Lincoln Electric SVM143-A Operator's Manual
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Lincoln Electric SVM143-A Operator's Manual

Lincoln Electric SVM143-A Operator's Manual

Heads & controls boom mount or bench models
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RETURN TO MAIN INDEX
SVM143-A
DH- 10 Heads & Controls
March, 1999
Boom Mount or Bench Models
For use with: DH-10 Control - Boom Mount Code 10357
DH-10 Drive - Boom Mount Codes 10358 (Std.), 10359 (Hi/Std.)
DH-10 Boom Package Codes 10380, 10495, 10496 (Std.), and 10517, 10518, 10519 (Hi/Std.)
Standard - Single Head Drive Codes 10190, 10191
DH-10 Feeder Double Head - Bench Model Codes 10360 (Std.), 10361 (Hi/Std.)
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
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR'S MANUAL
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
• 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

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Summary of Contents for Lincoln Electric SVM143-A

  • Page 1 RETURN TO MAIN INDEX SVM143-A DH- 10 Heads & Controls March, 1999 Boom Mount or Bench Models For use with: DH-10 Control - Boom Mount Code 10357 DH-10 Drive - Boom Mount Codes 10358 (Std.), 10359 (Hi/Std.) DH-10 Boom Package Codes 10380, 10495, 10496 (Std.), and 10517, 10518, 10519 (Hi/Std.) Standard - Single Head Drive Codes 10190, 10191 DH-10 Feeder Double Head - Bench Model Codes 10360 (Std.), 10361 (Hi/Std.)
  • Page 2 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Safety

    ELECTRIC SHOCK can kill. 3.a.The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 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.

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety ........... . . Installation .
  • Page 7 SECTION A-1 Installation ............... . Section A Technical Specifications —...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS – DH-10 Complete Units or Controls & Heads The K1499-1 or -2 DH-10 consists of a control and a double head 10 series wire drive assembly pre- mounted on a platform with two 2 in. O.D. spindle mountings. Specifications for the units follow: CONTROLS SECTION OF COMPLETE UNITS SPEC.# TYPE...

  • Page 9: General Description

    The wire type and size range for the wire drive used, and gear ratio change selected, are given in the Specifications. Recommended power sources are Lincoln Electric Company constant voltage power sources with 42 VAC auxiliary power and a 14-pin connector recepta- cle.

  • Page 10: Safety Precautions

    SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Turn the input power off at the power source disconnect switch before attempting to connect the input power to the DH-10 Control. • Only qualified personnel should perform this installation. ---------------------------------------------------------------------------------------- INSTALLATION OF THE DH-10 BOOM MOUNT WIRE FEEDER COMPONENTS Mounting the DH Double Header Wire...

  • Page 11: Wire Drive Speed Range Selection

    Connecting Wire Drive Unit to Control Box One head to control cable assembly is required for each head being used; however, only one electrode cable is required if an electrode cable jumper (provided) is con- nected between the two heads. The Head to Control cable assemblies are available in two types: K1498-“L”...

  • Page 12: Wire Feed Drive Roll Kits

    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 feedplate. It is the screw which is perpen- dicular to the feeding direction. b. Loosen the retaining screw, which is also accessed from bottom of feeder, using a 3/16 in.

  • Page 13: Gun And Cable Assemblies With Standard Connection

    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. Remove clamping screw & clamping collar from the drive shaft closest to the incoming side of the feeder.

  • Page 14: Gun And Cable Assemblies With Fast-Mate Connection

    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 Roll Kits in this section. 2. Lay the cable out straight. Insert the connector on the welding conductor cable into the brass conductor block on the front of the wire drive head.

  • Page 15: Electrical Installation

    GMAW Shielding Gas WARNING CYLINDER may explode if damaged. • Keep cylinder upright and chained to support. • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. •...

