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Lincoln Electric SVM132-A manual

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Table of contents for the manual

  • Page 1

    LN-8 SEMIA UTOMA TIC WIRE FEEDER SER VICE MANUAL SVM132-A May, 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 REPAIR THIS EQUIPMENT WITHOUT READ[...]

  • Page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC LN-8 SAFETY 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 a[...]

  • Page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC LN-8 SAFETY ii 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[...]

  • Page 4

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC LN-8 SAFETY 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?[...]

  • Page 5

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC LN-8 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 [...]

  • Page 6

    LN-8 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications - LN-8 . . . . . . . . [...]

  • Page 7

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SECTION A-1 INST ALLA TION LN-8 SECTION A-1 T ABLE OF CONTENTS -INST ALLA TION SECTION- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications - LN[...]

  • Page 8

    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 ELECTRODE DIAMETER SOLID 0.030 in. through 3/32 in. (0.76 through 2.36 mm) CORED 0.062 in. through 0.120 in. (1.57 through 3.05 mm) OPERATING -4 ˚ F to 104 ˚ F (-20 ˚ C to 40 [...]

  • Page 9

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-3 INST ALLA TION LN-8 A-3 MOUNTING LOCA TION The LN-8 can be operated as a free-standing unit, or it can be mounted to an undercarriage when portability is required. Refer to A[...]

  • Page 10

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-4 INST ALLA TION LN-8 A-4 LN-8S AND LN-8SE (AND CONVERTED LN-8N AND LN-8NE) 1. Use either a constant voltage or constant current type power source as required for the applicati[...]

  • Page 11

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-5 INST ALLA TION LN-8 A-5 Figure No. Power Source A.2 Connection of LN-8 to an Idealarc® R3S-400, 600 or 800 (with LVC) (Discontinued) A.3 Connection of LN-8 to an Idealarc R3[...]

  • Page 12

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-6 INST ALLA TION A-6 LN-8 ELECTRIC SHOCK CAN KILL TURN OFF INPUT POWER TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT. WARNING 2[...]

  • Page 13

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-7 INST ALLA TION A-7 LN-8 ELECTRIC SHOCK CAN KILL TURN OFF INPUT POWER TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT. WARNING 2[...]

  • Page 14

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-8 INST ALLA TION A-8 LN-8 ELECTRIC SHOCK CAN KILL TURN OFF INPUT POWER TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT. WARNING T[...]

  • Page 15

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-9 INST ALLA TION A-9 LN-8 ELECTRIC SHOCK CAN KILL TURN OFF INPUT POWER TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT. WARNING T[...]

  • Page 16

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-10 INST ALLA TION A-10 LN-8 ELECTRIC SHOCK CAN KILL TURN OFF INPUT POWER TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT. WARNING[...]

  • Page 17

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-11 INST ALLA TION A-11 LN-8 ELECTRIC SHOCK CAN KILL TURN OFF INPUT POWER TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT. WARNING[...]

  • Page 18

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-12 INST ALLA TION A-12 LN-8 GND 77 76 75 32 31 2 4 A B C 4 2 GND 32 31 21 DUAL PROCESS CONTACTOR 4 2 32 31 75 76 77 A A 4 2 32 31 75 76 77 B B A B C 4 2 GND 32 31 21 81 80 ELEC[...]

  • Page 19

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-13 INST ALLA TION A-13 LN-8 GND 77 76 75 32 31 2 4 A B C 4 2 GND 32 31 21 DUAL PROCESS CONTACTOR 4 2 32 31 75 76 77 A A 4 2 32 31 75 76 77 B B A B C 4 2 GND 32 31 21 81 80 ELEC[...]

  • Page 20

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-14 INST ALLA TION A-14 LN-8 ELECTRIC SHOCK CAN KILL TURN OFF INPUT POWER TO THE WELDING POWER SOURCE USING THE DISCONNECT SWITCH BEFORE WORKING ON THIS EQUIPMENT. WARNING[...]

