Sy[...]

A-7 INST ALLA TION LN-10 A-7 6) Install each drive roll by pushing over shaft until it butts up against locating shoulder on the drive roll shaft. (Do Not exceed maximum wire size rating of the wire drive). 7) Install Outer Wire Guide by sliding over locating pins and tightening in place. 8) Engage upper drive rolls if they are in the “open” po[...]

A-8 INST ALLA TION LN-10 A-8 Gun Cable Connection with Fast-Mate Connection 1. Check that the drive rolls, feeder guide tubes and gun connector guide tube are appropriate for the electrode size being used. If necessary, change them per “Wire Drive Roll Kits” in this section. 2. Connect gun to gun connector making sure all pins and gas tube line[...]

A-9 INST ALLA TION LN-10 A-9 ELECTRICAL INST ALLA TION Input Cable: LN-10 Control to Power Source Available Cable Assemblies: K1501 (Control Cable Only) Consists of a 9-conductor control cable with a 14-pin control cable plug, without electrode cable, and is available in lengths of 10 ft. (3 m), 17 ft. (5 m), 25 ft. (7.6 m), 33 ft. (10 m), 50 ft. ([...]

A-10 INST ALLA TION LN-10 A-10 OPTIONAL FEA TURES INST ALLA TION K1501, K1502 and K1503 Input Cable Assemblies See “Electrical Installation” for instructions. Dual Procedure Switch Options K683-1 Dual Procedure Switch (One per gun) - Requires K686-2 Adapter for LN-10. Kit includes gun switch, and mountings for Lincoln Innershield and Magnum gun[...]

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

B-2 OPERA TION B-2 LN-10 For K1563-2 (LN-10 Boom) or K1559-2 (LN-10 Bench) with 55-825 IPM (1.40-21.0 m/m) Low Speed Ratio set S1 DIP Switch as follows: For K1563-2 (LN-10 Boom) or K1559-2 (LN-10 Bench) with 80-1250 IPM (2.00-31.8 m/m) High Speed Ratio set S1 DIP Switch as follows: Setting the DIP Switches The DIP switches are each labeled with an [...]

B-3 OPERA TION B-3 LN-10 For K679-1 (Single Head Boom) with 50-770 IPM (1.27-19.5 m/m) Low Speed Ratio set S1 DIP Switch as follows: For K679-2 (Single Head Boom) with 80-1200 IPM (2.00-30.5 m/m) High Speed Ratio set S1 DIP Switch as follows: Welding Power Source Selection The LN-10 Control is set up for proper presettable weld voltage control by s[...]

B-4 OPERA TION B-4 LN-10 Metric/English Wire Feed Speed Display Selection The LN-10 Control is set up for Wire Feed Speed dis- play in Metric units (m/min.) or English units (IPM) by setting S2 DIP Switch 1 (Labeled “M”): S2 switch 1 OFF = IPM (as shipped) S2 switch 1 ON = m/min 4-Step T rigger Mode Operation Selection The LN-10 Control is set [...]

B-5 OPERA TION B-5 LN-10 Robotics Mode Selection The LN-10 control is set up for Robotics Mode by set- ting the S2 DIP Switch 4 (Labeled “R”). For Robotics Interface Mode to operate, a K1561-1 Robotics Interface Module must be installed. S2 switch 4 ON = Robotics mode ON S2 switch 4 OFF = Robotics mode OFF (As shipped) Maximum Limits Setting Mo[...]

B-6 OPERA TION B-6 LN-10 Keypad and Display Description Keypad - Seven key, membrane type with "snap" tac- tile feel and embossed domes. Long life design. Spatter resistant surface. Displays - Two digital LED displays with .56" (14.2 mm) character height. Top (3-1/2 digit) displays Preset and Actual (while welding) arc voltage in vol[...]

B-7 OPERA TION B-7 LN-10 T rigger Mode Selection Trigger Mode Select key - enables operator to choose mode of operation shown by the indicator lights. Pressing key caus- es mode lights to sequence (top to bottom) starting from the current indicated selection. Top Light - Indicates gun trigger has been selected to perform the Cold Feed Forward funct[...]

B-8 OPERA TION B-8 LN-10 Control Select key - enables operator to choose Run-In procedure as indicated by the light turning on. When light is on, the settings of Run-In Wire Feed Speed and Voltage are displayed. After Weld procedure is set, Run-in procedure should be set to optimize arc starting. Speed encoder knob can adjust run-in speed between m[...]

