Lincoln Electric SVM144-B 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. All items in Bold are supplied standard with the POWER MIG.

TABLE C.1 — AVAILABLE DRIVE ROLL KITS.

Wire

Size

Drive Roll Kit

 

 

 

Solid

0.023-0.030 in. (0.6-0.8 mm)

KP1696-030S

0.035 in. (0.9 mm)

KP1696-035S

Steel

0.045 in. (1.2 mm)

KP1696-045S

 

 

 

 

Cored

0.035 in. (0.9 mm)

KP1697-035C

0.045 in. (1.2 mm)

KP1697-045C

 

 

 

 

Aluminum

3/64 in. (1.2 mm)

KP1695-3/64A

 

 

 

3/64 in. (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 in. (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.

ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES

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

255.Each is rated 200 amps 60% duty cycle (or 250 amps 40% duty) and is equipped with the integrated connector, twist-lock trigger connector, fixed nozzle and insulator, and includes a liner, diffuser, and contact tips for the wire sizes specified:

 

 

English Wire

Metric Wire

Length

Part No.

Size

Size

10 ft (3.0 m)

K533-1

 

 

*12 ft (3.6 m)

K533-7

0.035 – 0.045 in.

0.9 – 1.2 mm

15 ft (4.5 m)

K533-3

 

 

*Fixed Nozzle

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.

TIMER KIT INSTALLATION (Optional K1701-1)

The timer kit adds selectable 4-step trigger interlock, spot and Run-In functions and manual adjustment of burnback time. Install as follows, or per the instructions included with the kit:

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K363P READI-REEL ADAPTER

The K363P Readi-Reel adapter mounts to the 2 in. spindle. 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 in. dia. x 5 ft. high) gas cylinders with “no lift” loading. Simple installation and easy instructions provided. Includes upper and lower cylinder supports, wheel axles and mounting hardware.

WARNING

Remove all input power to the POWER MIG 255 before proceeding.

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1.Verify that the following items have been included in the kit:

a.Timer board with harness and panel assembly.

b.Two screws.

2.Turn the power switch off and disconnect power from the machine to prepare for kit installation.

POWER MIG 255

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Contents Power MIG Safety Electric Shock can kill Safety Welding Sparks can cause fire or explosionPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionInstallation Technical Specifications Power MIGUncrating the Power MIG Safety PrecautionsLocation Power MIG Figure A.2 Triple Voltage Machine Input Connections GUN and Cable Installation Shielding GASOperation Section Section BOPERATIONB-2 Fumes and Gases can be dangerousWelding Capability OperationProduct Description LimitationsDescription of Controls Procedure for Changing Drive and Idle Roll Sets Wire Reel Loading READI-REELS, SPOOLS, or CoilsIdle Roll Pressure Setting Feeding Wire ElectrodeSetting RUN-IN Speed on STAN- Dard Power MIG Feeder To Start the WelderAvoiding Wire Feeding Problems Making a WeldFAN Control Input Line Voltage ProtectionAccessories Section Section CK363P READI-REEL Adapter AccessoriesDrive Roll Kits Dual Cylinder Mounting KIT K1702-1Operating Instructions For Timer KIT Making a Weld with the Spool GUN, Spool GUN Installed Spool GUN Adapter KITMaintenance Section Section DRoutine and Periodic Maintenance MaintenanceGUN Tubes and Nozzles Figure D.1 Component Locations Contact TIP and GAS Nozzle Installation Liner Removal Replacement5MAINTENANCED-5 To open up the handleTable D.2 Description English Size Metric SizeTheory of Operation Section Section EInput Line Voltage Theory of OperationMain Transformer Output Rectification Feedback ControlConstant Voltage Output Figure E.4 Constant Voltage OutputWire Drive Motor FeedbackThermal and Overload Protection Wire Feed Overload ProtectionOvercurrent Protection SCR Operation Figure E.6 SCR OperationPower MIG Troubleshooting & Repair Section Section FTroubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures WorkstationsOutput Problems SCR Rectifier Rectifier Function Problems Wire Feeding Problems Welding Problems Welding Problems Main Transformer Test Test DescriptionTest Procedure Main Transformer TestFigure F.1 Troubleshooting and Repair Test Description Rectifier Diode Bridge TestMaterials Needed Rectifier Diode Bridge Testing 208R 206 28 VAC 209R Power MIG Static SCR Rectifier Assembly Test Static SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Power MIG Active SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Figure F.7 Location Leads X2 Open switch SW-1 Wire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test for Supply Voltage to Tachometer 515B 206B 15 VDC 5J1 1J1Test for Feedback Voltage to Control Board 555 206B To 3.5 VDC 6J1 1J1Normal Open Circuit Voltage Waveform VoltsMachine Loaded to 250 Amps AT 26 VDC Scope Settings Typical Output Voltage Waveform Machine LoadedMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Power MIG Control PC Board Removal and Replacement Procedure DescriptionRemoval and Replacement Procedure Control PC BoardFigure F.11 Control Board Mounting Power MIG 41TROUBLESHOOTING & REPAIRF-41 Wire Drive Assembly Removal and Replacement ProcedureWire Drive Assembly Removal and Replacement ProcedureTOC Power MIG SCR Output Rectifier Removal and Replacement Procedure SCR Output Rectifier Removal and Replacement Figure F.15 Right Heat Sink Lead Disconnection Power MIG Capacitor Bank Removal and Replacement Procedure Capacitor Bank Removal and Replacement Troubleshooting & Repair Removal and Replacement Main Transformer and Output ChokeTOC Power MIG FAN Motor Assembly Removal and Replacement Procedure FAN Motor Assembly Removal and Replacement Retest After Repair Troubleshooting and RepairWire Speed Range Open Circuit VoltagePower MIG Electrical Diagrams Section Power MIG 255 208/230V Wiring Diagram Entire Machine Code 10563 L10979Power MIG 255 230/460/575V Wiring Diagram Entire Machine Code 10583 L10980Power MIG 255 230/460/575 Wiring Diagram Entire Machine Code 10986 L11980Power MIG 255 208/230 Wiring Diagram Entire Machine Code 10990 L11979Control PC Board Schematic G3520-1D1 Control PC Board Assembly G3521-1 3521Display PC Board Schematic L10951 PowermigDisplay PC Board Assembly L10952-1 Lincoln Electric COSnubber PC Board Schematic S24374 24374 SSnubber PC Board Assembly M19248-1 00 ~.04SVM Error Reporting Form