  • Page 21

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-15 INST ALLA TION LN-8 A-15 INPUT CABLE CONNECTIONS For connecting an LN-8 to a specific Lincoln Electric power source, use the appropriate steps in one of these paragraphs and[...]

  • Page 22

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-16 INST ALLA TION LN-8 A-16 2. The standard cable setup consists of an electrode cable and a control cable with a polarized plug on the wire feeder end. Position the control ca[...]

  • Page 23

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-17 INST ALLA TION LN-8 A-17 9. Remove the ingoing guide tube from the rear brass block of the wire feeder and plug the connector of the electrode cable extension into the brass[...]

  • Page 24

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-18 INST ALLA TION LN-8 A-18 GUN AND CABLE ASSEMBLIES GENERAL The LN-8 is used with various guns. In all cases, the gun is shipped connected to the cable and is ready to weld. U[...]

  • Page 25

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION LN-8 SECTION B-1 SECTION B-1 T ABLE OF CONTENTS -OPERA TION SECTION- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Safety Instructions . . . . . . . . . [...]

  • Page 26

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-2 OPERA TION B-2 CONTROLS AND THEIR FUNCTIONS CONST ANT CURRENT CONTROLS Operator controls for welding using a constant current power source are illustrated in Figure B.1. Refe[...]

  • Page 27

    B-3 OPERA TION B-3 CURRENT CONTROL . Adjusts welding current by controlling power source output. VOLTAGE CONTROL . Adjusts arc voltage by control- ling wire feed speed. TRIGGER INTERLOCK . With the switch in the OFF position, the wire feed motor runs and the welding cir- cuit is energized only when the gun trigger is pressed. The operator must hold[...]

  • Page 28

    B-4 OPERA TION B-4 CIRCUIT PROTECTION FIELD CIRCUIT FUSE . This 1/2 amp slow blow fuse, located on the Relay PC board, protects the field cir- cuit. It will blow if the field shorts or if one of the field circuit components on the Relay PC board fails. MOTOR THERMAL PROTECTION . The temperature sensing thermal protector mounted in the motor opens t[...]

  • Page 29

    B-5 OPERA TION B-5 WIRE FEED ROLLS AND GUIDE TUBES The drive rolls and guide tube kits are ordered sepa- rately. Refer to Figure B.3 and install these parts per the following instructions: 1. Loosen the idle roll spring pressure screw. 2. Remove the drive roll screw and clamping collar from the drive shaft. 3. Install the drive roll and replace the[...]

  • Page 30

    B-6 OPERA TION B-6 7. Install the large ingoing guide into the rear brass block and tighten the locking screw. 8. Install the outgoing guide tube with its plastic insert through the front brass block. Tighten the locking screw so the dog point goes into the groove on the O.D. of the guide tube. 9. Set the drive roll spring pressure: a. For wire siz[...]

  • Page 31

    B-7 OPERA TION B-7 FIGURE B.4 – CV-CC SWITCH WELDING WITH A CONST ANT VOL T AGE POWER SOURCE 1. Current and voltage adjustments Amps Control — All Power Sources Set the welding current (or wire feed speed) with the LN-8 Amps control. Volts Control — DC-600 Power Source a. Set the mode switch on the power source to CV Innersheild or CV Subarc,[...]

  • Page 32

    B-8 OPERA TION B-8 WIRE REEL LOADING – 50 AND 60 lb COILS (K303 WIRE REEL ST AND) MOUNTING A 50 OR 60 lb COIL 1. To remove the wire reel from its shaft, grasp the spring loaded knob and pull out. This straightens the knob so it seats into the shaft when released. Remove the reel. 2. Lay the reel flat on the floor. Loosen the spinner nut and remov[...]

  • Page 33

    B-9 OPERA TION B-9 WIRE REEL LOADING (K1524-1 UNIVERSAL WIRE REEL ST AND) TO MOUNT A 30 lb (14 kg) READI-REEL PACKAGE (USING THE MOLDED PLASTIC K363-P READI-REEL ADAPTER): The spindle should be located in the LOWER mount- ing hole. 1. Depress the Release Bar on the Retaining Collar and remove it from the spindle. See Figure B.6. 2. Place the Adapte[...]

