Lincoln Electric SVM 117-A Connect Output Components GUN Liner and Contact, Installation

Page 16

 

 

A-7

INSTALLATION

A-7

 

 

 

 

TOC

TOC

CONNECT OUTPUT COMPONENTS

GUN LINER AND CONTACT

TIP

 

 

INSTALLATION

 

Section

Master

INSTALL THE WORK CLAMP

 

 

 

 

 

 

 

 

 

 

 

The Magnum 250L gun and cable provided with the

to

to

Attach the work clamp to the cable which extends from

WIRE-MATIC 250 is factory installed with a liner for a

the front of the machine using the following procedure:

.035-.045” (0.9-1.2mm) diameter electrode and an

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.035” (0.9mm) contact tip.

 

 

 

 

 

 

 

 

1. Insert the lug on the end of the work cable through

 

 

 

 

 

the strain relief hole in the work clamp handle. See

1. If a .045” diameter wire size is to be used, install

 

 

 

Figure A.7.

the .045” contact tip (also provided).

 

 

 

2. Slide the work cable through the hole up to the bolt

2. For other wire sizes, use the following procedure

 

 

 

and nut.

for contact tip and gas nozzle installation.

See

 

 

 

 

Figure A.8.

 

3. Fasten work cable using the bolt and nut provided.

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a.

Choose the correct size contact tip for the

 

electrode being used (wire size is stenciled on

 

 

 

Section

Master

b

the side of the contact tip) and screw it snugly

Be sure the nozzle insulator is fully screwed

 

 

 

into the gas diffuser.

to

to

 

onto the gun tube and does not block the gas

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holes in the diffuser.

 

 

 

 

 

c.

Slip the appropriate gas nozzle onto the noz-

 

 

 

zle insulator. Either a standard .50" (12.7mm)

 

 

 

or optional .62” (15.9mm) I.D. slip-on gas noz-

 

 

 

zle may be used and should be selected

 

 

 

based on the welding application.

 

 

d.

Adjust the gas nozzle for the GMAW process

 

 

FIGURE A.7 - Installing The Work Clamp.

to be used.

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OUTPUT POLARITY CONNECTION

 

For the short-circuiting transfer process, the contact tip

 

 

 

Section

Master

 

end should be flush to extended to .12" (3.2mm). See

 

 

Figure A.8.

 

 

 

 

 

 

 

 

 

to

to

WARNING

 

For the spray transfer process, the contact tip should

 

 

be flush to recessed .12" (3.2mm). See Figure A.8.

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Turn the welder Power Switch OFF before chang-

 

 

 

 

 

 

 

 

 

ing output connection.

 

 

 

 

____________________________________

 

 

 

 

 

 

The welder is shipped from the factory connected for electrode positive (+) polarity. This is the normal polar- ity for GMA welding.

 

 

If negative (-) polarity is required, interchange the con-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TOC

TOC

nection of the two cables located in the wire drive com-

 

 

 

 

 

 

 

 

 

 

 

 

partment near the front panel. The negative lead is the

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Section

Master

lead closest to the front panel (where the leads come

 

 

 

 

 

 

out of the floor of the compartment) and should be

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

reconnected to the brass conductor tube of the gun

 

 

 

 

 

 

 

 

 

 

 

 

 

 

to

to

connector. The positive lead is stamped (+) on its ter-

FIGURE A.8 - Contact Tip and Electrode

minal and should be reconnected to the work lead ter-

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Connections.

minal.

 

 

 

 

 

 

 

 

 

 

 

 

WIRE-MATIC 250

Image 16
Contents WIRE-MATIC Safety Depends on YouSafety ARC Welding can be hazardousCylinder may explode if damaged Electric and MAG- Netic Fields IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcWIRE-MATIC Table of Contents Table of Contents Installation Duty Cycle Amps Volts at Rated Amps Current RangeFuse Superlag Type 750C CopperSafety Precautions Select Proper LocationInput Connections StackingFuse and Wire Sizes Input Power Connections and Ground ConnectionsConnect Shielding GAS Reconnect Procedure Figure A.4 Input Air Supply ConnectionsFigure A.5 Reconnect Diagram For 208/230/1/60 Machines Installation Install the Work ClampConnect Output Components GUN Liner and Contact Output Polarity ConnectionWire Size Conversion Parts GUN and Cable InstallationWIRE-MATIC Operation General Description Safety InstructionsWELDING, Cutting Design Features Advantages Unit FeaturesPower Source Features Recommended Processes and EquipmentWire Feeder Features Machine CapabilityLimitations Duty Cycle Amps VoltsControls and Settings Figure B.1 Operator ControlsProcedure 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 Installation Spool GUN Module BoardSpool GUN Connection BOX Installation Return Return to Section TOCSpool GUN Connection Spool GUN PreparationMaking a Weld with the Spool GUN Adapter K607-1 Installed Making the WeldTimer KIT K585-1 Steel Wire Sizes Part Number Aluminum Wire SizesDrive Roll Kits To Make Spot Plug WeldsMaintenance Routine and Periodic Maintenance Perform the following dailyMaintenance Contact TIP and GAS Nozzle Installation Cable CleaningDrive Rolls and Guide Tubes GUN Tubes and Nozzles DROP-IN Reel Spindle and ClipsLiner Removal Replacement Figure D.2 Liner maintenanceGUN Handle Disassembly To open up the handleDescription English Size Metric Size WIRE-MATIC Theory of Operation Input Line Voltage and Main TransformerOutput Rectification Feedback ControlConstant Voltage Output Figure E.4 Constant Voltage OutputWire Drive Motor FeedbackThermal Protection SCR Operation Figure E.6 SCR OperationWIRE-MATIC Troubleshooting & Repair HOW to USE Troubleshooting Guide Recommended Course of ActionElectric 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 Liquid elec Trolyte in these capacitors isPerform the Output Rectifier Test Description Main Transformer TestMaterials Needed Main Transformer Test Test Procedure ON/OFF Power Switch will be hot during these testsMain Transformer Test Static SCR Rectifier Assembly Test Leads Figure F.4 SCR 1 Test Points Active SCR Rectifier Assembly Test Leads Figure F.7 SCR Tester Circuit SCR connectionsWire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test Procedure Test for Supply Voltage to Tachometer Test for Feedback Voltage to the Control BoardScope Settings Normal Open Circuit Voltage WaveformMachine 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 Removal and Replacement Procedure Control PC Board Removal and ReplacementMaterials Needed Removal and REPLACE- Ment Procedure Wire Drive Assembly Removal and Replacement Wire Drive Assembly Removal and Replacement Procedure Figure F.11 Wire Drive Assembly RemovalSCR Output Rectifier Removal & Replacement Right side heat sink See Figure F.14 Disconnection Heat Sink LeadCapacitor Bank Removal and Replacement Bank Removal Replacement ComponentsMain Transformer Removal and Replacement Power Switch FAN Motor and FAN Removal and Replacement FAN Motor and FAN Removal and Replacement Procedure Figure F.16 Fan Motor and Fan Removal ComponentsTroubleshooting & Repair Wire Speed Range Open Circuit VoltageInput 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