Lincoln Electric SVM185-A service manual Electric Shock can kill, Fumes and Gases

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ii

 

 

SAFETY

 

 

 

 

 

 

 

 

ii

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ELECTRIC SHOCK can kill.

 

 

 

 

 

ARC RAYS can burn.

 

 

 

 

3.a. The electrode and work (or ground) circuits

 

 

 

 

 

4.a. Use a shield with the proper filter and cover

 

 

are electrically “hot” when the welder is on.

 

 

 

 

 

 

 

 

 

 

 

 

plates to protect your eyes from sparks and

 

 

Do not touch these “hot” parts with your bare

 

 

 

 

 

the rays of the arc when welding or observing

 

 

skin or wet clothing. Wear dry, hole-free

 

 

 

 

 

open arc welding. Headshield and filter lens

 

 

gloves to insulate hands.

 

 

 

 

 

should conform to ANSI Z87. I standards.

3.b. Insulate yourself from work and ground using dry insulation.

 

4.b. Use suitable clothing made from durable flame-resistant

 

Make certain the insulation is large enough to cover your full

 

 

 

material to protect your skin and that of your helpers from

 

area of physical contact with work and ground.

 

 

 

the arc rays.

 

 

 

 

 

 

 

 

In addition to the normal safety precautions, if welding

 

4.c. Protect other nearby personnel with suitable, non-flammable

 

must

be performed

under electrically hazardous

 

 

 

screening and/or warn them not to watch the arc nor expose

 

conditions (in damp locations or while wearing wet

 

 

 

themselves to the arc rays or to hot spatter or metal.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

clothing; on metal structures such as floors, gratings or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

scaffolds; when in cramped positions such as sitting,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FUMES AND GASES

 

 

kneeling or lying, if there is a high risk of unavoidable or

 

 

 

 

 

 

 

accidental contact with the workpiece or ground) use

 

 

 

 

 

can be dangerous.

 

 

 

the following equipment:

 

 

 

 

 

 

 

 

• Semiautomatic DC Constant Voltage (Wire) Welder.

 

 

 

 

 

5.a. Welding

may

produce fumes

and

gases

 

• DC Manual (Stick) Welder.

 

 

 

 

 

 

hazardous to health. Avoid breathing these

 

 

 

 

 

 

 

• AC Welder with Reduced Voltage Control.

 

 

 

 

 

 

fumes and gases.When welding, keep

 

 

 

 

 

 

 

 

 

 

your head out of the fume. Use enough

3.c. In semiautomatic or automatic wire welding, the electrode,

 

 

 

 

 

 

ventilation and/or exhaust at the arc to keep

 

electrode reel, welding head, nozzle or semiautomatic

 

 

 

fumes and gases away from the breathing zone. When

 

welding gun are also electrically “hot”.

 

 

 

welding with electrodes which require special

 

 

 

 

 

 

 

ventilation such as stainless or hard facing (see

3.d. Always

be sure the work cable makes a good electrical

 

 

 

instructions on container or MSDS) or on lead or

 

connection with the metal being welded. The connection

 

 

 

cadmium plated steel and other metals or coatings

 

should be as close as possible to the area being welded.

 

 

 

which produce highly toxic fumes, keep exposure as

 

 

 

 

 

 

 

low as possible and below Threshold Limit Values (TLV)

3.e. Ground the work or metal to be welded to a good electrical

 

 

 

using local exhaust or mechanical ventilation. In

 

(earth) ground.

 

 

 

 

confined spaces or in some circumstances, outdoors, a

 

 

 

 

 

 

 

respirator may be required. Additional precautions are

3.f.

Maintain the electrode holder, work clamp, welding cable and

 

 

 

also

required

when

welding

on

galvanized

steel.

 

welding machine in good, safe operating condition. Replace

 

5. b. The operation of welding fume control equipment is affected

 

damaged insulation.

 

 

 

 

 

 

 

by various factors including proper use and positioning of the

 

 

 

 

 

 

 

3.g. Never dip the electrode in water for cooling.

 

 

 

equipment, maintenance of the equipment and the specific

 

 

 

welding

procedure

and

 

application

involved.

 

 

 

 

 

 

 

 

3.h. Never

simultaneously

touch electrically “hot” parts of

 

 

 

Worker exposure level should be checked upon installation

 

 

 

and periodically thereafter to be certain it is within applicable

 

electrode holders connected to two welders because voltage

 

 

 

 

 

 

 

OSHA PEL and ACGIH TLV limits.

 

 

 

 

 

between the two can be the total of the open circuit voltage

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

of both welders.

 

 

5.c. Do not weld in locations near chlorinated hydrocarbon vapors

 

 

 

 

 

3.i. When working above floor level, use a safety belt to protect

 

 

 

coming

from degreasing, cleaning

or

spraying

operations.

 

 

 

The heat and rays of the arc can react with solvent vapors to

 

yourself from a fall should you get a shock.

 

 

 

 

 

 

 

form phosgene, a highly toxic gas, and other irritating prod-

 

 

 

 

 

 

 

3.j.

Also see Items 6.c. and 8.

 

 

 

ucts.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5.d. Shielding gases used for arc welding can displace air and

 

 

 

 

 

 

 

cause injury or death. Always use enough ventilation,

 

 

 

 

 

 

 

especially in confined areas, to insure breathing air is safe.

 

 

 

 

 

5.e. Read and understand the manufacturer’s instructions for this

 

 

 

 

 

 

 

 

 

 

 

 

equipment and the consumables to be used, including the

 

 

 

 

 

 

 

material safety data sheet (MSDS) and follow your

 

 

 

 

 

 

 

employer’s safety practices. MSDS forms are available from

 

 

 

 

 

 

 

your

welding

distributor or

from

the manufacturer.