  • Page 34

    B-10 OPERA TION B-10 TO MOUNT 10 TO 44 lb (4.5 to 20 kg) SPOOLS (12 in./300 mm DIAMETER) OR 14 lb (6 kg) INNERSHIELD COILS: The spindle should be located in the lower mounting hole. [For 8 in. (200 mm) spools, a K468 spindle adapter must first be slipped onto the spindle.] [For 13 to 14 lb (6 kg) Innershield coils, a K435 Coil Adapter must be used.[...]

  • Page 35

    B-11 OPERA TION B-11 FEEDING ELECTRODE TO THE LN-8N OR LN-8S 1. Turn the reel until the free end of the electrode is accessible. 2. While tightly holding the electrode, cut off the bent end and straighten the first six inches. Cut off the first inch. (If the electrode is not properly straightened, it may not feed or may not go into the outgoing gui[...]

  • Page 36

    B-12 OPERA TION B-12 SLOW ACCELERA TION ST ARTING (CODE 7926 AND ABOVE) The LN-8 has the capability of optimum starting for dif- ferent processes. This is accomplished by designing the LN-8 to start with two different speeds of con- trolled acceleration. As shipped, the unit is connected for fast acceleration, which is best for most open arc proced[...]

  • Page 37

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SECTION C-1 ACCESSORIES SECTION C-1 LN-8 T ABLE OF CONTENTS -ACCESSORIES SECTION- Accessories .................................................................................................................... ......... Section C General ...........................[...]

  • Page 38

    Product Number Name K163 UNDERCARRIAGE K178 MOUNTING PLATFORM K261 METER KIT K202 BURNBACK KIT K58 MAGNETIC SEPARATOR K119 GRAVITY FEED FLUX CONE K310 FLUX SCREEN K320 FLUX TANK K161 MECHANIZED TRAVEL POWER PACK K240 CONTACTOR KIT K317 DUAL PROCESS KIT (NO POLARITY CHANGE) K318 DUAL PROCESS CONTACTOR KIT (WITH POLARITY CHANGES) K303 50 THRU 60 lb ([...]

  • Page 39

    C-3 ACCESSORIES C-3 K163 UNDERCARRIAGE (REQUIRES K303, K377, OR K378) The undercarriage includes casters, wheels, a handle, and related hardware. Casters are mounted at the front and wheels are mounted at the rear of the plat- form. The handle is bolted to the front of the platform so the wire feeder can be tilted back and wheeled like a two-wheel [...]

  • Page 40

    C-4 ACCESSORIES C-4 K240 CONT ACTOR KIT Output contactor with pilot relay to make the electrode ‘cold’ when not welding. Must be ordered when using the LN-8 with SA-750, SAE, TM, R3M and R3R Idealarcs. Contactor kits are rated at 600 amps maxi- mum, and cannot be paralleled with each other. K317 DUAL PROCESS KIT (NO POLARITY CHANGE) The Dual Pr[...]

  • Page 41

    C-5 ACCESSORIES C-5 WELDING GUNS INNERSHIELD GUNS The K126 gun and cable assembly is recommended for most Innershield electrodes at up to 350 amps. The K115 gun and cable assembly is recommended for up to 450 amps. The K116 gun and cable assembly is recommended for up to 600 amps. NOTE: Linconditioner TM guns are recommended for locations where smo[...]

  • Page 42

    C-6 NOTES LN-8 C-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[...]

  • Page 43

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SECTION D-1 MAINTENANCE SECTION D-1 LN-8 T ABLE OF CONTENTS -MAINTENANCE SECTION- Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D Routine Maintenance . . . . . . . . . [...]

  • Page 44

    D-2 MAINTENANCE D-2 ROUTINE MAINTENANCE DRIVE ROLLS AND GUIDE TUBES After feeding every coil of wire, inspect the drive roll section. Clean the assembly as necessary. Do not use solvent to clean the drive roll assembly as it may wash the lubricant out of the bearings. The drive rolls and guide tubes are stamped with the wire sizes they will feed. I[...]

