Lincoln Electric SVM 117-A Safety Precautions, Select Proper Location, Input Connections, Tilting

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A-2

INSTALLATION

A-2

 

 

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Read entire Installation Section before installing the WIRE-MATIC 250

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should install this machine.

Turn the input power OFF at the dis- connect switch or fuse box before working on the equipment.

Do not touch electrically hot parts.

Always connect the WIRE-MATIC 250 ground- ing terminal to a good electrical earth ground through the cable plug per the National Electrical Code.

Set the Wire-Matic 250 ON/OFF Power switch to the OFF position when connecting power cord to input power.

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SELECT PROPER LOCATION

Place the WIRE-MATIC 250 where clean, cooling air can freely circulate in through the case back louvers and out through the case front louvers. Dirt, dust, or any foreign material that can be drawn into the machine case back louvers should be kept at a mini- mum. Not following these precautions can result in the nuisance shutdown of the machine because of exces- sive operating temperatures.

INPUT CONNECTIONS

WARNING

All input power must be electrically disconnected before proceeding.

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1.Before starting the installation, check with the local power company to determine if there is any ques- tion about whether your power supply is adequate for the voltage, amperes, phase, and frequency specified on the welder nameplate. Be sure the planned installation will meet the U.S. National Electrical Code and local code requirements. This welder may be operated from a single phase line or from one phase of a two or three phase line.

2.Models that have multiple input voltages specified on the nameplate (e.g., 208/230) are shipped con- nected for the highest voltage. If the welder is to be operated at a lower voltage, it must be recon- nected according to the instructions on the inside of the removable panel (Reconnect Access Door) near the top left side of the Case Back Assembly. See the Reconnect Section of this manual for details on reconnecting the machine to operate at different voltages.

3.Be sure the voltage, phase, and frequency of the input power is as specified on the machine rating plate. See Figure A.1 for the location of the machine's input cord entry, Reconnect Access Door, and Reconnect Panel, and Rear Nameplate.

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STACKING

The WIRE-MATIC 250 cannot be stacked.

TILTING

The Wire-Matic 250 must be placed on a stable, level surface so it will not topple over. Do not place the machine on an incline.

FIGURE A.1 - Case Back Assembly: Input Power

Cable Entry Connections.

WIRE-MATIC 250

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Contents Safety Depends on You WIRE-MATICARC Welding can be hazardous SafetyCylinder may explode if damaged Iii Electric and MAG- Netic FieldsSûreté Pour Soudage a L’Arc Précautions DE SûretéWIRE-MATIC Table of Contents Table of Contents Installation Type 750C Copper Duty Cycle Amps Volts at Rated AmpsCurrent Range Fuse SuperlagStacking Safety PrecautionsSelect Proper Location Input ConnectionsInput Power Connections and Ground Connections Fuse and Wire SizesConnect Shielding GAS Figure A.4 Input Air Supply Connections Reconnect ProcedureFigure A.5 Reconnect Diagram For 208/230/1/60 Machines Output Polarity Connection InstallationInstall the Work Clamp Connect Output Components GUN Liner and ContactGUN and Cable Installation Wire Size Conversion PartsWIRE-MATIC Operation WELDING, Cutting Safety InstructionsGeneral Description Recommended Processes and Equipment Design Features AdvantagesUnit Features Power Source FeaturesDuty Cycle Amps Volts Wire Feeder FeaturesMachine Capability LimitationsFigure B.1 Operator Controls Controls and SettingsLoading the Wire Reel Using the Wire Drive RollProcedure for Changing Drive Roll To mount 10 to 30 lb. spools 8 and 12 diameter Proper Wire FeedingFeeding Electrode Starting the Welder Setting Idle Roll PressureOperating Steps Making a Weld WIRE-MATIC Accessories K607-1 Spool GUN Adapter KIT OPTIONS/ACCESSORIESInstalling the K607-1 Spool GUN Adapter KIT Spool GUN Module Board InstallationReturn Return to Section TOC Spool GUN Connection BOX InstallationSpool GUN Preparation Spool GUN ConnectionMaking the Weld Making a Weld with the Spool GUN Adapter K607-1 InstalledTimer KIT K585-1 To Make Spot Plug Welds Steel Wire Sizes Part NumberAluminum Wire Sizes Drive Roll KitsMaintenance Perform the following daily Routine and Periodic MaintenanceMaintenance DROP-IN Reel Spindle and Clips Contact TIP and GAS Nozzle InstallationCable Cleaning Drive Rolls and Guide Tubes GUN Tubes and NozzlesFigure D.2 Liner maintenance Liner Removal ReplacementTo open up the handle GUN Handle DisassemblyDescription English Size Metric Size WIRE-MATIC Theory of Operation Transformer Input Line Voltage and MainFeedback Control Output RectificationFigure E.4 Constant Voltage Output Constant Voltage OutputFeedback Wire Drive MotorThermal Protection Figure E.6 SCR Operation SCR OperationWIRE-MATIC Troubleshooting & Repair Recommended Course of Action HOW to USE Troubleshooting GuideBoard can be dam- aged by static electricity PC Board Troubleshooting ProceduresElectric Shock can kill Main Transformer Rectifier Assembly Test To Section TOC Perform the SCR Rectifier Perform the Wire Drive Motor Trolyte in these capacitors is Liquid elecPerform the Output Rectifier Materials Needed Main Transformer TestTest Description ON/OFF Power Switch will be hot during these tests Main Transformer Test Test ProcedureMain Transformer Test Static SCR Rectifier Assembly Test Leads Figure F.4 SCR 1 Test Points Active SCR Rectifier Assembly Test Leads SCR connections Figure F.7 SCR Tester CircuitWire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test Procedure Test for Feedback Voltage to the Control Board Test for Supply Voltage to TachometerNormal Open Circuit Voltage Waveform Scope SettingsTypical Output Voltage Waveform Machine Loaded Machine Loaded to 250 Amps AT 26 VDC Scope SettingsMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Materials Needed Control PC Board Removal and ReplacementRemoval and Replacement Procedure Removal and REPLACE- Ment Procedure Wire Drive Assembly Removal and Replacement Figure F.11 Wire Drive Assembly Removal Wire Drive Assembly Removal and Replacement ProcedureSCR Output Rectifier Removal & Replacement Disconnection Heat Sink Lead Right side heat sink See Figure F.14Capacitor Bank Removal and Replacement Components Bank Removal ReplacementMain Transformer Removal and Replacement Power Switch FAN Motor and FAN Removal and Replacement Figure F.16 Fan Motor and Fan Removal Components FAN Motor and FAN Removal and Replacement ProcedureTroubleshooting & Repair 230/60 375 Wire Speed RangeOpen Circuit Voltage Input Volts/HertzWIRE-MATIC Table of Contents Electrical Diagrams Section WIRE-MATIC Electrical Diagrams Spool GUN Option Wiring Diagram 208/230 Code To Section Available from Lincoln Control PC Board G2332 Layout