B-9 OPERA TION B-9 LN-10 Maximum and Minimum Limits Setting Modes Limits setting modes are available for limiting the range for setting wire feed speed and voltage. The limits can be set independently for each procedure. The following steps should be followed for setting the maximum and minimum limits: 1. Turn off the power at the power source. 2. [...]

B-10 OPERA TION B-10 LN-10 DUAL PROCEDURE REMOTE CONTROL (K1449-1) When this option is connected to the LN-10 Control Box receptacle, and the Procedure Key selects “REMOTE” the front panel knob controls and proce- dure selection is transferred to the knob encoder con- trols and Procedure Selector Switch of the remote, which function in the exac[...]

B-11 OPERA TION B-11 LN-10 T o Mount a 50-60 Lb. (22.7-27.2 kg) Coil: (Using K1504-1 Coil Reel) (For 50-60 lb Readi- Reels a K438 Readi-Reel Adapter must be used). The Spindle must be located in the UPPER mounting hole. 1) With the K1504-1 Coil Reel mounted on to the 2" (51 mm) spindle (or with reel laying flat on the floor) loosen the spinner[...]

B-12 OPERA TION B-12 LN-10 1 ) Press end of gun against a solid object that is electrically isolated from the welder output and press the gun trigger for several seconds. 2) If the wire "birdnests", jams, or breaks at the drive roll, the drive roll pressure is too great. Back the pressure setting out 1/2 turn, run new wire through gun, an[...]

B-13 OPERA TION B-13 DH-10 WIRE REEL CHANGING At the end of a coil, remove the last of the old elec- trode coil from the conductor cable by either pulling it out at the nozzle end of the gun or by using the follow- ing procedure: 1) Cut the end of the electrode off at the gun end. Do not break it off by hand because this puts a slight bend in the w[...]

B-14 OPERA TION B-14 DH-10 EXPLANA TION OF PROMPTING AND ERROR MESSAGES Display Prompt or Error Acc Displayed on Voltage display, indicates WFS display is showing acceleration setting, “1" to “5" (See “Acceleration Selection” in this section). OFF Displayed on WFS and voltage displays; indi- cates limits for WFS or voltage are off[...]

SECTION C-1 ACCESSORIES SECTION C-1 LN-10 T ABLE OF CONTENTS -ACCESSORIES SECTION- Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

KP1505 Series DRIVE ROLL AND WIRE GUIDE KITS KP1507 Series DRIVE ROLL AND WIRE GUIDE KITS K1501 INPUT CABLE ASSEMBLY (CONTROL CABLE ONLY) K1502 INPUT CABLE ASSEMBLY K1503 INPUT CABLE ASSEMBLY K1520-1 115V/42V TRANSFORMER KIT K590-4 WATER CONNECTION KIT K659-1 GAS GUARD REGULATOR K1449-1 DUAL PROCEDURE REMOTE CONTROL K1450-”L” EXTENSION CABLE (?[...]

C-3 ACCESSORIES C-3 LN-10 TABLE C.2 – DRIVE ROLL AND GUIDE TUBE KITS Wire Size 4-Roll 4-Roll 10-Series Drives Synergic 7F Drives (4-Driven) (2-Driven) Solid Steel Electrode 0.025” (0.6 mm) KP1505 - 030S KP655 - 025S 0.030” (0.8 mm) KP1505 - 030S KP655 - 030S 0.035” (0.9 mm) KP1505 - 035S KP655 - 035S 0.040” (1.0 mm) KP1505 - 045S KP655 - [...]

C-4 ACCESSORIES C-4 K1450- ” L ” - Extension cables are available in lengths “L” of 12, 16 or 25 ft. (3.6, 4.9 or 7.6) to match the control to Feeder cable length used. K683-1 DUAL PROCEDURE SWITCH Requires K686-2 Adapter for LN-10. Kit includes gun switch, and mountings for Lincoln Innershield and Magnum guns, with 15 ft. (4.5 m) control c[...]

C-5 ACCESSORIES C-5 GUN ADAPTERS (FOR 10 SERIES WIRE DRIVE) Adapts 10 Series heads for desired gun connection: K1500-1 for standard Lincoln Innershield gun con- nection, or with Fast-Made™ guns with K489-2 Fast- Mate Adapter Kit. Also for Magnum 200/300/400 with K466-1 connection kit, or Magnum 550 with K613-1. K1500-2 for Magnum 200/300/400 gun [...]

C-6 ACCESSORIES C-6 LN-10 K1557-1 SWIVEL MOUNT The K1557-1 Swivel mount attaches to the power source. This kit includes a feeder adapter plate that allows the feeder to rotate on top of the power source. The feeder can be easily separated from the swivel mount at any time. This option is compatible with the K1556-1 Light Duty Caster Kit. K1556-1 LI[...]

