Lincoln Electric SVM189-B service manual Connect Leads and Cables on, Machine, Load Wire Spool

Page 17

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B-7

OPERATION

B-7

 

 

B. CONNECT LEADS AND CABLES ON

LOCATE COMPONENTS

FIGURE B.7

THE MACHINE

 

TO CONNECT TO THE

 

 

FRONT OF MACHINE

 

 

 

 

 

 

 

CASE SIDE DOOR

(See Figure B.7)

 

 

 

1. Open the case side door

 

 

 

2. Slide the connector end of the gun and cable

SLIDE

OPEN LATCH DOOR

 

 

 

 

CONNECTOR

through the hole in the machine front and into the

 

END HERE

TERMINAL END

 

 

gun connector bushing on the wire drive.

 

 

 

 

(FITS ON STUD INSIDE

 

 

 

SEE FIGURE BELOW)

3. Make sure the gun connector end is seated fully

into the wire drive and tighten the thumbscrew to

secure the gun connector.

4. Plug the gun trigger lead connector into the 4 pin

gun trigger receptacle on the machine front.

(4 PIN)

 

LEAD CONNECTOR

 

 

WORK CLAMP

 

ALL COMPONENTS SHOWN CONNECTED

 

(FRONT AND SIDE DOOR IS REMOVED

GUN AND CABLE

FOR CLARITY)

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5.

Wire Drive Polarity. Flux cored welding requires

 

negative (-) polarity. Connect the short power cable

 

from the wire drive to the negative (-) output termi-

 

nal and tighten the thumbscrew.

6.

Work Lead Connection. Slide the lugged end of the

 

work cable through the hole in the machine front

 

and place on the positive (+) output terminal and

 

tighten thumbscrew.

C. LOAD WIRE SPOOL

THUMB SCREW TO

TIGHTEN CONNECTOR

BUSHING

CONNECTOR

END ATTACH

(4 PIN) TRIGGER RECEPTACLE PLUGGED IN

WORK CLAMP

SHORT POWER CABLE NEGATIVE "-" OUTPUT TERMINAL

WORK LEAD

CONNECTION

POSITIVE "+"

OUTPUT TERMINAL

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(See Figure B.8)

1.Locate the blue labeled 4"(102mm) diameter spool of .035”(0.9mm) NR-211MP flux-cored wire and place onto wire spool spindle. Orient the spool so that the wire feeds off the top of the spool.

2.Secure spool in place by tightening the wing nut against the against the spacer that holds the wire spool on the spindle.

3.Open the top drive roll pressure arm by rotating the tension adjustor arm down and pivoting the drive roll pressure arm up.

4.Remove the outer wire guide.

4a. Slide gun out of drive slightly.

5.Remove the lower drive roll and inner wire guide.

6.Install the .025”-.035”(0.6mm-0.9mm) inner wire guide.

7.Install the .030”/.045”(0.8mm/1.1mm) knurled lower drive roll.

8.Carefully unwind and straighten the first six inches of welding wire from the spool. Do not let the end of the wire go to prevent the wire from unspooling.

FIGURE B.8

TOP DRIVE ROLL PRESSURE ARM

TENSION ADJUSTOR DOWN

WIRE SPOOL

.035" (0.9mm)

