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Lincoln Electric SVM154-A Service Manual

Ln-10 heads & controls boom mount or bench models.
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10 Series Wire Drive - Boom Mount Code 10443, 10444, 10763, 10764
LN-10 - Zipline Boom Package Code 10497, 10498 , 10771, 10772
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.
• 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
RETURN TO MAIN INDEX
LN- 10 Heads & Controls
Boom Mount or Bench Models
For use with: LN-10 Control - Boom Mount Code 10442
LN-10 Boom Package Code 10445, 10765
Synergic 7F Drive Code 10190, 10191
LN-10 - Bench Model Code 10440, 10441, 10761, 10762

SERVICE MANUAL

• World's Leader in Welding and Cutting Products •
SVM154-A
Copyright © 2001 Lincoln Global Inc.
September, 2002

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   Summary of Contents for Lincoln Electric SVM154-A

  • Page 1: Service Manual

    • World's Leader in Welding and Cutting Products • • 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 RETURN TO MAIN INDEX Copyright © 2001 Lincoln Global Inc. SVM154-A September, 2002...

  • 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.

  • 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 – LN-10 Head & Control WIRE DRIVE OR WIRE DRIVE SECTION OF FEEDER SPEC.# TYPE LOW SPEED RATIO Speed K1563-1 10 Series 35-500 IPM Std Drive Boom Mount (0.89-12.7 M/M) K1563-2 10 Series 55 - 825 IPM Hi-Speed Boom Mount (1.40 - 21.0 M/M) K679-1 Synergic 7F*...

  • Page 9: Recommended Processes And Equipment

    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: Mounting Of Synergic 7f Wire Drive Unit (k679-1 Or -2)

    5/16-18 THREAD 2.25 6.00 11.00 3.00 BOTTOM FRONT 10.50 14.50 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.

  • Page 11: Electrode Routing

    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 into the wire drive unit is kept at a minimum.

  • Page 12: Wire Feed Drive Roll Kits

    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.

  • Page 13: Gun And Cable Assemblies With Standard Connection

    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.

  • Page 14: Gun Cable Connection With Fast-mate Connection

    • 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. • Keep cylinder away from welding or other live elec- trical circuits.

  • Page 15: Electrical Installation

    ELECTRICAL INSTALLATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • 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 16: Optional Features Installation

    When installed and properly configured, the K1561-1 Robotics Interface Module allows complete control of the welding process from the robot controller. The Lincoln Electric Company’s Automation Center should be contacted for questions regarding installa- tion or operation of the Robotics Interface Module.

  • Page 17

    SECTION B-1 Operation ............... . . Section B Safety Precautions .

  • Page 18: Operation

    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 inch- ing with gun trigger, electrode and drive mech- anism are “hot” to work and ground and could remain energized several seconds after the gun trigger is released.

  • Page 19: Welding Power Source Selection

    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: Pwr Sources Head 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: Pwr Sources Head Welding Power Source Selection...

  • Page 20: Metric/english Wire Feed Speed Display Selection

    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) M 4 S R + - S2 switch 1 ON = m/min M 4 S R + -...

  • Page 21: Robotics Mode Selection

    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 M 4 S R + - S2 switch 4 OFF = Robotics mode OFF (As shipped) M 4 S R + -...

  • Page 22: Keypad And Display Operation

    RUN-IN VOLTS / WFS SPOT BURNBACK POSTFLOW TIMER CONTROL THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO U.S.A. Keypad and Display Description Keypad - Seven key, membrane type with "snap" tac- tile feel and embossed domes. Long life design. Spatter resistant surface.

  • Page 23: Trigger Mode Selection

    Trigger Mode Selection Trigger Mode Select key COLD FEED - enables operator to TRIGGER 2-STEP STD choose mode of operation 4-STEP LOCK shown by the indicator lights. Pressing key caus- SPOT mode sequence (top to bottom) starting from the current indicated selection.

  • Page 24: Digital "memory" Voltmeter

    CONTROL 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.

  • Page 25: Maximum And Minimum Limits Setting Modes

    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.

  • Page 26: Dual Procedure Remote Control (k1449-1

    B-10 DUAL PROCEDURE 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 exact same manner.

  • Page 27: (using K1504-1 Coil Reel

    B-11 To 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 nut and remove the reel cover.

  • Page 28: Procedure For Setting Angle Of Feedplate

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

  • Page 29: Wire Reel Changing

    B-13 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.