SECTION D-1 MAINTENANCE SECTION D-1 LN-10 T ABLE OF CONTENTS -MAINTENANCE SECTION- Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

D-2 MAINTENANCE D-2 LN-10 A voiding Wire Feeding Problems Wire feeding problems can be avoided by observing the following gun handling and feeder set up proce- dures: a) Do not kink or pull cable around sharp corners. b) Keep the electrode cable as straight as possible when welding or loading electrode through cable. c ) Do not allow dolly wheels o[...]

D-3 MAINTENANCE D-3 LN-10 7 6 5 4 2 3 1 Bench Model Shown Bench Model Shown Bench Model Only FIGURE D.1 - MAJOR COMPONENT LOCA TIONS 1. Control Box Assembly 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[...]

SECTION E-1 THEOR Y OF OPERA TION LN-10 SECTION E-1 T ABLE OF CONTENTS -THEOR Y OF OPERA TION SECTION- Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

GENERAL DESCRIPTION The LN-10 is a single head, 42 VAC input, 4-roll wire feeder. A single control with dual procedure presetta- bility of wire feed speed (inches per minute or meters per minute) and arc voltage is used in conjunction with a Lincoln constant voltage (CV) welding power source. The LN-10 wire feeders have controls providing key- pad [...]

E-3 THEOR Y OF OPERA TION LN-10 E-3 INPUT RECEPT ACLE, CONTROL BOARD AND OPERA T OR CONTROLS The 42 VAC input voltage is applied to the LN-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 wher[...]

E-4 THEOR Y OF OPERA TION LN-10 E-4 WIRE FEED HEAD AND RECEPT ACLE The leads to the drive motor, gas solenoid, and the tach (hall effect device) are brought into the control box via the wire drive receptacle. This 14-pin recepta- cle also houses the gun trigger leads, the electrode voltage sense lead and the leads for the optional dual procedure sw[...]

E-5 THEOR Y OF OPERA TION LN-10 E-5 WIRE FEED OVERLOAD PROTECTION The LN-10 has solid-state overload protection of the wire drive motor. If the wire drive motor becomes overloaded for an extended period of time, the protec- tion circuitry turns off the power source, wire feed and gas solenoid, and then displays “H30” on the WFS display (with bl[...]

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[...]

F-1 TROUBLESHOOTING AND REP AIR F-1 LN-10 T ABLE OF CONTENTS -TROUBLESHOOTING AND REP AIR SECTION- Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

LN-10 F-2 TROUBLESHOOTING AND REP AIR F-2 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhi[...]

F-3 TROUBLESHOOTING AND REP AIR F-3 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 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.[...]

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[...]

F-5 TROUBLESHOOTING AND REP AIR F-5 LN-10 TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION The drive motor does not turn when the gun trigger is activated. The displays are lit and the correct input voltage (42 VAC) is applied to [...]

F-6 TROUBLESHOOTING AND REP AIR F-6 LN-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION The wire feeds and the gas sole- noid operates but no arc voltage is present. 1. Make certain the electrode and work cables are connected correctly. 2. Make cert[...]

F-7 TROUBLESHOOTING AND REP AIR F-7 LN-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION The wire feed speed does not change when welding current is established. The voltmeter does not function properly. The welding may vary from normal performance. [...]

F-8 TROUBLESHOOTING AND REP AIR F-8 LN-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION The “Cold Feed Forward” and/or the “Cold Feed Reverse” buttons do not function properly. The motor operates properly in other modes. The “Gas Purge” [...]

F-9 TROUBLESHOOTING AND REP AIR F-9 LN-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION The “Timer” or "Control” button does not function correctly. Pressing the trigger key has no effect while not welding. One of the encoder control knob[...]

F-10 TROUBLESHOOTING AND REP AIR F-10 LN-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION Neither encoder control knob functions. The LN-10 is dead. The displays and LEDs on the keypad are off. The green and red LEDs on the control board are not lit[...]

F-1 1 TROUBLESHOOTING AND REP AIR F-1 1 LN-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 functioning[...]

F-12 TROUBLESHOOTING AND REP AIR F-12 LN-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION The knobs do not control the com- plete range of wire feed speed or voltage. An “Er” message is displayed when the LN-10 is powered up. A “GLP” message[...]

