Lincoln Electric SVM170-A GUN and Cable Installation, Shielding GAS, Auxiliary Power Receptacles

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A-6

INSTALLATION

A-6

GUN AND CABLE INSTALLATION

 

WARNING

 

 

 

The Magnum 250L gun and cable provided with the

 

CYLINDER may explode if

POWER MIG 255C is factory installed with a liner for

 

 

damaged.

0.035-0.045 in. (0.9-1.2 mm) electrode and an 0.035

 

 

• Gas under pressure is explosive. Always keep

in. (0.9 mm) contact tip. Install the 0.045 tip (also pro-

 

 

gas cylinders in an upright position and always

vided) if this wire size is being used.

 

 

 

 

keep chained to undercarriage or stationary

 

 

 

support. See American National Standard Z-

WARNING

 

 

49.1, “Safety in Welding and Cutting” pub-

 

 

lished by the American Welding Society.

Turn the welder power switch off before installing

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3. Stand to one side away from the outlet and open

gun and cable.

 

 

the cylinder valve for an instant. This blows away

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any dust or dirt which may have accumulated in

 

 

1. Lay the cable out straight.

 

the valve outlet.

 

 

 

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2.Unscrew knurled screw on the drive unit front end (inside wire feed compartment) until tip of screw no longer protrudes into gun opening as seen from front of machine.

3.Insert the male end of gun cable into the female casting through opening in front panel. Make sure connector is fully inserted and tighten knurled screw.

4.Connect the gun trigger connector from the gun and cable to the mating receptacle inside the compartment located above the gun connection made in item 3 above. Make sure that the key- ways are aligned, insert and tighten retaining ring.

SHIELDING GAS

(For Gas Metal Arc Welding Processes)

Customer must provide cylinder of appropriate type shielding gas for the process being used.

A gas flow regulator, for CO2 or Argon blend gas, and an inlet gas hose are factory provided with the POWER MIG 255C. Install the shielding gas supply as follows:

1.Set gas cylinder on rear platform of POWER MIG 255C. Hook chain in place to secure cylinder to rear of welder.

2.Remove the cylinder cap. Inspect the cylinder valves and regulator for damaged threads, dirt, dust, oil or grease. Remove dust and dirt with a clean cloth.

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

WARNING

Be sure to keep your face away from the valve out- let when “cracking” the valve.

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4.Attach the flow regulator to the cylinder valve and tighten the union nut(s) securely with a wrench.

NOTE: If connecting to 100% CO2 cylinder, insert regulator adapter between regulator and cylinder valve. If adapter is equipped with a plastic washer, be sure it is seated for connection to the CO2 cylinder.

5.Attach one end of the inlet gas hose to the outlet fitting of the flow regulator, the other end to the POWER MIG 255C rear fitting, and tighten the union nuts securely with a wrench.

6.Before opening the cylinder valve, turn the regu- lator adjusting knob counterclockwise until the adjusting spring pressure is released.

7.Standing to one side, open the cylinder valve slowly a fraction of a turn. When the cylinder pres- sure gauge pointer stops moving, open the valve fully.

WARNING

Never stand directly in front of or behind the flow regulator when opening the cylinder valve. Always stand to one side.

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8.The flow regulator is adjustable. Adjust it to the flow rate recommended for the procedure and process being used before making the weld.

AUXILIARY POWER RECEPTACLES

(For 208/230V Models only)

This machine is equipped with 15Amp 120V receptacle with 15Amp Circuit Breaker. The receptacle is UL and CSA approved.