  • Page 30: Explanation Of Prompting And Error Messages

    B-14 EXPLANATION OF PROMPTING AND ERROR MESSAGES Display Prompt or Error Displayed on Voltage display, indicates WFS display is showing acceleration setting, “1" to “5" (See “Acceleration Selection” in this section). Displayed on WFS and voltage displays; indi- cates limits for WFS or voltage are off for the displayed procedure.

  • Page 31

    SECTION C-1 Accessories ............... Section C General .

  • Page 32

    GENERAL The following is a list of all the accessories that can be used with the LN-10 Wire Feeder. A description of each item is given later in the section. TABLE C.1 — LN-10 WIRE FEEDER ACCESSORIES. KP1505 Series DRIVE ROLL AND WIRE GUIDE KITS KP1507 Series DRIVE ROLL AND WIRE GUIDE KITS K1501...

  • Page 33: Accessories

    TABLE C.2 – DRIVE ROLL AND GUIDE TUBE KITS Wire Size Solid Steel Electrode 0.025” (0.6 mm) 0.030” (0.8 mm) 0.035” (0.9 mm) 0.040” (1.0 mm) 0.045” (1.2 mm) 0.052” (1.4 mm) 1/16” (1.6 mm) 5/64” (2.0 mm) 3/32” (2.4 mm) Cored Electrode 0.030 (0.8 mm)

  • Page 34: Input Cable Assemblies

    INPUT CABLE ASSEMBLIES: K1501 (Control Cable Only) Consists of a 9-conduc- tor 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.

  • Page 35: Gun Adapters (for 10 Series Wire Drive

    Fanuc robot. When installed and properly configured, the K1561-1 Robotics Interface Module allows com- plete control of the welding process from the robot controller. The Lincoln Electric Company’s Automation Center should be contacted for questions regarding installa- tion or operation of the Robotics Interface Module. LN-10...

  • Page 36

    ACCESSORIES 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.

  • Page 37

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

  • Page 38: Maintenance

    MAINTENANCE 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, electrode and drive mechanism are “hot” to work and ground and could remain energized several seconds after the gun trigger is released.

  • Page 39

    MAINTENANCE FIGURE D.1 - MAJOR COMPONENT LOCATIONS 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) Bench Model Only Bench Model Shown...

  • Page 40

    SECTION E-1 THEORY OF OPERATION -THEORY OF OPERATION SECTION- Theory of Operation ..............Section E General Description .

  • Page 41: Theory Of Operation

    THEORY OF OPERATION FIGURE E.1 — LN-10 GENERAL DESCRIPTION. OPTIONAL REMOTE CONTROL INPUT CABLE RECEPTACLE 42VAC ENCODER 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.

  • Page 42: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 — LN-10 INPUT RECEPTACLE, CONTROL BOARD AND OPERATOR CONTROLS. OPTIONAL REMOTE CONTROL INPUT CABLE RECEPTACLE 42VAC INPUT RECEPTACLE, CONTROL BOARD AND OPERATOR 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.

  • Page 43: Wire Feed Head And Receptacle

    THEORY OF OPERATION FIGURE E.3 — LN-10 WIRE FEED HEAD AND RECEPTACLE. INPUT CABLE RECEPTACLE 42VAC WIRE FEED HEAD AND RECEPTACLE 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.

  • Page 44: Protection And Shutdown

    THEORY OF OPERATION PROTECTION AND SHUTDOWN 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”...

  • Page 45

    NOTES LN-10...

  • Page 46: Pc Board Troubleshooting Procedures

    TROUBLESHOOTING AND REPAIR -TROUBLESHOOTING AND REPAIR SECTION- Troubleshooting and Repair ............Section F How to Use Troubleshooting Guide .

  • Page 47: Troubleshooting And Repair

    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 48: Pc Board Troubleshooting Procedures

    - If the PC board uses protective shorting jumpers, don’t remove them until installation is complete. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.

  • Page 49

    NOTES LN-10...

  • Page 50: Troubleshooting Guide

    The WFS can be pre- set. 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 1-800-833-9353.

  • Page 51

    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 1-800-833-9353.

  • Page 52

    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 1-800-833-9353.

  • Page 53

    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 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 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 1-800-833-9353.

  • Page 56

    The dual procedure switch is not functioning at the gun. 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 1-800-833-9353.

  • Page 57

    LN-10 is powered up. A “GLP” message is displayed. 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 1-800-833-9353.

  • Page 58

    LED is in the REMOTE position. 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 1-800-833-9353.

  • Page 59

    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 1-800-833-9353.