  • Page 45

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SECTION E-1 THEOR Y OF OPERA TION SECTION E-1 LN-8 T ABLE OF CONTENTS -THEOR Y OF OPERA TION SECTION- Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E General Description . . [...]

  • Page 46

    E-2 THEOR Y OF OPERA TION E-2 GENERAL DESCRIPTION The LN-8 is a semiautomatic wire feeder designed for Innershield (FCAW) and gas metal arc processes with the appro- priate accessories. It is also suitable for constant voltage (CV) submerged arc welding processes. With the optional variable voltage board installed the LN-8 can be used with constant[...]

  • Page 47

    E-3 THEOR Y OF OPERA TION E-3 GUN TRIGGER AND 1CR RELA Y CONT ACT CONTROL CIRCUITS When the gun trigger switch is activat- ed (closed) the 1CR relay is energized. Three sets of isolated contacts incor- porated within the 1CR relay perform several functions. One set of contacts completes the circuit to energize the wire feed motor armature and also [...]

  • Page 48

    E-4 THEOR Y OF OPERA TION E-4 V ARIABLE VOL T AGE BOARD, METER SHUNT , WIRE SPEED AND REMOTE OUTPUT CONTROLS The optional variable voltage board enables the LN-8 to be used with a con- stant current power source. The vari- able voltage board monitors the arc voltage via leads #21 and #567 and modifies the wire feed speed according to arc voltage va[...]

  • Page 49

    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 E-5 THEOR Y OF OPERA TION E-5 SCR OPERA TION A silicon controlled rectifier (SCR) is a three terminal semi-conductor device used to control currents to a load. Refer to Figure E.[...]

  • Page 50

    E-6 NOTES LN-8 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[...]

  • Page 51

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC LN-8 SECTION F TROUBLESHOOTING AND REP AIR SECTION F T ABLE OF CONTENTS -TROUBLESHOOTING AND REP AIR SECTION- Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sec tion F How to Use Troublesh[...]

  • Page 52

    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 LN-8 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 procedur[...]

  • Page 53

    LN-8 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 TROUBLESHOOTING & REP AIR F-3 F-3 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections[...]

  • Page 54

    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 1. Check the Ground Lead Protector (GLP). Reset if necessary. 2. Check the circuit breaker. Reset if necessary. 3. Make sure 115VAC is being applied to the LN-8 at the input rece[...]

  • Page 55

    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 1. The 1CR relay, located on the power board, may be faulty. Check or replace. Note: The relay may operate but the indi- vidual contacts may not be func- tioning properly. 2. If [...]

  • Page 56

    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-6 TROUBLESHOOTING AND REP AIR F-6 LN-8 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electr[...]

  • Page 57

    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-7 TROUBLESHOOTING AND REP AIR F-7 LN-8 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electr[...]

  • Page 58

    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-8 TROUBLESHOOTING AND REP AIR F-8 LN-8 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electr[...]

  • Page 59

    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-9 TROUBLESHOOTING AND REP AIR F-9 LN-8 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electr[...]

  • Page 60

    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-10 TROUBLESHOOTING AND REP AIR F-10 LN-8 ELECTRICAL SEQUENCE OF OPERA TION FIGURE F.1 – LN-8 ELECTRICAL SEQUENCE OF OPERATION LN-8 TURN ON POWER SOURCE PRESS GUN TRIGGER CLOS[...]

  • Page 61

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-11 TROUBLESHOOTING AND REP AIR F-11 FIGURE F.1 – LN-8 ELECTRICAL SEQUENCE OF OPERATION (continued) LN-8 DE-ENERGIZES 2 CR REED SWITCH OPENS INTERLOCK ON 1 CR (NOTE 2) OPENS 5[...]

  • Page 62

    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 LN-8 F-12 TROUBLESHOOTING AND REP AIR F-12 TEST DESCRIPTION This test will aid the technician in determining if the Trigger Transformer is functioning properly. MA TERIALS NEEDED[...]