POWER MIG 255C

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Contents Power MIG 255C Safety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents For ALL Sections Installation Table of Contents Installation SectionTechnical Specifications Power MIG 255C Safety Precautions Uncrating the Power MIG 255CInput POWER, Grounding and Connection Diagrams LocationInstallation Figure A.2 Triple Voltage Machine Input Connections GUN and Cable Installation Auxiliary Power ReceptaclesShielding GAS Table of Contents Operation Section OperationOPERATIONB-2 Wear eye, ear and body protec- tionProduct Description Recommended Processes and EquipmentWelding Capability LimitationsWire Size Conversion Parts Wire Drive RollDescription of Controls Procedure for Changing Wire Reel Loading Readi REELS, Spools or CoilsDrive and Idle Roll Sets Feeding Wire Electrode Idle Roll Pressure SettingWire Drive Configuration To Start the WelderFigure B.4 When Timer Option is not installed Instructions to Enter Slow RUN-INInstructions to Enter Fast RUN-IN Making a WeldAvoiding Wire Feeding Problems Wire Feed Overload ProtectionFAN Control Input Line Voltage ProtectionWelding Thermal Overload Protection Overcurrent ProtectionAccessories Table of Contents Accessories SectionDrive Roll Kits Magnum GUN Connection KITK363P READI-REEL Adapter Dual Cylinder Mounting KIT K1702-1Operating Instructions for Timer KIT Connecting the Spool GUN to the Power MIG 255CK1738-1 Spool Gun Hanger Accessory Spool GUNMaking a Weld with the Prince XL Spool GUN Making a Weld with the Magnum SG Spool GUNSG Spool Gun Wire Feed Speed Power MIG Maintenance Table of Contents Maintenance SectionGUN Tubes and Nozzles General Maintenance GUN Cable CleaningContact TIP and GAS Nozzle Installation Liner Removal and ReplacementGUN Handle Disassembly Table D.1MAINTENANCED-4 English Metric DescriptionTable of Contents Theory of Operation Section Theory of OperationInput Line Voltage Main TransformerOutput Rectification Feedback ControlConstant Voltage Output Figure E.4 Constant Voltage OutputWire Drive Motor FeedbackWire Feed Overload Protection Thermal and Overload ProtectionSCR Operation Figure E.6 SCR OperationPower MIG 255C Troubleshooting and Repair Table of Contents Troubleshooting and Repair Section2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Troubleshooting Guide Output ProblemsProblems Possible Areas Symptoms Misadjustments Course of ActionTrolyte in these capacitors is Toxic. Avoid contact with anyPerform the SCR Rectifier Function Problems Wire Feeding Problems Welding Problems Welding Problems Test Procedures Main Transformer TestTest Description Materials NeededTest Procedure ON/OFF Power Switch will be hot during these tests115VAC 16J5 8J5206 3J5 Rectifier Diode Bridge Test 16TROUBLESHOOTING and REPAIRF-16 Figure F.2 G3521 Rectifier Diode Bridge Location208 206 28 VAC 209 354 206 36 VDCPower MIG 255C Static SCR Rectifier Assembly Test Static SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Power MIG 255C Active SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Figure F.7 Location Leads X2 Figure F.8 Wire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test 4J1Test for Supply Voltage to Tachometer 515B 206B 15 VDC 5J1 1J1Test for Feedback Voltage to Control Board 555 206B To 3.5 VDC 6J1 1J1Normal Open Circuit Voltage Waveform VoltsMachine 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 and Repair Typical SCR Gate Voltage Waveform Power MIG 255C Component Replacement Procedures Control PC Board Removal and ReplacementDescription Removal and Replacement ProcedureFigure F.11 Control Board Mounting Power MIG 255C Wire Drive Assembly Removal and Replacement Wire Drive Assembly Removal and Replacement Procedure Power MIG 255C SCR Output Rectifier Removal and Replacement SCR Output Rectifier Removal and Replacement Figure F.15 Right Heat Sink Lead Disconnection Power MIG 255C Capacitor Bank Removal and Replacement Capacitor Bank Removal and Replacement Main Transformer and Output Choke Removal and Replacement 52TROUBLESHOOTING and REPAIRF-52 Main Transformer and Output ChokeTOC Power MIG 255C FAN Motor Assembly Removal and Replacement FAN Motor Assembly Removal and Replacement Wire Speed Range Retest After RepairOpen Circuit Voltage Input Volts/HertzPower MIG 255C Electrical Diagrams Section Section G-1Electrical Diagrams Wiring Diagram Entire Machine Code 11192 L12464Wiring Diagram Entire Machine Code 11218 L12506 Schematic Entire Machine G4752 Schematic Control PC Board G4823-2D1 Sheet Electrical Diagrams Electrical Diagrams PC Board Assembly Control G4824-2D1 Item Used with QTY Part Number DescriptionSchematic Display PC Board L10951 PowermigPC Board Assembly Display L10952 Lincoln Electric COSVM Error Reporting Form