Lincoln Electric SVM189-B service manual Electronic Wire Drive Motor Protection

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E-7	THEORY OF OPERATION	E-7

THERMAL PROTECTION

The Compact Wire Welders have a rated output duty cycle as defined in the Technical Specification page. If the duty cycle is exceeded, a thermal protector will shut off the output until the machine cools to a reasonable operating temperature. This is an automatic function of and does not require user intervention. The fan contin- ues to run during cooling. If the fan is not turning or the air intake louvers become obstructed, the input power must then be removed and the fan problem or air obstruction corrected.

OUTPUT OVERLOAD

The Compact Wire Welders are equipped with a circuit breaker which protects the machine from damage if maximum output is exceeded. The circuit breaker must be manually reset.

ELECTRONIC WIRE DRIVE MOTOR PROTECTION

The Compact Wire Welders built-in protection for wire drive motor overload.

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