1. Perform the Gas Solenoid Test . 2. The control board may be faulty. 1. The control board may be faulty. 2. The control cable between the power source and the LN-10 may be defective. 1. Perform the Tach Adjustment and Feedback Test. 2. The control board may be faulty. 1. Check for continuity between the pins of the Amphenol con- nector on the lef[...]

F-14 TROUBLESHOOTING AND REP AIR F-14 LN-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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 in t[...]

F-15 TROUBLESHOOTING AND REP AIR F-15 LN-10 Observe all Safety Guidelines detailed throughout this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION 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. The el[...]

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[...]

WIRE DRIVE MOTOR TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and pre[...]

F-18 TROUBLESHOOTING AND REP AIR F-18 LN-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 and[...]

F-19 TROUBLESHOOTING AND REP AIR F-19 T ACH ADJUSTMENT AND FEEDBACK 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 warranty. For your safety and to avoid elec[...]

F-20 TROUBLESHOOTING AND REP AIR F-20 LN-10 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 the hall effect device to the control board. 7. If the above voltage reading is not cor- r[...]

F-21 TROUBLESHOOTING AND REP AIR F-21 LN-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 touches and stops against the rotating part inside the gearbox. See Figure F.2A. 5. Back the module out 1/2 turn. Using the 9/16 in. wrench and carefully snug the lock nut with[...]

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[...]

F-23 TROUBLESHOOTING 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 warranty. For your safety and to avoid electrical sho[...]

F-24 TROUBLESHOOTING AND REP AIR F-24 LN-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 and [...]

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) 1J10 4J10 TRIGGER 100 OHMS (50 OHMS TYPICAL) 1J10 6J10 PROCEDURE 100 OHMS (50 OHMS TYPICAL) 1J10 7J10 COLD FEED FORWARD 100 OHMS (50 OHMS TYPICAL) 1J10 8J10 COLD FEED REVER[...]

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[...]

F-27 TROUBLESHOOTING AND REP AIR F-27 ENCODER PC BOARD 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 warranty. For your safety and to avoid electrical shock,[...]

F-28 TROUBLESHOOTING AND REP AIR F-28 LN-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 enc[...]

F-29 TROUBLESHOOTING 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 danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, pleas[...]

F-30 TROUBLESHOOTING AND REP AIR F-30 LN-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 Diagram. If the leads and con- nections are OK the control board may be faulty. 7. If the 10 VDC is present at the solenoid leads and the solenoid does not activate the solenoid m[...]

F-31 TROUBLESHOOTING AND REP AIR F-31 DISPLA Y PC BOARD REMOV AL AND REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoi[...]

F-32 TROUBLESHOOTING AND REP AIR F-32 LN-10 REPLACEMENT PROCEDURE 1. Install plug J10 into the new display board. 2. Mount the display board onto the six mounting pins. 3. Install plug J11 into the new display board. 4. Reinstall the control panel. REMOV AL PROCEDURE 1. Remove input power to the LN-10 unit. 2. Using the 5/16 in. nut driver, remove [...]

F-33 TROUBLESHOOTING AND REP AIR F-33 GAS SOLENOID REMOV AL AND REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid e[...]

F-34 TROUBLESHOOTING AND REP AIR F-34 LN-10 8. Using the Phillips head screwdriver remove the two screws holding the solenoid to the bracket. Remove the solenoid. 9. Mount the new solenoid onto the bracket using the two Phillips head screws. 10. Install the solenoid assembly into the LN-10. 11. Connect the gas hose. 12. Connect the two wires previo[...]

ENCODER PC BOARD REMOV AL AND REPLACEMENT Service and repair should only be performed by Lincoln Electric factory trained per- sonnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe al[...]

F-36 TROUBLESHOOTING AND REP AIR F-36 LN-10 7. R e move harness plug J17 from the encoder PC board. 8. Install harness plug J17 into the new encoder PC board. 9. Assemble the PC board into the front panel and secure with the washer and nut previously removed. 10. Assemble the felt washer, spacer and control knob onto the shaft and secure with the 5[...]

F-37 TROUBLESHOOTING 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 danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safe[...]

F-38 TROUBLESHOOTING AND REP AIR F-38 LN-10 7. Disconnect the motor armature leads. 8. Remove any necessary cable ties. 9. Using the 3/4 in. wrench remove the electrode cable from the wire feed assembly. 10. Using the 7/16 in. socket wrench and extension remove four mounting screws, lock washers and flat washers. The motor, gear box and feed head a[...]

