Lincoln Electric SVM170-A service manual Procedure for Changing, Drive and Idle Roll Sets

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Master TOC

B-5

 

OPERATION

B-5

 

 

 

 

 

PROCEDURE FOR CHANGING

5.

Rotate the spindle and adapter so the retaining spring is

DRIVE AND IDLE ROLL SETS

 

at the 12 o'clock position.

 

 

 

 

1. Turn off the power source.

6.

Position the Readi-Reel so that it will rotate in a direction

 

 

 

when feeding so as to be de- reeled from top of the coil.

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2.Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back of the machine. Lift the cast idle roll assembly and allow it to sit in an upright position.

3.Remove the outside wire guide retaining plate by loosening the two large knurled screws.

4.Twist the drive roll retaining mechanism to the unlocked position as shown below and remove the drive roll. (See Figure B.2)

FIGURE B.2

5.Remove the inside wire guide plate.

6.Replace the drive and idle rolls and inside wire guide with a set marked for the new wire size. NOTE: Be sure that the gun liner and contact tip are also sized to match the selected wire size.

7.Manually feed the wire from the wire reel, over the drive roll groove and through the wire guide and then into the brass bushing of the gun and cable assembly.

8.Replace the outside wire guide retaining plate by tightening the two large knurled screws. Reposition the adjustable pressure arm to its original position to apply pressure. Adjust pressure as necessary.

7.Set one of the Readi-Reel inside cage wires on the slot in the retaining spring tab.

8.Lower the Readi-Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter.

9.Slide cage all the way onto the adapter until the retaining spring "pops up" fully.

WARNING

CHECK TO BE SURE THE RETAINING SPRING HAS FULLY RETURNED TO THE LOCKING POSITION AND HAS SECURELY LOCKED THE READI-REEL CAGE IN PLACE. RETAINING SPRING MUST REST ON THE CAGE, NOT THE WELDING ELECTRODE.

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10.To remove Readi-Reel from Adapter, depress retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands. Do not remove adapter from spindle.

2 IN. O.D. ADAPTER

SPINDLE RETAINING SPRING

RETAINING

COLLAR

BRAKE

HOLDING

PIN GROOVES

READI-REEL

INSIDE

CAGE RELEASE

WIRES BAR

To Mount 10 to 44 Lb. (4.5-20 kg) Spools (12"/300 mm Diameter) or 14Lb.(6 Kg) Innershield Coils:

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WIRE REEL LOADING - READI REELS, SPOOLS OR COILS

To Mount a 30 Lb. (14 kg) Readi-Reel Package (Using the Molded Plastic K363-P Readi-Reel Adapter:)

1.Open the Wire Drive Compartment Door

2.Depress the Release Bar on the Retaining Collar and remove it from the spindle.

3.Place the Optional Adapter on the spindle

4.Re-install the Retaining Collar. Make sure that the Release Bar "pops up" and that the collar retainers fully engage the retaining ring groove on the spindle.

(For 13-14 lb. (6 Kg) Innershield coils, a K435 Coil Adapter must be used).

(For 10 lb.(4.5 Kg) 8 inch(203mm) diameter spools, a K468 spindle adapter must be used).

1.Open the Wire Drive Compartment Door

2.Depress the Release Bar on the Retaining Collar and remove it from the spindle.

3.Place the spool on the spindle making certain the spindle brake pin enters one of the holes in the back side of the spool (Note: an arrow mark on the spin- dle lines up with the brake holding pin to assist in lin- ing up a hole). Be certain the wire comes off the reel in a direction so as to de-reel from the top of the coil.

4.Re-install the Retaining Collar. Make sure that the Release Bar "pops up" and that the collar retainers fully engage the retaining ring groove on the spindle.