  • Page 16: Optional Features Installation

    A-10 K1503 Consists of a 9-conductor control cable with a 14-pin plug and 2/0 (67 mm ) electrode cable with Twist-Mate™ connector. It is rated at 500 amps, 60% duty cycle and is available in lengths of 10 ft (3 m), 17 ft (5 m), 25 ft (7.6 m), 33 ft (10 m) and 50 ft (15 m) and 100 ft (30 m) is also available with a 3/0 (85 mm electrode cable.
  • Page 17 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 K489-7 for Fast-Mate (or European style) gun connec- tions, including Dual Schedule Fast-Mate guns. K1500-1 for standard Lincoln Innershield gun connec- tion, or with Fast-Mate™...
  • Page 18 A-12 A-12 INSTALLATION DH-10...
  • Page 19 SECTION B-1 Operation ............... . . Section B Safety Precautions .

  • Page 20: Safety Precautions

    SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Unless using cold feed feature when inching with gun trigger, electrode and drive mechanism are “hot” to work and ground and could remain energized several seconds after the gun trigger is released.

  • Page 21: Welding Power Source Selection

    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: HEAD 1 HEAD 2 For K1563-1 (LN-10 Boom) with 50-750 IPM (1.25- 19.0 m/m) High Speed Ratio set S2 DIP Switch as follows: (initial factory setting) HEAD 2 HEAD 1...

  • Page 22: Metric/English Wire Feed Speed Display Selection

    Pulse Power 500: Pwr Sources V300 PRO: Pwr Sources Other Power Source Independent: Pwr Sources Set the DIP switches as shown for all other power sources which can be controlled with a 10KΩ poten- tiometer circuit. All DH-10 features operate as described elsewhere in this manual except for the following differences: 1.

  • Page 23: Low Security Mode Selection

    VOLTS / WFS SPOT BURNBACK POSTFLOW CONTROL TIMER THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO U.S.A. Keypad and Display Description Keypad - Eight key, membrane type with “snap” tac- tile feel and embossed domes. Long life design. Spatter resistant surface. Displays - Two digital LED displays with 0.56 in.

  • Page 24: Operation Keys

    Dual procedure settings, including; trigger mode, cold feed speed, Run-in and weld speed and voltage, timers and acceleration are automatically saved for each feeder when power is removed. This feature does not require batteries and when power is restored it will automatically return all settings to the state they were in when power was removed.

  • Page 25: Display Control Keys

    Display Control Keys Timer Select key - enables operator to TIMER choose burnback, spot or gas timers, as indicated by the appropriate light. Pressing the key causes lights to sequence (top to bottom, then all off) starting from the current indicated selection. When a timer is selected the Voltage display shows the time setting in seconds, as indicated by “SEC”...

  • Page 26: Wire Reel Loading - Readi-Reel, Spools Or Coils

    To change acceleration hold the Gas Purge Key closed, then press the Control key. The top (Voltage) display shows “Acc” indicating acceleration setting, 1 thru 5, is displayed on the bottom (Speed) display. Use the speed encoder knob to change setting of 1 thru 5.

  • Page 27: To Mount 10 To 44 Lb (4.5 To 20 Kg) Spools (12 In/300 Mm Diameter) Or 14 Lb (6 Kg) Innershield Coils (Figure

    CAUTION 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 rest on the cage, not the welding elec- trode. ___________________________________________ 9. To remove Readi-Reel from Adapter, depress retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands.

  • Page 28: Feeding Electrode And Brake Adjustment

    Gas Guard flow adjusting Key counterclockwise to the desired gas flow rate. MAKING A WELD 1. Use only a Lincoln Electric recommended con- stant voltage DC power source compatible with the DH-10 Wire Feeder. 2. Properly connect the electrode and work leads for the correct electrode polarity.

  • Page 29: Wire Reel Changing

    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 procedure if using front panel, remote control or optional dual procedure switch.) (Refer to Operation Keys and Display Control Keys in this section.) 5.

  • Page 30: Grounding Lead Protector

    B-12 GROUNDING LEAD PROTECTOR 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 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.
  • Page 31 SECTION C-1 Accessories ............... Section C General .