 

 

 

 

 

5.f. Also see item 1.b.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Aug ‘06

POWER FEED® 25M

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Contents Power Feed 25M Power Feed 25M SafetyFumes and Gases Electric Shock can killIii For ElectricallySûreté Pour Soudage a L’Arc Précautions DE SûretéElectromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Power Feed 25M K2536-1 InstallationSafety Precautions High Frequency Protection LocationElectric Shock can Kill Function Power Source Wire FeederWiring Digital Control CABLE, K1543-XXWeld Cable Size Coaxial Weld CableTable A.1 Build UP of Shielding GAS MAY Electrode Polarity Shielding GAS ConnectionGmaw GtawOFF Changing the Drive Motor Gear RatioProcedure to Install Drive Rolls and Wire Guides Wire Drive ConfigurationLoading Spools of Wire Remote Sense Lead SpecificationsTypical System Configurations Table of Contents Operation Section Operation Safety PrecautionsGeneral Description Definition of Welding TermsDuty Cycle Recommended Power Sources Recommended ProcessesEquipment Limitations Left Display window Connector for a remote control11. ON/OFF switch Pin connectorDefinition ON-OFF SwitchStatus LED Table B.1Smaw Stick Welding Technology Power Sources7OPERATIONB-7 Making a Weld with WaveformMSP4 Operation Process Mode8OPERATIONB-8 Smaw Stick Welding DisplayNON-SYNERGIC Gmaw and Fcaw WeldingThree non-synergic welding modes are available Non-Synergic Gmaw and Fcaw Welding Display Modes 5 MSP4 OperationFigure B.5 Gmaw MIG Synergic Welding220 26.4 ARC Control Steel and Stainless Synergic GMAW-P Pulsed MIG WeldingStainless Steel Gmaw Migwelding 220 Pulse-on-Pulse Welding 16OPERATIONB-16Aluminum Synergic GMAW-P Pulsed Migand GMAW-PP Pulse on PulseAluminum Pulse Welding Aluminum GMAW-P and GMAW-PPFigure B.14 Aluminum GMAW-P and GMAW-PP WeldingAluminum Pulse and Pulse-On-Pulse Synergic Weld Display Figure B.15 GMAW-STT WeldingGMAW-STT 109Figure B.16 TailoutGtaw TIG Welding Touch StartTIG OFF Feed 10A SET-UP Features MenuPower Feed 10M All ModelsQuick Preflow time will not be accessible from the MSP4 Operation PROCEDURE/MEMORY Panel Opera User Memories Tion Limits may be set for LimitsParameter Range Units MSP4 DisplayHigh Limit Low LimitParameter Name Item D Escription Internal ControlsStep Trigger Operation Cold FEED/GAS Purge SwitchLight Switch Heater SwitchWeld 34OPERATIONPreflow StrikeFigure B.20 Figure B.21 UpslopePostflow 37OPERATIONB-37Figure B.23 StartRear Controls DescriptionLiter/Min Operation on Lincnet Power SourcesFlow Meter ScfhTable of Contents Accessories Section Drive Roll Kits Used AccessoriesFactory Installed Equipment Wire Type Electrode Size KP KITK2593-xx #1 Co-Axial Power Cable Accessories K1500-5 Gun Receiver Bushing compatible Water cooling cover on the case front of the inner InstallationCooling KIT Use a 5/16 nut driver to remove the screws holdingFigure C.1 Python Water Cooled GunsPower Feed 25M Table of Contents Maintenance Section Calibration Specification MaintenanceRoutine Maintenance Periodic Maintenance1TABLE of CONTENTS-THEORY of Operation Section E-1 Figure E.2 General Physical Description Theory of OperationFigure E.3 GAS Solenoid Controls Power Feed 25MControl BOX User Interface Status Light States TroubleshootingComponent is causing the problem. By using the status Component Status LightsStatus Light States CON’T 1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Troubleshooting and RepairSee Setting DIP Switches Wire Drive Troubleshooting and Repair Output Problems Power Power source is functioning Make certain the Power WaveSetting Dip Switches in the Wire Troubleshooting and Repair Fault Code Description Possible Adjustments ArcLink System Error CodesPower Feed 25M Voltage Sense PC Board Test Test DescriptionMaterials Needed Figure F.1 Plug J1 and J2 Locations ProcedureTach Feedback Test Blue RED Drive Motor Test #550 #551 Gear BOX and Drive Motor Removal and Replacement Procedure Gear BOX Removal and Drive Motor Figure F.4 Gear BOX and Drive Motor Removal and ReplacementTo Remove the Wire Drive Assembly from the Gear BOX Replacement ProceduresTo Remove the Drive Motor from the Gear BOX Retest After Repair SET UPTable of Contents Diagram Section Wiring Diagram Complete Machine Code 11313 G5585 Electrical DiagramsG5638 Schematic Complete Machine Code 11313 G5638Schematic 42 VAC & Arclink Feeder PC Board #1 G3883-2 Schematic 42 VAC & Arclink Feeder PC Board #2 G3883-2 Schematic MSP4 Optional Display PC Board G4456 Schematic SPI Display PC Board L11756 PC Board Assembly SPI Display L11757-1 Schematic Voltage Sense Select PC Board S24779 PC Board Assembly Voltage Sense Select M19540 Schematic Spool GUN PC Board L12008 PC Board Assembly Spool GUN M20159