POWER MIG 255C

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Contents Power MIG 255C California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents For ALL Sections Table of Contents Installation Section InstallationTechnical Specifications Power MIG 255C Uncrating the Power MIG 255C Safety PrecautionsInput POWER, Grounding and Connection Diagrams LocationInstallation Figure A.2 Triple Voltage Machine Input Connections Shielding GAS GUN and Cable InstallationAuxiliary Power Receptacles Operation Table of Contents Operation SectionWear eye, ear and body protec- tion OPERATIONB-2Recommended Processes and Equipment Product DescriptionWelding Capability LimitationsDescription of Controls Wire Size Conversion PartsWire Drive Roll Drive and Idle Roll Sets Procedure for ChangingWire Reel Loading Readi REELS, Spools or Coils Idle Roll Pressure Setting Feeding Wire ElectrodeWire Drive Configuration To Start the WelderFigure B.4 Instructions to Enter Slow RUN-IN When Timer Option is not installedInstructions to Enter Fast RUN-IN Making a WeldWire Feed Overload Protection Avoiding Wire Feeding ProblemsFAN Control Input Line Voltage ProtectionOvercurrent Protection Welding Thermal Overload ProtectionTable of Contents Accessories Section AccessoriesMagnum GUN Connection KIT Drive Roll KitsK363P READI-REEL Adapter Dual Cylinder Mounting KIT K1702-1Connecting the Spool GUN to the Power MIG 255C Operating Instructions for Timer KITK1738-1 Spool Gun Hanger Accessory Spool GUNMaking a Weld with the Magnum SG Spool GUN Making a Weld with the Prince XL Spool GUNSG Spool Gun Wire Feed Speed Power MIG Table of Contents Maintenance Section MaintenanceGUN Cable Cleaning GUN Tubes and Nozzles General MaintenanceContact TIP and GAS Nozzle Installation Liner Removal and ReplacementTable D.1 GUN Handle DisassemblyEnglish Metric Description MAINTENANCED-4Theory of Operation Table of Contents Theory of Operation SectionMain Transformer Input Line VoltageFeedback Control Output RectificationFigure E.4 Constant Voltage Output Constant Voltage OutputFeedback Wire Drive MotorThermal and Overload Protection Wire Feed Overload ProtectionFigure E.6 SCR Operation SCR OperationPower MIG 255C Table of Contents Troubleshooting and Repair Section Troubleshooting and RepairHOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Output Problems Troubleshooting GuideSymptoms Misadjustments Course of Action Problems Possible AreasTrolyte in these capacitors is Toxic. Avoid contact with anyPerform the SCR Rectifier Function Problems Wire Feeding Problems Welding Problems Welding Problems Main Transformer Test Test ProceduresTest Description Materials NeededON/OFF Power Switch will be hot during these tests Test Procedure16J5 8J5 115VAC206 3J5 Rectifier Diode Bridge Test Figure F.2 G3521 Rectifier Diode Bridge Location 16TROUBLESHOOTING and REPAIRF-16354 206 36 VDC 208 206 28 VAC 209Power 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 4J1 Wire Drive Motor and Tachometer Feedback Test515B 206B 15 VDC 5J1 1J1 Test for Supply Voltage to Tachometer555 206B To 3.5 VDC 6J1 1J1 Test for Feedback Voltage to Control BoardVolts Normal Open Circuit Voltage WaveformTypical 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 and Repair Typical SCR Gate Voltage Waveform Power MIG 255C Description Component Replacement ProceduresControl PC Board Removal and Replacement Procedure Removal and ReplacementFigure 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 Main Transformer and Output Choke 52TROUBLESHOOTING and REPAIRF-52TOC Power MIG 255C FAN Motor Assembly Removal and Replacement FAN Motor Assembly Removal and Replacement Retest After Repair Wire Speed RangeOpen Circuit Voltage Input Volts/HertzPower MIG 255C Section G-1 Electrical Diagrams SectionWiring Diagram Entire Machine Code 11192 L12464 Electrical DiagramsWiring Diagram Entire Machine Code 11218 L12506 Schematic Entire Machine G4752 Schematic Control PC Board G4823-2D1 Sheet Electrical Diagrams Electrical Diagrams Item Used with QTY Part Number Description PC Board Assembly Control G4824-2D1Powermig Schematic Display PC Board L10951Lincoln Electric CO PC Board Assembly Display L10952SVM Error Reporting Form