Lincoln Electric SVM 117-A service manual Making a Weld

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B-8

OPERATION

B-8

 

 

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NOTE: The unit will remember the run-in mode from the previous power down and return you to that same state the next time you power up. Therefore, it is not necessary to repeat either of the above procedures each time the unit is powered up. You need only per- form one of the above procedures when you want to change the run-in mode.

NOTE. When the gun trigger is first closed before turn- ing on the welder, there is no output power or wire feed until the trigger is opened and re-closed, regardless of the WIRE SPEED CONTROL POTENTIOMETER KNOB setting.

MAKING A WELD

1.Check that the electrode polarity is correct for the process being used.

2.Turn the POWER SWITCH to ON.

3.Set desired arc voltage and wire speed for the electrode wire, material type and thickness, and gas (for GMAW) being used.

NOTE: Use the Application Chart on the door inside the wire compartment as a quick reference for some common welding procedures.

NOTE: If Timer Kit is installed, see the Accessories Section of this manual to select the desired mode and for additional welding information Spot and Stitch modes.

4.Inch the electrode through the gun and cable.

5.Cut the electrode within approximately 3/8" (10mm) of the end of the contact tip or 3/4" (20mm) for Outershields.

NOTE: When the trigger is pulled, the wire feeder feeds wire at low speed regardless of the set wire feed speed until the welding arc starts or 2 seconds has elapsed. This feature enhances starting and makes it easier to set the stickout. The 2 second limit permits high speed loading of the gun and cable. To change run-in mode, refer to Changing Run In Mode Section.

6.If welding gas is to be used, turn on the gas supply and set the required flow rate (typically 25-35 CFH; 12-16 Liters/min).

NOTE: When using Innershield electrode, the gas nozzle may be removed from the insulation on the end of the gun. This will give improved visibility and elimi-

nate the possibility of the gas nozzle overheating.

7.Connect the work cable to metal to be welded. Work clamp (if used) must make good electrical contact to the work. The work must be grounded.

WARNING

When using an open arc process, it is necessary to use correct eye, head and body protection.

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8.Position electrode over joint. End of electrode may be lightly touching the work.

9.Lower welding helmet, close gun trigger, and begin welding. Hold the gun so the contact tip to work distance is about 3/8 inch (10mm) or 3/4" (20mm) for Outershield.

10.To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out.

11.When no more welding is to be done, close the valve on gas cylinder (if used), momentarily oper- ate gun trigger to release gas pressure.

12.Turn POWER SWITCH to OFF.

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 Safety Instructions General DescriptionWELDING, Cutting 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 SettingsUsing the Wire Drive Roll Procedure for Changing Drive RollLoading the Wire Reel Proper Wire Feeding Feeding ElectrodeTo mount 10 to 30 lb. spools 8 and 12 diameter Setting Idle Roll Pressure Operating StepsStarting the Welder Making a Weld WIRE-MATIC Accessories OPTIONS/ACCESSORIES Installing the K607-1 Spool GUN Adapter KITK607-1 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 GuidePC Board Troubleshooting Procedures Electric Shock can killBoard 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 Main Transformer Test Test DescriptionMaterials 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 Control PC Board Removal and Replacement Removal and Replacement ProcedureMaterials 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 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