  • Page 32: Accessories

    GENERAL The following is a list of all the accessories that can be used with the DH-10 Dual Head Wire Feeder. A description of each item is given later in the section. TABLE C.1 — DH-10 DUAL HEAD WIRE FEEDER ACCESSORIES. KP1505 Series DRIVE ROLL AND GUIDE TUBE KITS KP1507 Series...

  • Page 33: Accessories

    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 ROLL AND GUIDE TUBE KITS. Wire Size Solid Steel Electrode 0.023 in.

  • Page 34: Input Cable Assemblies

    INPUT CABLE ASSEMBLIES (One required per DH-10 Control Box.) K1501 (Control Cable Only) - Consists of a 9-conduc- tor control cable with a 14-pin control cable plug, with- out 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 (15 m) and 100 ft (30 m).

  • Page 35: Gun Adapters (For Dh Wire Drive Heads

    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.
  • Page 36 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.

  • Page 37: Periodic Maintenance

    SECTION D-1 Maintenance ..............Section D Safety Precautions .

  • Page 38: Safety Precautions

    SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • When inching with gun trigger, elec- trode and drive mechanism are “hot” to work and ground and could remain energized several seconds after the gun trigger is released.

  • Page 39: Periodic Maintenance

    PERIODIC MAINTENANCE Wire Drive Motor and Gearbox 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.
  • Page 40 MAINTENANCE DH-10...
  • Page 41 SECTION E-1 THEORY OF OPERATION -THEORY OF OPERATION SECTION- Theory of Operation ..............Section E General Description .

  • Page 42: Theory Of Operation

    THEORY OF OPERATION FIGURE E.1 — GENERAL DESCRIPTION. SOLENOID TO GUN TRIGGER DUAL PROCEDURE WIRE DRIVE MOTOR TACH FEEDBACK INPUT CABLE RECEPTACLE 42VDC 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.

  • Page 43: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 — INPUT RECEPTACLE, CONTROL BOARD AND OPERATOR CONTROLS. SOLENOID TO GUN TRIGGER DUAL PROCEDURE WIRE DRIVE MOTOR TACH FEEDBACK INPUT CABLE RECEPTACLE 42VDC INPUT RECEPTACLE, CONTROL BOARD, AND OPERATOR CONTROLS The 42 VAC input voltage is applied to the DH-10 through a 9-pin amphenol type receptacle.

  • Page 44: Wire Feed Heads And Receptacles

    THEORY OF OPERATION FIGURE E.3 — WIRE FEED HEADS AND RECEPTACLES. SOLENOID TO GUN TRIGGER DUAL PROCEDURE WIRE DRIVE MOTOR TACH FEEDBACK INPUT CABLE RECEPTACLE 42VDC WIRE FEED HEADS AND RECEPTACLES 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.
  • Page 45 TROUBLESHOOTING AND REPAIR -TROUBLESHOOTING AND REPAIR SECTION- Troubleshooting and Repair ............Section F How to Use Troubleshooting Guide .

  • Page 46: How To Use Troubleshooting Guide

    TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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 and machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 47: Pc Board Troubleshooting Procedures

    TROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING 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. ------------------------------------------------- CAUTION Sometimes machine failures appear to be due to PC board failures.
  • Page 48 TROUBLESHOOTING AND REPAIR 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 spare (known good) PC board available for PC board troubleshooting. NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

  • Page 49: Troubleshooting Guide

    The WFS can be preset. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

  • Page 50: Troubleshooting And Repair

    If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 51 The wire feeds properly. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 52 The “Procedure” button does not function properly. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 53 Neither encoder control knob functions. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 54 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 55 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 56 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 57 The preset WFS does not match the actual WFS. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 58 The contact tip seizes in the gun liner. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 59 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 60 F-16 F-16 NOTES DH-10...

  • Page 61: Test Procedures

    WIRE DRIVE MOTOR TEST WARNING 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 warran- ty.
  • Page 62 F-18 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR TEST (continued) FIGURE F.1 — WIRE DRIVE MOTOR TEST. TEST PROCEDURE 1. Remove input power to the DH-10 unit. 2. Using the 5/16 in. nutdriver, remove the wire drive cover. 3. Locate the motor armature leads for the motor to be tested (one black (-) lead and one white (+) lead).

