Lincoln Electric SVM 117-A service manual Cylinder may explode if damaged

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SAFETY

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WELDING SPARKS can cause fire or explosion.

4.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot

materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

4.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

4.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

4.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

4.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

4.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

4.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

4.h. Also see item 7c.

CYLINDER may explode if damaged.

5.a. Use only compressed gas cylinders

containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

5.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

5.c. Cylinders should be located:

Away from areas where they may be struck or subjected to physical damage.

A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

5.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

5.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

5.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

5.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

6.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

6.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

6.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

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Feb. ‘95

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