NR-211-MP

INNER WIRE GUIDE REMOVED

LOWER DRIVE ROLL REMOVED

OUTER WIRE

GUIDE REMOVED

COMPACT WIRE WELDERS

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Contents SVM189-B Safety Depends on YouCalifornia Proposition 65 Warnings SafetyElectric Shock can kill ARC Rays can burn Iii Welding CuttingFor Electrically Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications InstallationSelect Suitable Location Safety PrecautionsStacking TiltingIdentify and Locate Components Table of Contents Operation Section Product Description Product Capabilities OperationCommon Welding Abbreviations Wear eye, ear and body protec- tionSee Figure B.2 Controls and SettingsSee Figure B.1 Drive Roll Tension Thumbscrew Turning See Figure B.3Number Part Number Wire Diameter Drive Roll Drive Roll Part Inner Wire GuideItems Needed for Flux Cored Welding Setting UP and Making a FLUX-CORED WeldMachine Load Wire SpoolConnect Leads and Cables on Figure B.9 025 MIG Conversion Kit K2526-1Shielding GAS Install Shielding GASConnect Leads and Cables on the Machine 11OPERATIONDo not Remove or Conceal Warning Labels 12OPERATIONFigure B.20 Compact Wire Welders Table of Contents Accessories Section K2525-1 Spot Timer Kit AccessoriesK2532-1 Magnum 100SG Spool Gun K2377-1 Small Canvas CoverK520-Utility Cart K2275-1 Welding Cart Unpacking the Spool GUN Technical Specifications Magnum 100SG Spool GUN K2532-1Locating Spool GUN Components Features Safety PrecautionsFigure C.3 Assembly of Items Inside the Magnum Spool GUNSpool GUN Safety Precautions Welding MachinesRecommended Welding Machines Open the Machine Spool GUN / Wire Drive Selector Switch InstallationDisconnect input power from the machine 11.C. Connect harness P8 6-pin to board J5 6- pin Electrical Connections11.B. Connect P5 6-pin to harness J8 6-pin 544A 543A If Machine does have Optional Spot Timer .A. thru 12.DRE-ASSEMBLE Machine AS Follows Mounting the SwitchDisconnect input power to the machine ACCESSORIESC-13Routine Welding Machine Preparation Preparing the Spool GUNFigure C.5 Loading Aluminum WireFigure C.11 Figure C.17 Connecting the GUN to the Welding MachineTable of Contents Maintenance Section Routine Maintenance MaintenanceMaintenance Safety Precautions For Magnum 100L GUN GUN and Cable MaintenanceOverload Protection Liner trim length Changing LinerGUN Handle Parts Major Component Locations Maintenance 1TABLE of CONTENTS-THEORY of Operation Section E-1 General Description Theory of OperationInput Line VOLTAGE, FAN Motor & Main Transformer Figure E.3 Input Power CircuitsFigure E.4 Output Circuits Output CONTROL, Rectification & Voltage FeedbackFigure E.5 TRIGGER, GAS Solenoid & Wire Drive TRIGGER, GAS Solenoid and Wire DriveFigure E.6 SCR Operation SCR OperationElectronic Wire Drive Motor Protection Compact Wire Welders Table of Contents Troubleshooting & Repair HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board Troubleshooting Procedures Wiring Diagram OUTPUT/FEEDING Problems Feeding Problems Welding Problems Maintenance Section Issues Maintenance Section Cone or gas diffuser Materials Needed Case Cover Removal and Replacement ProcedureTest Description Figure F.1 Case Removal ProcedureGAS Solenoid Test GasSolenoid Leads Wire Drive Motor Test MOT-MOT+ Test ProcedureMain Transformer Test Secondary Test Procedure Secondary Lead Compact Wire Welders FAN Motor Test Figure F.5. Control Board Lead Locations Volts 10Volts 20ms Scope SettingsTypical Output Voltage Waveform Machine Loaded Abnormal Open Circuit Voltage Waveform Control Board Removal and Replacement Procedure See Figure F.7 Nameplate Control Knob Compact Wire Welders Power Module Removal and Replacement Procedure Viewed from Rear of Machine Center Panel PolarityPanel CenterPanelScrews OutputStuds Compact Wire Welders Misc. Hand Tools Dow Corning Fine Steel Wool See Figure F.12 Dow Corning Figure F.12 DOW Corning Application Areas Transformer Compact Wire Welders Wire Drive Motor Removal and Replacement Procedure Lincolnelectric Phillips Mounting Screws Compact Wire Welders FAN Motor Assembly Removal and Replacement Procedure Viewed from Rear of Machine Center Panel CenterPanelScrews Locking Tabs Fan Wire Speed Range Troubleshooting & Repair Retest After Repair 125 AMP UnitsRetest After Repair 140 AMP Units Open Circuit VoltageTroubleshooting & Repair Retest After Repair 180 AMP Units Table of Contents Diagram Section COmpacT WirE WElDErS Wiring DiagramSpool GUN Interface Wiring Diagram Wiring Diagram Thermostat TMP FAN TS1 M20410-3 a COmpacT WirE WElDErSSchEmaTic cOmplETE machiNE m21240 C12 R1Feed R24
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