Lincoln Electric SVM170-A service manual Safety, California Proposition 65 Warnings

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SAFETY

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WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

 

The engine exhaust from this product contains

are known to the State of California to cause can-

 

chemicals known to the State of California to cause

cer, birth defects, and other reproductive harm.

 

cancer, birth defects, or other reproductive harm.

 

 

 

The Above For Diesel Engines

 

The Above For Gasoline Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes

outdoors.

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1.c. Do not add the fuel near an open flame weld- ing arc or when the engine is running. Stop the engine and allow it to cool before refuel- ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes

have been eliminated.

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1.d. Keep all equipment safety guards, covers and devices in posi- tion and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

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1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods

while the engine is running.

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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

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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 Input POWER, Grounding and Connection Diagrams Safety PrecautionsUncrating the Power MIG 255C LocationInstallation Figure A.2 Triple Voltage Machine Input Connections Shielding GAS GUN and Cable InstallationAuxiliary Power Receptacles Table of Contents Operation Section OperationOPERATIONB-2 Wear eye, ear and body protec- tionWelding Capability Product DescriptionRecommended Processes and Equipment LimitationsDescription of Controls Wire Size Conversion PartsWire Drive Roll Drive and Idle Roll Sets Procedure for ChangingWire Reel Loading Readi REELS, Spools or Coils Wire Drive Configuration Feeding Wire ElectrodeIdle Roll Pressure Setting To Start the WelderFigure B.4 Instructions to Enter Fast RUN-IN When Timer Option is not installedInstructions to Enter Slow RUN-IN Making a WeldFAN Control Avoiding Wire Feeding ProblemsWire Feed Overload Protection Input Line Voltage ProtectionWelding Thermal Overload Protection Overcurrent ProtectionAccessories Table of Contents Accessories SectionK363P READI-REEL Adapter Drive Roll KitsMagnum GUN Connection KIT Dual Cylinder Mounting KIT K1702-1K1738-1 Spool Gun Hanger Accessory Operating Instructions for Timer KITConnecting the Spool GUN to the Power MIG 255C 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 SectionContact TIP and GAS Nozzle Installation GUN Tubes and Nozzles General MaintenanceGUN Cable Cleaning 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 ProblemsTrolyte in these capacitors is Problems Possible AreasSymptoms Misadjustments Course of Action Toxic. Avoid contact with anyPerform the SCR Rectifier Function Problems Wire Feeding Problems Welding Problems Welding Problems Test Description Test ProceduresMain Transformer Test 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 Description Component Replacement ProceduresControl PC Board Removal and Replacement 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 Open Circuit Voltage Wire Speed RangeRetest After Repair 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