Lincoln Electric SVM170-A service manual Making a Weld with the Prince XL Spool GUN

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C-4	ACCESSORIES	C-4

	FIGURE C.1

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GAS LINE

AND 5/8 FITTING

7-PIN SPOOL GUN RECEPTACLE

K2445-1

CABLE ADAPTER (7-pin to 6-pin)

Note: This adapter is only for The Magnum SG Spool Gun.

+POSITIVE CABLE AND STUD

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MAKING A WELD WITH THE PRINCE XL SPOOL GUN

The POWER MIG control circuitry is designed to sense either the spool gun or (built in) wire feeder trigger circuitry. The spool gun can easily be plugged in and will be ready to use.

CAUTION

Closing either gun trigger will cause the electrode of both guns to be electrically "HOT". Be sure unused gun is positioned so electrode or tip will not contact metal case or other metal common to work.

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1.Pulling the trigger for the built-in feeder gun:

a.Disables spool gun operation.

b.Closing feeder gun trigger starts feeder gun welding and makes both electrodes electrical- ly "HOT".

2.Pulling SPOOL GUN Trigger:

a.Disables built-in feeder gun operation.

b.Closing spool gun trigger starts spool gun weld-ing and makes both electrodes electrically "HOT".

3.Operation with POWER MIG 255C:

a.Turn the POWER MIG 255C input power ON.

b.Adjusting the voltage control will increase or decrease your welding voltage.

c.Adjusting the wire speed control on the spool gun will increase or decrease the spool gun wire feed speed.

d.To aid in set-up, the POWER MIG 255C wire feed speed(WFS) meter will display the approx- imate WFS of the gun. Actual WFS at the gun may vary from the displayed value due to ten- sion setting, liner condition or gun variation.

4.The following procedure settings for Aluminum 4043 can be used as initial settings for making test welds to determine final settings:

Wire Diameter	Wire Feed Speed	Arc voltage
In. (mm)	Display	Setting
.030” (.8mm)	270	15V
.035” (.9mm)	250	16V
3/64” (1.2mm)	240	20V

5.To return to normal POWER MIG 255C welding, release the spool gun trigger and reset feeder gun voltage procedure setting if necessary.

MAKING A WELD WITH THE MAGNUM SG SPOOL GUN

The POWER MIG control circuitry is designed to sense either the spool gun or (built in) wire feeder trigger circuitry. The spool gun can easily be plugged in and will be ready to use.

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 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