  • Page 63: Tach Adjustment And Feedback Test

    TACH ADJUSTMENT AND FEEDBACK TEST WARNING 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.
  • Page 64 F-20 TROUBLESHOOTING AND REPAIR TACH ADJUSTMENT AND FEEDBACK TEST (continued) FIGURE F.2 — TACH FEEDBACK TEST. TEST PROCEDURE 1. Remove input power to the DH-10 unit. 2. Using the 5/16 in. nutdriver, remove the wire drive cover. 3. Locate the three hall effect leads (blue, red and black).
  • Page 65 F-21 TROUBLESHOOTING AND REPAIR TACH ADJUSTMENT AND FEEDBACK TEST (continued) TACH ADJUSTMENT PROCEDURE Proper positioning of the module is critical to the proper operation the DH-10 wire feeder. If the device is not screwed in far enough the motor speed could be unstable or run at full speed with no control.
  • Page 66 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: Keypad Resistance Test

    KEYPAD RESISTANCE TEST WARNING 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.
  • Page 68 F-24 TROUBLESHOOTING AND REPAIR KEYPAD RESISTANCE TEST (continued) FIGURE F.3 — KEYPAD RESISTANCE TEST. DISPLAY BOARD TEST PROCEDURE 1. Remove input power to the DH-10 unit. 2. Using the 5/16 in. nutdriver, remove the two screws from the top of the control panel.
  • Page 69 F-25 TROUBLESHOOTING AND REPAIR KEYPAD RESISTANCE TEST (continued) NOTE: There should not be continuity between pins until a key is pressed on the keypad. TABLE F.1 — KEYPAD RESISTANCE TEST. TEST POINTS FROM PIN TO PIN 1J10 2J10 CONTROL 1J10 3J10 TIMER 1J10...
  • Page 70 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: Encoder Pc Board Test

    ENCODER PC BOARD TEST WARNING 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.
  • Page 72 F-28 TROUBLESHOOTING AND REPAIR ENCODER PC BOARD TEST (continued) FIGURE F.4 — ENCODER PC BOARD TEST. #526 #517 #505 TEST PROCEDURE 1. Remove input power to the DH-10 unit. 2. Using the 5/16 in. nutdriver, remove the two screws from the top of the control panel.

  • Page 73: Gas Solenoid Test

    GAS SOLENOID TEST WARNING 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.
  • Page 74 F-30 TROUBLESHOOTING AND REPAIR GAS SOLENOID TEST (continued) FIGURE F.5 — GAS SOLENOID TEST. NOTE: WIRE FEEDER SHOWN TEST PROCEDURE 1. Remove input power to the DH-10 unit. 2. Using the 5/16 in. nutdriver, remove the wire drive cover. 3. Locate the gas solenoids and lead quick connects.

  • Page 75: Component Replacement Procedures

    DISPLAY PC BOARD REMOVAL AND REPLACEMENT WARNING 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.
  • Page 76 F-32 TROUBLESHOOTING AND REPAIR DISPLAY PC BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.6 — DISPLAY PC BOARD REMOVAL AND REPLACEMENT. DISPLAY PC BOARD MOUNTING REMOVAL PROCEDURE 1. Remove input power to the DH-10 unit. 2. Using the 5/16 in. nutdriver, remove the two screws from the top of the control panel.

  • Page 77: Gas Solenoid Removal And Replacement

    GAS SOLENOID REMOVAL AND REPLACEMENT WARNING 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.
  • Page 78 F-34 TROUBLESHOOTING AND REPAIR GAS SOLENOID REMOVAL AND REPLACEMENT (continued) FIGURE F.7 — GAS SOLENOID REMOVAL AND REPLACEMENT. NOTE: WIRE FEEDER SHOWN WITH DRIVE MOTOR ASSEMBLY REMOVED FOR CLARITY PROCEDURE 1. Remove input power to the DH-10 unit. 2. Using the 5/16 in. nutdriver, remove the wire drive cover.