  • Page 63

    F-13 TROUBLESHOOTING AND REP AIR F-13 TEST PROCEDURE 1. Remove input power to the LN-8. 2. Using the 5/16 in. nutdriver, remove the screws holding the left side cover assembly. 3. Disconnect the Molex plug from the under-side of the relay board. See Figure F.2. 4. Apply power (115VAC) to the black primary transformer leads, pins 2 and 3. 5. Using t[...]

  • Page 64

    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-14 TROUBLESHOOTING AND REP AIR F-14 LN-8 TEST DESCRIPTION This test will aid the technician in determining if the correct voltages are present in the LN-8. MA TERIALS NEEDED 5/[...]

  • Page 65

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-15 TROUBLESHOOTING AND REP AIR F-15 TEST DESCRIPTION 1. Remove input power to the LN-8. 2. Using the 5/16 in. nutdriver, remove the screws from the left side cover assembly. 3.[...]

  • Page 66

    INTERNAL VOL T AGE TEST (continued) TABLE F.1 – VOLTAGE TEST POINTS 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-16 TROUBLESHOOTING AND REP AIR F-16 LN-8 ACCEPTABLE CHECKPOINT TEST VOLTAGE LOCATIONS DESCRIPTION LEAD NO.[...]

  • Page 67

    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-17 TROUBLESHOOTING AND REP AIR F-17 LN-8 TEST DESCRIPTION This test will determine if the control relay is functioning properly by measuring the resistance across the contacts [...]

  • Page 68

    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-18 TROUBLESHOOTING AND REP AIR F-18 TEST PROCEDURE 1. Remove input power to the LN-8. 2. Using the 5/16 in. nutdriver, remove the screws from the left side cover assembly. 3. L[...]

  • Page 69

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-19 TROUBLESHOOTING AND REP AIR F-19 7. Measure the resistance across the contacts. A resistance of less than one ohm indicates that the con- tacts are closed. An infinite resis[...]

  • 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 F-20 TROUBLESHOOTING AND REP AIR F-20 LN-8 TEST DESCRIPTION This test will help determine if the drive motor is functioning correctly. MA TERIALS NEEDED 5/16 in. nutdriver Volt-O[...]

  • Page 71

    F-21 TROUBLESHOOTING AND REP AIR F-21 TEST PROCEDURE 1. Remove input power to LN-8. 2. Remove the electrode wire or dis- engage drive rolls. 3. Using the 5/16 in. nutdriver, remove the screws from the left side cover assembly. 4. Lift the left side cover. 5. Locate leads #539 and #541 at the control board. See Figure F.5. DRIVE MOT OR TEST (continu[...]

  • Page 72

    F-22 TROUBLESHOOTING AND REP AIR F-22 6. Locate leads #626 and #627 at the relay board. 7. If a variable voltage board is installed in the LN-8, make cer- tain the mode switch is in the CV position. 8. Apply 115VAC to the input recep- tacle at pins C and D. 9. With the gun trigger activated or the gun trigger terminals jumpered together, (see wirin[...]

  • Page 73

    F-23 TROUBLESHOOTING AND REP AIR F-23 To further check the drive motor: 12. Remove input power (115VAC) from the LN-8. 13. Locate and remove leads #539 and #541 from the control board, see Figure F.5 . 14. Locate and remove leads #626 and #627 from the relay board. 15. Using the ohmmeter, measure the resistances per Table F.3. 16. If the motor resi[...]

  • Page 74

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-24 TROUBLESHOOTING AND REP AIR F-24 LN-8 MA TERIALS NEEDED 5/16 in. nutdriver 1/2 in. wrench 5/64 in. Allen wrench Small slothead screwdriver Soldering iron and solder POTENTIO[...]

  • Page 75

    F-25 TROUBLESHOOTING AND REP AIR F-25 REP AIR PROCEDURE 1. Remove input power to the LN-8 2. Using the 5/16 in. nutdriver, remove the screws from the left side cover assembly. 3. Using a 5/64 in. Allen wrench or slothead screwdriver, loosen the setscrew on the potentiometer knob and remove the knob from the potentiometer. Refer to Figure F.7. 4. Re[...]