F-39 TROUBLESHOOTING AND REP AIR F-39 LN-10 TO REMOVE THE WIRE DRIVE ASSEMBL Y FROM THE GEAR BOX: 16. Using the 3/16 in. Allen wrench loosen the two Allen screws located at the bot- tom of the wire drive unit. 17. Remove lead #67 from the conductor block. 1 8 . Carefully slide and remove the wire drive assembly from the gear box assembly. TO REMOVE[...]

F-40 TROUBLESHOOTING AND REP AIR F-40 LN-10 7. Install the gear box inspection cover and secure it with the slot head screws and nut previously removed. 8. Place the entire assembly into the LN-10 unit. Align the mounting holes with wire feeder base. 9. Secure the assembly to the wire feeder base using the four screws, lock wash- ers and flat washe[...]

F-41 LN-10 F-41 TROUBLESHOOTING AND REP AIR Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe al[...]

F-42 TROUBLESHOOTING AND REP AIR LN-10 F-42 PROCEDURE 1. Remove input power to the LN-10 unit. 2. Remove the reed switch plug from the front of the machine. See Figure F.11. 3. Remove the Reed Switch Cover. See Figure F.11. 4. Using a 3/4” socket, remove the two nuts from the copper energizer. Remove Reed Switch and cop- per energizer assembly. U[...]

F-43 TROUBLESHOOTING AND REP AIR F-43 LN-10 Check the Feeder selection and Procedure keys for proper operation. 1. Press the Trigger key. The LEDs should toggle through the various trig- ger selections as the key is pressed and released. 2. Press the Timer key. The LEDs should toggle through the various modes as the key is pressed and released. 3. [...]

ELECTRICAL DIAGRAMS G-1 G-1 LN-10 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams Section ...........................................................................................Section G Wiring Diagram (Control) ..............................................................................[...]

ELECTRICAL DIAGRAMS G-2 LN-10 WIRING DIAGRAM - LN-10 (CONTROL) 505 2 4 OPTIONAL REMOTE CONTROL KIT ENCODER PC BOARD VOLTS 527 526 3 5 7 ENCODER PC BOARD WFS 500 516 8 J11 J17** J17** B D C B B A E F J19*** 3 3 R AC 542 500 553 552 551 * 5 J10 2 1 554 512A 10 G A B G L N 10 9 7 INPUT CABLE J12 500 1 23456 K H 8 FOR CONNECTION TO ROBOTICS INTERFACE H[...]

ELECTRICAL DIAGRAMS G-3 LN-10 WIRING DIAGRAM - LN-10 (WIRE DRIVE) 512 541 539 522 512 J3 P3 GEARBOX 1 3 B 1 2 GUN A 1 3 U R 520 J6 519 B 67 561 560 520 519 U P.M. TACH. 6 3 2 M 12 E 4 J 1 I 5 N 13 H G F L 561 520 560 519 67 561 B R 560 2 2 R 3 U B CHOKE PLUG ASSEMBLY 7 P1 12 P4 8 1 14 CONNECTOR CAVITY NUMBERING SEQUENCE P2 1 4 (NON LEAD SIDE OF CON[...]

Return 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 Retur n to Master TOC ELECTRICAL DIAGRAMS G-4 LN-10 SCHEMA TIC - CONTROL PC BOARD #1 G-4 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.[...]

Return 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 Retur n to Master TOC ELECTRICAL DIAGRAMS G-5 LN-10 SCHEMA TIC - CONTROL PC BOARD #2 500 PROC A BLACK 519 TACH RED BLUE PROC B DUAL PROCEDURE 520 J7 6 2.21K R232 D50 4.7 35V C33 J1 4 500 4.75 K R236[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

Return 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 Retur n to Master TOC ELECTRICAL DIAGRAMS G-7 LN-10 SCHEMA TIC - DISPLA Y PC BOARD COLD FEED REVERSE 500 500 500 500 500 5V_B D1 X4 3 4 50V 0.1 C4 LED13 MC14489 Vss Vdd X8 3 14 500 100 R37 100 R39 M[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

ELECTRICAL DIAGRAMS G-9 LN-10 SCHEMA TIC - ENCODER PC BOARD SYNERGIC 7F 475 R1 D1 50V 0.1 C1 475 R2 D2 D3 1.8 20V C2 J17 8 J17 3 D4 J17 5 J17 4 J17 6 J17 7 J17 1 J17 2 +5VDC FILE: S22066_1BA TO CONTROL BOARD 22066 CAPACITORS = GENERAL INFORMATION THE INTERCHANGEABILITY OR CIRCUITRY OF N.A. A PRINTED OF A COMPLETE ON 3 PLACE DECIMALS IS + .OO2 MAY C[...]

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information w[...]