Lincoln Electric SVM157-A service manual Accessories, Drive Roll Kits, K363P READI-REEL Adapter

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C-2

ACCESSORIES

C-2

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DRIVE ROLL KITS

Refer to Table C.1 for various drive roll kits that are available for the POWER MIG 200.The item in Bold is supplied standard with the POWER MIG 200.

 

Wire

Size

Drive Roll Kit

 

 

 

 

 

Solid

.023”-.030” (0.6-0.8 mm)

KP1696-030S

 

.035” (0.9 mm)

KP1696-035S

 

Steel

 

.045” (1.2 mm)

KP1696-045S

 

 

 

 

 

 

 

Cored

.035” (0.9 mm)

KP1697-035C

 

.045” (1.2 mm)

KP1697-045C

 

 

 

 

 

 

 

Aluminum

3/64” (1.2 mm)

KP1695-3/64A

 

 

 

 

TABLE C.1

3/64" (1.2 mm) ALUMINUM FEEDING KIT (K1703-1)

This kit helps push feeding aluminum through standard machine feeder and gun. It provides gun and wire drive conversion parts to weld with 3/64" (1.2 mm) aluminum wire. 5356 alloy aluminum wire is recommended for best push feeding performance.

Kit includes drive rolls and wire guide plate for the wire drive, liner and two contact tips for the gun, along with installation instructions.

K363P READI-REEL ADAPTER

The K363P Readi-Reel Adapter mounts to the 2" spin- dle. It is needed to mount the 22-30 lb. Readi-Reels.

DUAL CYLINDER MOUNTING KIT (K1702-1)

Permits stable side-by-side mounting of two full size (9" dia. x 5' high) gas cylinders with “no lift” loading. Simple installation and easy instructions provided. Includes upper and lower cylinder supports, wheel axles and mounting hardware.

ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES

The following Magnum 250L gun and cable assemblies are separately available for use with the POWER MIG

200.Each is rated 200 amps 60% duty cycle and is equipped with the integrated connector, twist-lock trig- ger connector, fixed nozzle and insulator, and includes a liner, diffuser, and contact tips for the wire sizes spec- ified:

 

 

English Wire

Metric Wire

Length

Part No.

Size

Size

10' (3.0 m)

K533-1

 

 

12' (3.6 m)

K533-2

.035– .045"

0.9 – 1.2 mm

15' (4.5 m)

K533-3

 

 

 

 

 

 

10' *3.0 m)

K533-4

 

 

12' (3.6 m)

K533-5

.025– .030"

0.6 – 0.8 mm

15' (4.5 m)

K533-6

 

 

 

 

 

 

TABLE C.2

MAGNUM GUN CONNECTION KIT (Optional K466-6)

Using the optional K466-6 Magnum Connection kit for the POWER MIG permits use of standard Magnum 200, 300 or 400 gun and cable assemblies.

SPOOL GUN AND ADAPTER KIT (K1809-1)

The K1809-1includes the Magnum 250SG Spool gun and the adapter kit for connecting the spool gun to the Power MIG 200.

The Adapter Kit provides toggle switch selection between the machine’s use with its feeder gun or the spool gun for same polarity welding with different wire and gas processes.

The kit includes a spool gun adapter module assembly with a single connecting plug and trigger switch, a rear gas inlet, fitting hose, solenoid valve assembly, and mounting hardware with installation and operation instructions.

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WARNING

Remove all input power to the POWER MIG 200 before installing the Spool Gun and Kit.

POWER MIG 200

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Contents Power MIG Safety Depends on YouSafety California Proposition 65 WarningsElectric Shock can kill ARC Rays can burnCylinder may explode if damaged IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionInstallation Technical Specifications Power MIG3INSTALLATIONA-3 Figure A.1 Dual Voltage Machine Input Connections Output Polarity Connections Figure A.2 Triple Voltage Machine Input ConnectionsCylinder may explode if damaged GUN and Cable InstallationShielding GAS Operation Section Operation Section BOperation Wear eye, ear and body protec- tionWire Drive Roll Wire Size Conversion PartsProduct Description Recommended Processes and EquipmentTo Start the Welder Procedure for Changing Drive and Idle Roll SetsWire Reel Loading READI-REELS, Spools or Coils Feeding Wire Electrode Making a Weld Idle Roll Pressure SettingAvoiding Wire Feeding Problems Wire Feed Overload ProtectionFAN Control Input Line Voltage VariationsAccessories Section Accessories Drive Roll KitsK363P READI-REEL Adapter Dual Cylinder Mounting KIT K1702-1Installed Adapter KIT and Spool GUNPower MIG Maintenance Section Maintenance Cause poor wire feeding Liner Removal and REPLACE- MentThis screw should only be gently tightened Overtightening will split or collapse the linerGUN Handle Disassembly English Metric Description SizeMaintenance Power MIG Line Switch Theory of Operation SectionTheory of Operation Output Rectification Contactor and Control Board Motor Control BoardControl BOARD, GUN Trigger and Wire Drive Motor Figure E.4 Optional CircuitsWirefeed Overload Protection Thermal and Overload ProtectionPower MIG Troubleshooting and Repair Section Troubleshooting and Repair Section FTroubleshooting and Repair How To Use Troubleshooting GuidePC Board Troubleshooting Procedures Perform the Main Transformer Perform the Output Contactor Your body These capacitors is toxicAvoid contact with any portion Function Problems Tachometer Feedback Test Welding Problems Weld bead is narrow or ropy Make sure the welding proce Materials Needed Main Transformer TestTest Description ON/OFF Power Switch will be hot during these tests Main Transformer TestX10 Table F.1. Test Points Input Voltage Test PointsWire Drive Motor and Tachometer Feedback Test Test Procedure Figure F.4. Plug J4Disconnect the main AC input power to the machine Test for Supply Voltage to TachometerTest for Feedback Voltage to Control Board VDCOutput Bridge Rectifier Test Test Procedure Output Bridge Rectifier TestContactor Test Contactor Test Figure F.7. Contactor Terminals and LeadsVolts 10.0 Typical Output Voltage Waveform Machine Loaded MAX TAP GVolts 20.0 Normal Open Circuit Voltage Waveform MAX TAP GMachine Loaded to 180 Amps AT 16 VDC Scope Settings Volts 20.0 Control Board Replacement DescriptionControl Board Replacement ProcedureWire Drive Motor Assembly Replacement Wire Drive Motor Assembly Replacement Wire DriveBolt Gas Hose TOC Output Diode Bridge Rectifier Replacement Output Diode Bridge Rectifier Mounting Bracket Mounting Bolts Rectifier Power MIG Output Capacitors Replacement Output Capacitors Replacement Figure F.14. Capacitor Bank LocationLead Mounting Bolts Nuts & Lock washers Places Power MIG 41TROUBLESHOOTING and REPAIRF-41 Main Transformer ReplacementMain Transformer Replacement See Figure F.17Replacement Figure F.17. Leads X9, X10, 104B,104C, & H1BX2 X3 X4 X5 X6 X7 Lead Power MIG FAN BLADE/MOTOR Replacement FAN BLADE/MOTOR Replacement Perform the Output Capacitor Bank Removal ProcedureOutput Contactor Replacement Output Contactor Replacement Figure F.24Mounting Bolts Retest After Repair Electrical Diagrams Table of Contents Electrical Diagrams SectionPower MIG 200 208/230V Wiring DiagramSchematic Control PC Board PC Board ASSEMBLY-CONTROL G3851-1SVM Error Reporting Form
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