  • Page 76

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-26 TROUBLESHOOTING AND REP AIR F-26 LN-8 MA TERIALS NEEDED 5/16 in. nutdriver 9/16 in. wrench CIRCUIT BREAKER REPLACEMENT Service and repair should be performed only by Lincoln[...]

  • Page 77

    F-27 TROUBLESHOOTING AND REP AIR F-27 REP AIR PROCEDURE 1. Using the 5/16 in. nutdriver, remove the screws from the left side cover assembly. 2. Tag and remove the two connec- tors from the back of the circuit breaker. Refer to Figure F.8. 3. Using the 9/16 in. wrench, remove the retaining nut that secures the circuit breaker to the center panel on[...]

  • Page 78

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-28 TROUBLESHOOTING AND REP AIR F-28 LN-8 MA TERIALS NEEDED 5/16 in. nutdriver 3/32 in. wrench Jewelers’ flat blade screwdriver Soldering iron and solder GROUND LEAD PROTECT O[...]

  • Page 79

    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-29 TROUBLESHOOTING AND REP AIR F-29 REP AIR PROCEDURE 1. Using the 5/16 in. nutdriver, remove the screws from the left side cover assembly. 2. Using the 3/32 in. wrench and jew[...]

  • Page 80

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-30 TROUBLESHOOTING AND REP AIR F-30 LN-8 MA TERIALS NEEDED 5/16 in. nutdriver Flat blade screwdriver Needlenose pliers TRIGGER TRANSFORMER REPLACEMENT Service and repair should[...]

  • Page 81

    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-31 TROUBLESHOOTING AND REP AIR F-31 REP AIR PROCEDURE 1. Using the 5/16 in. nutdriver remove the screws from the left side cover assembly. 2. Remove the Relay PC board as descr[...]

  • Page 82

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-32 TROUBLESHOOTING AND REP AIR F-32 LN-8 MA TERIALS NEEDED 5/16 in. nutdriver Phillips screwdriver PC BOARD REPLACEMENT Service and repair should be performed only by Lincoln E[...]

  • Page 83

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-33 TROUBLESHOOTING AND REP AIR F-33 REP AIR PROCEDURE 1. Observe the static precautions detailed in the PC Board Troubleshooting Procedures at the beginning of this section. 2.[...]

  • Page 84

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-34 TROUBLESHOOTING AND REP AIR F-34 RELA Y BOARD REMOV AL AND REPLACEMENT 1. If the Relay PC board is being replaced, remove the 1CR Relay from the PC board. 2. Disconnect all [...]

  • Page 85

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-35 TROUBLESHOOTING AND REP AIR F-35 LN-8 MA TERIALS NEEDED Offset flat blade screwdriver Flat blade screwdriver Phillips screwdriver 7/16 in. wrench 1/2 in. wrench 11/32 in. wr[...]

  • Page 86

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-36 TROUBLESHOOTING AND REP AIR F-36 REP AIR PROCEDURE 1. Using the 5/16 in. nutdriver, remove the screws from the left side cover assembly. 2. Disconnect drive motor leads #539[...]

  • Page 87

    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-37 TROUBLESHOOTING AND REP AIR F-37 7. Disconnect two leads #567 (blue), and lead #568 (blue) from the shunt using the 11/32 in. wrench. See Figure F.12. Note the lead placemen[...]

  • Page 88

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-38 TROUBLESHOOTING AND REP AIR F-38 10. Using a 1/2 in. wrench, remove the four hex head screws, lockwash- ers and flat washers that hold the mounting plate to the gear box ass[...]

  • Page 89

    F-39 TROUBLESHOOTING AND REP AIR F-39 14. Install the gearbox assembly onto the insulation sheet and mounting plate using four hex head screws, lockwashers and flat washers. Ensure that the edge of the mount- ing plate that has the single mounting hole is under the drive motor. 15. Place the wire drive assembly into the case. Secure the wire drive [...]