  • Page 79: Encoder Pc Board Removal And Replacement

    ENCODER PC BOARD REMOVAL AND REPLACEMENT WARNING 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.
  • Page 80 F-36 TROUBLESHOOTING AND REPAIR ENCODER PC BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.8 — ENCODER PC BOARD REMOVAL AND REPLACEMENT. ENCODER PC BOARD PROCEDURE 1. Remove input power to the DH-10 unit. 2. Using the 5/16 in. nutdriver remove the two screws from the top of the control panel.

  • Page 81: Wire Drive Motor And Gear Box Removal And Replacement

    WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT WARNING 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.
  • Page 82 F-38 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT (continued) FIGURE F.9 — WIRE FEED ASSEMBLY REMOVAL. MOTOR ARMATURE LEADS CAP SCREW LOCK WASHER FLATWASHER PROCEDURE 1. Remove input power to the DH-10 unit. 2. Remove the electrode wire from the wire drive.
  • Page 83 F-39 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT (continued) FIGURE F.10 — DRIVE MOTOR AND WIRE DRIVE ASSEMBLY REMOVAL. GEAR BOX TO REMOVE THE DRIVE MOTOR FROM THE GEAR BOX: 12. Using the slot head screwdriver and 7/16 in.
  • Page 84 F-40 TROUBLESHOOTING AND REPAIR WIRE DRIVE MOTOR AND GEAR BOX REMOVAL AND REPLACEMENT (continued) 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 drive unit using the 3/16 in.

  • Page 85: Retest After Repair

    F-41 TROUBLESHOOTING AND REPAIR If a failed test indicates that any mechanical part which could affect the machine's elec- trical characteristics 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 DH-10 unit.
  • Page 86 F-42 F-42 NOTES DH-10...
  • Page 87 Your Company__________________________ Your Name_____________________________ Please give detailed description below: ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ SD287 01/99 Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309...
  • Page 88 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section...Section G Wiring Diagram (Control) (L10218)...G-2 Wiring Diagram (Wire Drive) (M17871) ...G-3 Control Board Schmatic (Sheet 1) (G3040-1) ...G-4 Control Board Schmatic (Sheet 2) (G3040-2) ...G-5 Display Board Schematic (L10138) ...G-6 Encoder Board Schematic (S22066) ...G-7 Control Board Layout (G3041-2) ...G-8 Display Board Layout (L10139-1) ...G-9...
  • Page 89 Wiring Diagram (Control) (L10218) J17** VOLTS J17** TO MOTOR TACHOMETER TO MOTOR TACHOMETER TO MOTOR TACHOMETER TO BRASS BLOCK VOLTAGE SENSE NOTES: N.A. FOR G3041-2 AND HIGHER CONTROL P.C. BOARDS: THE JUMPER (SHOWN) OR TO DUAL PROCEDURE SWITCH THE OPTIONAL REMOTE SWITCH INTERFACE MODULE (NOT SHOWN) MUST BE INSTALLED TO DUAL PROCEDURE SWITCH IN J5 ON THE CONTROL P.C.

  • Page 90: Wiring Diagram (Wire Drive) (M17871

    ELECTRICAL DIAGRAMS Wiring Diagram (Wire Drive) (M17871) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. ASSEMBLY HEAD ASSEMBLY...

  • Page 91: Control Board Schmatic (Sheet 1) (G3040-1

    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 avail- able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 92 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 avail- able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

  • Page 93: Display Board Schematic (L10138

    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 avail- able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

  • Page 94: Encoder Board Schematic (S22066

    ELECTRICAL DIAGRAMS Encoder Board Schematic (S22066) DH-10 S22066 4-7-95...

  • Page 95: Electrical Diagrams

    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 avail- able from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

  • Page 96: Display Board Layout (L10139-1

    ELECTRICAL DIAGRAMS Display Board Layout (L10139-1) DH-10 L10139-1 5-2-97...

  • Page 97: Encoder Board Layout (M17797-1

    Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
  • Page 98 NOTES DH-10...

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