Lincoln Electric SVM114-C Electric Shock can kill, Fumes and Gases, Can be dangerous

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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

 

electrode reel, welding head, nozzle or semiautomatic

 

 

 

 

fumes and gases away from the breathing zone. When

 

welding gun are also electrically “hot”.

 

 

 

 

welding with electrodes which require special

 

 

 

 

 

 

 

 

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

 

connection with the metal being welded. The connection

 

 

 

 

cadmium plated steel and other metals or coatings

 

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

 

 

 

 

which produce highly toxic fumes, keep exposure as

 

 

 

 

 

 

 

 

low as possible and below Threshold Limit Values (TLV)

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

 

 

 

 

using local exhaust or mechanical ventilation. In

 

(earth) ground.

 

 

 

 

 

confined spaces or in some circumstances, outdoors, a

 

 

 

 

 

 

 

 

respirator may be required. Additional precautions are

3.f.

Maintain the electrode holder, work clamp, welding cable and

 

 

 

 

also

required

when

welding

on

galvanized

steel.

 

welding machine in good, safe operating condition. Replace

 

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

 

damaged insulation.

 

 

 

 

 

 

 

 

by various factors including proper use and positioning of the

 

 

 

 

 

 

 

 

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

 

 

 

 

equipment, maintenance of the equipment and the specific

 

 

 

 

welding

procedure

and

 

application

involved.

 

 

 

 

 

 

 

 

 

3.h. Never

simultaneously

touch electrically “hot” parts of

 

 

 

 

Worker exposure level should be checked upon installation

 

 

 

 

and periodically thereafter to be certain it is within applicable

 

electrode holders connected to two welders because voltage

 

 

 

 

 

 

 

 

 

OSHA PEL and ACGIH TLV limits.

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

of both welders.

 

 

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

 

 

 

 

 

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

 

 

 

 

coming

from degreasing, cleaning

or

spraying

operations.

 

 

 

 

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

 

yourself from a fall should you get a shock.

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

3.j.

Also see Items 6.c. and 8.

 

 

 

 

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.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Aug ‘06