  • Page 90

    F-40 TROUBLESHOOTING AND REP AIR F-40 If a failed test indicates that any mechanical part that could affect the machine’s electrical characteristics must be replaced or if any electrical components are repaired or replaced, the machine must be retested and meet the following standards. RETEST AFTER REP AIR LN-8 Return to Section TOC Return to Sec[...]

  • Page 91

    G-1 ELECTRICAL DIAGRAMS G-1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS -ELECTRICAL DIAGRAMS SECTION- Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G Wiring Diagram . . . . . . . . . . . . . . . . [...]

  • Page 92

    G-2 ELECTRICAL DIAGRAMS LN-8 W iring Diagram 2 502 4 504 531 32A * 1 6 2 3 4 5 2 502 4 504 531 32A 528 525 WIRE FEED MOTOR 539 U 541 B R 626 627 W BURNBACK P.C. BOARD JUMPER CONNECTOR IS REMOVED AND CONNECTOR "B" PLUGGED INTO OPTIONAL BURNBACK P.C. BOARD. CONNECTOR "B" THERMAL CIRCUIT BREAKER G A 2 4 31 32 21 75 76 77 B C D E F [...]

  • Page 93

    G-3 ELECTRICAL DIAGRAMS LN-8 CONNECTION SCHEMA TIC 14669 Ch’ge. Sht. No. 3-31-83N 11-14-86G 2-13-87G t UNLESS OTHERWISE SPECIFIED TOLERANCE ON HOLE SIZES PER E2056 ON 2 PLACE DECIMALS IS .02 WITH PUBLISHED STANDARDS. ON 3 PLACE DECIMALS IS .002 ON ALL ANGLES IS .5 OF A DEGREE MATERIAL TOLERANCE (" ") TO AGREE THE LINCOLN ELECTRIC CO. CL[...]

  • Page 94

    G-4 ELECTRICAL DIAGRAMS LN-8 OPERA TING SCHEMA TIC 5 4 2 3 6 1 32A 531 4 504 502 2 2 4 1CR 504 N.A. 32 32A 5 AMP CIRCUIT BREAKER TP201 C204 77 76 75 R20 T1 526 525A C205 525 R205 523 524 S1 R204 S2 536 R202 D205 529 2CR 528 D204 1CR C201 R206 SCR 531 C202 R203 C203 (R) (W) 627 S3 683 682 1CR D201 D202 C206 R201 626 F201 531 1CR 32A 7 32A D103 D104 [...]

  • Page 95

    G-5 ELECTRICAL DIAGRAMS LN-8 CONTROL BOARD (L5767) SCHEMA TIC G-5 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 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC[...]

  • Page 96

    G-6 ELECTRICAL DIAGRAMS LN-8 V ARIABLE VOL T AGE BOARD (L5039) SCHEMA TIC 12-3-92E G-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 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board leve[...]

  • Page 97

    G-7 ELECTRICAL DIAGRAMS LN-8 CONTROL BOARD (L5767) LA YOUT LN-8 CONTROL L5767-1 D6 D7 1 2345678 N O BAL CAL FS ITEM REQ’D. PART No. IDENTIFICATION C1 C2 C3 C4 C5 C6,C10,C11,C12,C13 C7,C8 C9 1 1 1 1 1 5 2 1 S13490-42 S13490-67 S13490-104 S13490-25 T11577-26 S16668-5 S13490-102 T11577-52 1.0/35 2/50 39uF/20V 4.7/35 .1/100 .022/50 .047/100 .0047 or [...]

  • Page 98

    G-8 ELECTRICAL DIAGRAMS LN-8 V ARIABLE VOL T AGE BOARD (L5039) LA YOUT IDENTIFICATION PART NO. REQ’D ITEM INDUCTANCE = HENRY CAPACITORS = MFD VOLTS L5039-1 LN-8 VARIABLE VOLTAGE VV CV 8-31-2001E L5039-1 G-8 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 M[...]

  • Page 99

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We 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 wi[...]