Lincoln Electric SVM189-B service manual Electric Shock can kill ARC Rays can burn

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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

 

 

 

 

fumes

and

gases

away from

the breathing

zone. When

electrode

reel,

welding head, nozzle

or

semiautomatic

 

 

 

 

 

 

 

 

welding

with

electrodes

which

require

special

welding gun are also electrically “hot”.

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

cadmium

plated

steel and

other metals

or

coatings

connection

with

the

metal

being

welded. The connection

 

 

 

 

 

 

 

 

which produce highly toxic fumes, keep exposure as

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

 

 

 

 

 

 

 

 

low as possible and within applicable OSHA PEL and

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

ACGIH TLV limits using local exhaust or mechanical ven-

 

 

 

 

tilation. In confined spaces or in some circumstances,

(earth) ground.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

outdoors, a respirator may be required. Additional pre-

 

 

 

 

 

 

 

 

 

 

 

 

3.f. Maintain the electrode holder, work clamp, welding cable and

 

 

 

 

cautions are also required when welding on galvanized

 

 

 

 

steel.

 

 

 

 

 

 

 

 

welding machine in good, safe operating condition. Replace

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

damaged insulation.

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

by various factors including proper use and positioning of the

 

 

 

 

 

equipment, maintenance of the equipment and the specific

 

 

 

 

 

 

 

 

 

 

 

 

3.h. Never simultaneously touch electrically

“hot” parts of

 

 

 

 

welding procedure and application involved. Worker expo-

 

 

 

 

sure level should be checked upon installation and periodi-

electrode holders connected to two welders because voltage

 

 

 

 

 

 

 

 

cally thereafter to be certain it is within applicable OSHA PEL

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

 

 

 

 

 

 

 

 

and ACGIH TLV limits.

 

 

 

 

 

of both welders.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

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

 

 

 

 

coming from degreasing, cleaning or spraying operations.

yourself from a fall should you get a shock.

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

3.j. Also see Items 6.c. and 8.

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

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.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 Welding Cutting For ElectricallyIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications InstallationTilting Safety PrecautionsSelect Suitable Location StackingIdentify and Locate Components Table of Contents Operation Section Wear eye, ear and body protec- tion OperationProduct Description Product Capabilities Common Welding AbbreviationsControls and Settings See Figure B.1See Figure B.2 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 WeldLoad Wire Spool Connect Leads and Cables onMachine 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 K2377-1 Small Canvas Cover AccessoriesK2525-1 Spot Timer Kit K2532-1 Magnum 100SG Spool GunK520-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 GUNSafety Precautions Welding Machines Recommended Welding MachinesSpool GUN Spool GUN / Wire Drive Selector Switch Installation Disconnect input power from the machineOpen the Machine Electrical Connections 11.B. Connect P5 6-pin to harness J8 6-pin11.C. Connect harness P8 6-pin to board J5 6- pin 544A 543A If Machine does have Optional Spot Timer .A. thru 12.DRE-ASSEMBLE Machine AS Follows Mounting the SwitchPreparing the Spool GUN ACCESSORIESC-13Disconnect input power to the machine Routine Welding Machine PreparationFigure C.5 Loading Aluminum WireFigure C.11 Figure C.17 Connecting the GUN to the Welding MachineTable of Contents Maintenance Section Maintenance Maintenance Safety PrecautionsRoutine Maintenance GUN and Cable Maintenance Overload ProtectionFor Magnum 100L GUN Changing Liner GUN Handle PartsLiner trim length 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 Case Cover Removal and Replacement Procedure Test DescriptionMaterials Needed 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 Scope Settings Typical Output Voltage Waveform Machine LoadedVolts 10Volts 20ms 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 Open Circuit Voltage Troubleshooting & Repair Retest After Repair 125 AMP UnitsWire Speed Range Retest After Repair 140 AMP UnitsTroubleshooting & 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