Image 3
Contents Semiautomatic Wire Feeder California Proposition 65 Warnings SafetyElectric Shock can kill Fumes and GasesCan be dangerous Welding and Cutting Sparks can Cause fire or explosion Cylinder may explode if damagedIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Section Table of ContentsCurrentrent InstallationTechnical Specifications LN-25 Wire Feed SpeedPower Source Connection Safety PrecautionsFor GMA GUN and Cables INVERTEC, CV300 and Other Newer Lincoln Power SourcesGUN Cable Connection to Feeder With CV AdapterWork Cable Connection Wire Feed Drive Roll and Guide Tube KitsWeld Cable Connection Electrode Cable ConnectionLN-25 Operation Section Operation Welding CapabilityRead and Understand Entire Section Before Operating Machine LN-25 Instruments Controls Electrode Polarity SwitchWire Feed Mode Switch Wire Speed Dial and Range SwitchRemote ARC Voltage Control Optional GAS Post PRE-FLOW Timers OptionalWork Clip Lead AWGMounting 10 to 30 LB Spools Sequence of OperationLoading Electrode Mounting 22 to 30 LB READI-REELCOILS6OPERATIONB-6 Loading Wire DriveIdle Roll Pressure Setting Grooves READI-REEL Inside Cage WiresMinimum Arc Volts Presetting Wire Feed SpeedSetting Constant Wire Feed Speed CV Mode Setting ARC Sensing Wire Feed Speed CC ModeMaking a Weld Figure B.4 VV CC Wire Speed SettingProcedure AT END of Coil WeldingCylinder may explode if damaged Circuit Protection and Automatic Shutdown Overvoltage ShutdownMotor Overload Shutdown Accessories Section C Accessories SectionTable C.1 AccessoriesLN-25 Option Chart How to use Table C.1Optional Accessories K434-1 GAS Flow Timer KITGAS Solenoid KIT K430-2 for Codes LN-25 Contactor KIT K443-1 for Codes K433 Power Source Remote BOXK432 Remote Control Cable Assembly Remote Output Control Options and Control Cable AssembliesK444, K444-1 or K444-2 Remote Voltage Control KIT K439 Remote Extension Cable AssemblyK625, K626, K627 Remote Control Cable Assembly K624-1 42V Remote Output Control ModuleDIA. Hole Connector Must be Insulated in this AreaTo GUN Switch Connect Leads to Pins a and C Style aMaintenance Section Maintenance Routine MaintenanceAdjusting Speed Sensor Module Calibration of LN-25 Wire Speed Dial LN-25 Theory of Operation Section Figure E.1 Theory of Operation Block DiagramControl Circuit Operation Input Power CircuitTheory of Operation General DescriptionTrigger Circuit Feedback and Control CircuitsLater Models Optional CircuitsContactor GAS SolenoidControl PC Board Fuses Protective Devices CircuitsLN-25 Troubleshooting and Repair Section HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Troubleshooting and RepairFeeding Problems Feeding Problems Hall Effect For Codes below 10500 only GAS Solenoid Valve and Solenoid PC Board TestTest Description Materials NeededGAS Solenoid Valve Test ProcedureScrew Wire Reel Retaining Collar Case DoorFigure F.2 Solenoid Leads Troubleshooting and Repair PC Board for K430 GAS Solenoid KIT GAS Solenoid Valve and Solenoid PC Board Test512 624A 621 J11LN-25 For Codes Above 10500 only GAS Solenoid Valve and Control PC Board TestFigure F.5 Control BOX Cover Removal For Codes Above 10500 onlyFigure F.6. Solenoid Leads Solenoid LeadsControl PC Board Solenoid Circuitry Test Figure F.7. Applied Voltage Polarity667 555 691 621 500 512 690 G3425LN-25 Hall Effect Module Test Hall Effect Module Test G2196 539 541 500539 G1757 Figure F.11 Control PC Board Codes Above LN-25 Wire Drive Motor Test Drive Motor Lead IN-LINE Connector Hall Effect Module Contactor & Contactor PC Board Test Contactor & Contactor PC Board Test Contactor Test ProcedureContactor Coil Leads S2096328TROUBLESHOOTING and Repair F-28 Contactor PC Board Test667 J14 LN-25 Tools Required Contactor PC Board ReplacementRepair Procedure Contactor PC Board Replacement33TROUBLESHOOTING and Repair F-33 Figure F.17 Control PC Board Replacement Figure F.21. Control PC Board Codes 9812 and below Control PC Board ReplacementJ14 Figure F.22. Plug Locations for L12253- Control BoardFigure F.24. Control Board Replacement PC Board Screw For Codes below Contactor ReplacementContactor Replacement 40TROUBLESHOOTING and Repair F-40For Codes Above Figure F.26 Phillips Head Screwdriver Wrench Pliers GAS Solenoid Present ReplacementPurge Switch Leads Solenoid Plug J11 GAS Solenoid Valve AND/OR Solenoid PC Board ifFigure F.29. Solenoid Assembly Wiring Codes 9812 and below Figure F.31. GAS Solenoid Assembly for Earlier Codes Phillips Head Screwdriver Wrench Slot Head Screwdriver Mylar Insulation Electrode Cable 48TROUBLESHOOTING and Repair F-48Drive Motor and Gearbox Replacement and Access to Hall Effect ModuleG1757 Figure F.34. Drive Motor Replacement Retest After Repair LN-25 Table of Contents Electrical Diagrams Section Electrical DiagramsOptional 42 Volt Remote Output Control Wiring Diagram Above Code 11140 G4679Wiring Diagram Code 10556 Thru 10500 L10925 Wiring Diagram Code 10100 Thru 10500 L9644 Wiring Diagram below Code 9900 L7545 LN-25 Across the ARC Model Schematic Complete Machine Codes Above 11140 G5366Schematic Complete Machine below Code 9900 only G1833 Schematic Control PC BD Above Code 11140 G4616-5 Schematic Control PC BD Code 10556 Thru 10558 G3424-3 Schematic Control PC BD Code 10100 Thru 10500 G2194 PC Board Assembly Control Abovr Code 11140 L12253-3 L12253L12253-3 G3425 PC Board Assembly Control Code 10556 Thru 10558 G3425-3PC Board Assembly Control Code 10100 Thru 10500 G2196-1 LN-25 Control PC Board Assembly Control below Code 9900 G1757-6Contactor Schematic Contactor PC BD Above Code 10500 M10965Schematic Contactor PC BD Code 10100 Thru 10500 M17621 Electrical Diagrams Electrical Diagrams L10863 PC Board Assembly Contactor Above Code 10500 L10863-1PC Board Assembly Contactor Code 10100 Thru 10500 L9670-1 PC Board Assembly Contactor below Code 9900 L9185-2