  • Page 60

    “blast-offs”. The bead may be nar- row, ropey and have porosity. 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 1-800-833-9353.

  • Page 61

    F-16 F-16 NOTES LN-10...

  • Page 62: 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 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- cautions detailed throughout this manual.

  • Page 63

    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 LN-10 unit. 2. Using the 5/16 in. nut driver, remove the wire drive cover. 3. Locate the motor armature leads for the motor to be tested (one black (-) lead and one white (+) lead).

  • Page 64: 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 warranty.

  • Page 65

    F-20 TROUBLESHOOTING AND REPAIR TACH ADJUSTMENT AND FEEDBACK TEST (continued) FIGURE F.2 — TACH FEEDBACK TEST. #555 BLUE TEST PROCEDURE 1. Remove input power to the LN-10 unit. 2. Using the 5/16 in. nut driver, remove the wire drive cover. 3.

  • Page 66

    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 LN-10 wire feed- er. If the device is not screwed in far enough the motor speed could be unstable or run at full speed with no control.

  • Page 67

    F-22 F-22 NOTES LN-10...

  • Page 68: 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 warranty.

  • Page 69

    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 LN-10 unit. 2. Using the 5/16 in. nut driver, remove the two screws from the top of the con- trol panel.

  • Page 70

    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 71

    F-26 F-26 NOTES LN-10...

  • Page 72: 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 warranty.

  • Page 73

    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 LN-10 unit. 2. Using the 5/16 in. nut driver, remove the two screws from the top of the con- trol panel.

  • Page 74: 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 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- cautions detailed throughout this manual.

  • Page 75: Troubleshooting And Repair

    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 LN-10 unit. 2. Using the 5/16 in. nut driver, remove the wire drive cover. 3.

  • Page 76: 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 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- cautions detailed throughout this manual.

  • Page 77

    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 LN-10 unit. 2. Using the 5/16 in. nut driver, remove the two screws from the top of the con- trol panel.

  • Page 78: Gas Solenoid Removal And Replacement

    GAS SOLENOID REMOVAL AND REPLACEMENT WARNING 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 all safety notes and pre- cautions detailed throughout this manual.

  • Page 79

    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 LN-10 unit. 2. Using the 5/16 in. nut driver, remove the wire drive cover.

  • Page 80: 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 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 all safety notes and pre- cautions detailed throughout this manual.

  • Page 81

    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 LN-10 unit. 2. Using the 5/16 in. nut driver remove the two screws from the top of the control panel.

  • Page 82: 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 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- cautions detailed throughout this manual.

  • Page 83

    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 LN-10 unit. 2. Remove the electrode wire from the wire drive.

  • Page 84

    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 flat head screwdriver and 7/16 in.

  • Page 85

    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 86: Current Sensing Reed Switch Removal And Replacement

    CURRENT SENSING REED SWITCH 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 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- cautions detailed throughout this manual.

  • Page 87

    F-42 TROUBLESHOOTING AND REPAIR CURRENT SENSING REED SWITCH REMOVAL AND REPLACEMENT (CONTINUED) FIGURE F.11 — CURRENT SENSING REED SWITCH /PLUG LOCATION. Current Sensing Reed Switch Reed Switch Cover PROCEDURE 1. Remove input power to the LN-10 unit. 2. Remove the reed switch plug from the front of the machine.

  • Page 88: Retest After Repair

    F-43 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 LN-10 unit.

  • Page 89

    ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section...Section G Wiring Diagram (Control) ...G-2 Wiring Diagram (Wire Drive) ...G-3 Control Board Schematic (Sheet 1) ...G-4 Control Board Schematic (Sheet 2) ...G-5 Control Board Layout ...G-6 Display Board Schematic...G-7 Display Board Layout...G-8 Encoder Board Schematic ...G-9 Encoder Board Layout ...G-10...

  • Page 90: Electrical Diagrams

    ELECTRICAL DIAGRAMS WIRING DIAGRAM - LN-10 (CONTROL) 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. LN-10...

  • Page 91

    ELECTRICAL DIAGRAMS WIRING DIAGRAM - LN-10 (WIRE DRIVE) 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. LN-10...

  • Page 92

    ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. LN-10...

  • Page 93

    ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD #2 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. LN-10...

  • Page 94

    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 95

    ELECTRICAL DIAGRAMS SCHEMATIC - DISPLAY PC BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. LN-10...

  • Page 96

    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 97

    ELECTRICAL DIAGRAMS SCHEMATIC - ENCODER PC BOARD NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. LN-10...

  • Page 98

    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 99

    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...

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