Lincoln Electric SVM189-B Safety Precautions, Select Suitable Location, Stacking, Tilting

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A-3

INSTALLATION

A-3

 

 

 

 

 

 

 

 

 

 

 

TECHNICAL SPECIFICATIONS

125 Amp units

 

 

 

 

 

 

 

 

 

INPUT – SINGLE PHASE ONLY

 

 

to Section

to Master

Standard Voltage/Frequency

120 V / 60 Hz

Input Current

20 Amps @ rated output

Return

Return

Duty Cycle

20% Duty Cycle

Welding Current Range

30-125 Amps

RATED OUTPUT

Current

90 Amps

OUTPUT

Maximum-Open Circuit Voltage

33 V

Voltage at Rated Amperes

19

Wire Speed Range

50 - 500 in/min.

(1.3 - 12.7 m/min.)

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RECOMMENDED INPUT CABLE AND FUSE SIZES

 

Input Voltage / Frequency

Fuse or Breaker Size1,2

Input Amps

 

Power Cord

Extension Cord

 

 

 

 

 

 

 

 

 

120 V

60 Hz

20 Amp

20

 

15 Amp, 125 V,

3 Conductor #12

AWG

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Three Prong Plug

(4mm2) or Larger

 

 

 

 

 

 

(NEMA Type 5-15P)

up to 50 ft.(15.2m)

 

 

 

 

 

 

 

 

 

 

 

PHYSICAL DIMENSIONS

 

 

 

 

 

 

 

 

 

 

 

Height

 

Width

 

Depth

 

 

Weight

13.7 in

 

10.15 in

 

17.9 in

 

 

48 Ibs

347 mm

258 mm

 

454 mm

 

 

21.7 kg

 

 

 

 

 

 

 

 

 

1If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.

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2Requirements For Maximum Output

In order to utilize the maximum output capability of the machine, a branch circuit capable of 25 amps at 120 volts, 60 Hertz is required.

Read entire installation section before starting installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

Only qualified personnel should perform this installation.

Only personnel that have read and under- stood the machine’s Operating Manual should install and operate this equipment.

Machine must be plugged into a recepta- cle which is grounded per any national, local or other applicable electrical codes.

The Machine power switch is to be in the OFF (“O”) position when installing work cable and gun and when connecting power cord to input power.

SELECT SUITABLE LOCATION

Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages and cause overheating.

STACKING

Compact Wire Welders cannot be stacked.

TILTING

Each machine must be placed on a secure, level sur- face, directly or on recommended cart. The machine may topple over if this procedure is not followed.

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 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- tionControls 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 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 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 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 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 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