Lincoln Electric SVM 117-A service manual Machine Capability, Limitations, Wire Feeder Features

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B-3

OPERATION

B-3

 

 

WIRE FEEDER FEATURES:

MACHINE CAPABILITY

 

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Drop-in Wire Loading - The innovative spindle snaps into the Readi-Reel adapter (optional) or most any 2" (51mm) I.D. wire spool. The wire spindle drops into the top-loading WIRE-MATIC 250 case design. Accommodating standard 12" (305mm) and 8" (203mm) diameter coils, the unique spindle and sup- port design automatically provides appropriate de-reel- ing drag to prevent wire reel overrun and loop-offs without manual brake adjustment.

Tachometer Controlled Wire Drive - Precision con- trol of permanent magnet motor provides proper wire feed acceleration and speed accuracy, independent of fluctuations in line voltage and wire loading. This gives reliable arc starting and weld consistency.

Low Speed Start - When the trigger is pulled, the wire feeder feeds wire at low speed regardless of the set wire feed speed until welding current is drawn or 2 sec- onds has expired. This feature enhances starting and makes setting stickout easy. The 2 second limit per- mits high speed loading of the gun and cable. In later versions of the WIRE-MATIC 250, a user selectable feature allows the wire feeder to feed wire directly at the set speed, thus bypassing the 2 second slow start.

Solid State Overload Protection - No circuit breaker to reset. Simply pull the trigger to resume welding once the overload condition has been cleared.

Unique Drive Roll and Guide Tube Design - Precisely aligned guide tubes and drive rolls provide long life. The design also permits quick reload by sim- ply starting wire into ingoing guide tube. Adjustable tension setting minimizes 'birdnesting', eliminates milling through the wire, and gives positive feeding. The double groove, reversible drive roll included with the WIRE-MATIC 250 allows use of .030" (0.8mm) through .045" (1.2mm) diameter wire. Drive roll kits for other sizes and types of wire are also available.

Quick-Connect Welding Gun - Gun connector has integrated welding power and gas connection with sep- arate front-paneltwist-lock trigger connection mount.

Gun and Cable - A 12 ft. (3.6m) GMAW gun and cable assembly, rated 200 amps 60% duty, or 250 amps 35% duty, is provided with the WIRE-MATIC 250. A liner, diffuser and contact tips for .035" (0.9mm) and .045" (1.2mm) electrodes are included.

The WIRE-MATIC 250 is rated on the following duty cycles based on a 10-minute time period (i.e., for 60% duty cycle, it is 6 minutes on and 4 minutes off).

Duty Cycle

Amps.

Volts

 

 

 

100%

145

26

60%

200

28

35%

250

26

 

 

 

LIMITATIONS

The WIRE-MATIC 250 may not operate satisfactorily if powered with a portable or in-plant generating system.

WIRE-MATIC 250

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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 Fuse Superlag Duty Cycle Amps Volts at Rated AmpsCurrent Range Type 750C CopperInput Connections Safety PrecautionsSelect Proper Location 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 Connect Output Components GUN Liner and Contact InstallationInstall the Work Clamp Output Polarity ConnectionWire Size Conversion Parts GUN and Cable InstallationWIRE-MATIC Operation General Description Safety InstructionsWELDING, Cutting Power Source Features Design Features AdvantagesUnit Features Recommended Processes and EquipmentLimitations Wire Feeder FeaturesMachine Capability 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 Drive Roll Kits Steel Wire Sizes Part NumberAluminum Wire Sizes To Make Spot Plug WeldsMaintenance Routine and Periodic Maintenance Perform the following dailyMaintenance Drive Rolls and Guide Tubes GUN Tubes and Nozzles Contact TIP and GAS Nozzle InstallationCable Cleaning 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 Input Volts/Hertz Wire Speed RangeOpen Circuit Voltage 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