Lincoln Electric SVM 117-A service manual Connect Shielding GAS

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A-4

INSTALLATION

A-4

 

 

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For the 230/460/575V/ 60 HZ model which is not equipped with a plug, an input cord, or a receptacle, the input power supply leads must be connected directly to the Reconnect Panel as shown in Figure A.3. Refer to Technical Specifications at the begin- ning of this chapter for proper wire sizes.

1.Connect the input power leads to terminals L1 and L2 on the Reconnect Panel Assembly.

a.For input power supply leads of 10 AWG or smaller are used, connect leads to Reconnect Panel using the ferrules (S19117-1) provided.

b.Strip 1/2" (13mm) of insulation from the input power supply leads.

c.Place ferrule over wire.

d.Torque the terminal screws to 16 in.-lbs. (1.8nm).

FIGURE A.3 - Input Power Connection For 230/460/575 Volt Models.

WARNING

Gas under pressure is explosive. Always keep gas cylinders in an

upright position and always keep

chained to undercarriage or sta-

tionary Y support. See American National Standard Z-49.1, “Safety in Welding and Cutting” published

by the American Welding Society.

____________________________________

1.Set the gas cylinder on the rear platform of the WIRE-MATIC 250.

2.Hook the chain in place to secure cylinder to rear of welder.

3.Remove the cylinder cap.

4.Inspect the cylinder valves for damaged threads, dirt, dust, oil or grease.

a. Remove dust and dirt with a clean cloth.

NOTE: DO NOT ATTACH THE REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT! Inform your gas supplier of this condition. Oil or grease in the pres- ence of high pressure oxygen is explosive.

5.Stand to one side away from the outlet and open the cylinder valve for an instant to blow away any dust or dirt which may have accumulated in the valve outlet.

BE SURE TO KEEP YOUR FACE AWAY FROM THE VALVE OUTLET WHEN OPENING THE VALVE.

6.Inspect the regulator for damaged threads, dirt, dust, oil or grease.

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CONNECT SHIELDING GAS

Customer must provide cylinder of appropriate type of shielding gas for gas metal arc welding for the process being used. See Figure A.4 for the location of the com- ponents used to connect the air supply cylinder.

NOTE: For CO2 or Argon blend gas, the optional K586-1 Adjustable Gas Regulator and Hose Kit should be used. See Accessories Section of this manual.

a. Remove dust and dirt with a clean cloth.

NOTE: DO NOT USE THE REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT! Have an authorized repair station clean the regulator or repair any damage.

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 Current Range Duty Cycle Amps Volts at Rated AmpsFuse Superlag Type 750C CopperSelect Proper Location Safety PrecautionsInput Connections StackingInput 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 Install the Work Clamp InstallationConnect Output Components GUN Liner and Contact Output Polarity ConnectionGUN and Cable Installation Wire Size Conversion PartsWIRE-MATIC Operation General Description Safety InstructionsWELDING, Cutting Unit Features Design Features AdvantagesPower Source Features Recommended Processes and EquipmentMachine Capability Wire Feeder FeaturesLimitations Duty Cycle Amps VoltsFigure B.1 Operator Controls Controls and SettingsProcedure for Changing Drive Roll Using the Wire Drive RollLoading the Wire Reel Feeding Electrode Proper Wire FeedingTo mount 10 to 30 lb. spools 8 and 12 diameter Operating Steps Setting Idle Roll PressureStarting the Welder Making a Weld WIRE-MATIC Accessories Installing the K607-1 Spool GUN Adapter KIT OPTIONS/ACCESSORIESK607-1 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 Aluminum Wire Sizes Steel Wire Sizes Part NumberDrive Roll Kits To Make Spot Plug WeldsMaintenance Perform the following daily Routine and Periodic MaintenanceMaintenance Cable Cleaning Contact TIP and GAS Nozzle InstallationDrive Rolls and Guide Tubes GUN Tubes and Nozzles DROP-IN Reel Spindle and ClipsFigure 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 GuideElectric Shock can kill PC Board Troubleshooting ProceduresBoard can be dam- aged by static electricity 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 Test Description Main Transformer TestMaterials Needed 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 Removal and Replacement Procedure Control PC Board Removal and ReplacementMaterials Needed 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 Open Circuit Voltage Wire Speed RangeInput Volts/Hertz 230/60 375WIRE-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