Lincoln Electric SVM170-A GUN Tubes and Nozzles General Maintenance, GUN Cable Cleaning

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D-2

 

 

MAINTENANCE

D-2

 

 

 

 

 

 

 

 

 

 

 

 

SAFETY PRECAUTIONS

 

 

 

1. Be sure the nozzle insulator is fully screwed onto the

 

 

 

 

 

 

 

 

 

gun tube and does not block the gas holes in the dif-

 

 

 

WARNING

 

 

 

 

fuser.

 

 

 

 

 

• Have a qualified electrician do the

2. Slip the appropriate gas nozzle onto the nozzle insu-

 

 

 

 

 

 

 

 

 

 

lator. Either a standard .50" (12.7 mm) or optional

 

 

 

maintenance

and

troubleshooting

 

 

 

 

 

.62" (15.9 mm) I.D. slip-on gas nozzle may be used

 

 

 

work.

 

 

 

 

 

 

 

 

 

 

 

 

 

and should be selected based on the welding appli-

 

 

 

 

 

 

 

 

 

 

 

 

• Disconnect

the input power off

 

cation.

 

 

 

 

 

 

Adjust the gas nozzle as appropriate

for the

 

 

 

using the disconnect switch at the

 

 

 

 

 

GMAW process to be used. Typically, the con-

 

 

 

main input supply before working

 

 

 

 

 

tact tip end should be flush to .12" (3.2 mm)

 

 

 

inside machine.

 

 

 

 

 

 

 

 

 

 

 

extended for the short-circuiting transfer process

 

 

 

 

 

 

 

 

 

• Unplug the power cable if it is connected to a

 

and .12" (3.2 mm) recessed for spray transfer.

 

 

 

 

 

receptacle.

 

 

 

 

GUN TUBES AND NOZZLES

 

 

------------------------------------------------------------------------

 

 

 

 

 

 

GENERAL MAINTENANCE

 

 

 

a. Replace worn contact tips as required.

 

 

In extremely dusty locations, dirt may clog the air

b. Remove spatter from inside of gas noz-zle and from

passages causing the welder to run hot. Blow dirt out

 

tip after each 10 minutes of arc time or as required.

of the welder with low-pressure air at regular intervals

 

 

 

 

 

to eliminate excessive dirt and dust build-up on internal

GUN CABLE CLEANING

 

 

parts.

 

 

 

 

 

 

 

 

 

 

To help prevent feeding problems, clean cable liner

The fan motors have sealed ball

bearings

which

after using approximately 300 pounds (136 kg) of elec-

require no service.

 

 

 

 

trode. Remove the cable from the wire feeder and lay

 

 

 

 

 

 

 

 

it out straight on the floor. Remove the contact tip from

DRIVE ROLLS AND GUIDE PLATES

 

 

the gun. Using an air hose and only partial pressure,

 

 

gently blow out the cable liner from the gas diffuser

After every coil of wire, inspect

the wire

drive

end.

 

 

mechanism. Clean it as necessary by blowing with low

 

 

 

 

pressure compressed air. Do not

use solvents for

 

CAUTION

 

 

cleaning the idle roll because it may wash the lubricant

 

 

 

 

 

 

 

 

out of the bearing.

 

 

 

 

 

 

 

 

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All drive rolls are stamped with the wire sizes they will feed. If a wire size other than that stamped on the roll is used, the drive roll must be changed.

For instructions on replacing or changing drive roll, see "Wire Drive Rolls" in Operation section.

CONTACT TIP AND GAS NOZZLE INSTALLATION

a.Choose the correct size contact tip for the electrode being used (wire size is stenciled on the side of the contact tip) and screw it snugly into the gas diffuser.

b.Screw the appropriate fixed gas nozzle fully onto the diffuser. Either the standard .50" (12.7 mm) flush nozzle or other optional flush or recessed (spray arc) nozzle sizes may be used. (See Table D.2 in this section.)

c.If using optional adjustable slip-on noz-zles, see Table D.2 in this section.

Excessive pressure at the start may cause the dirt to form a plug.

Flex the cable over its entire length and again blow out the cable. Repeat this procedure until no further dirt comes out. If this has been done and feed problems are experienced, try liner replacement, and refer to trouble shooting section on rough wire feeding.

LINER REMOVAL AND REPLACEMENT

NOTE: Changing the liner for a different wire size requires replacement of the gas diffuser per Table D.1 to properly secure the different liner.

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 GUN and Cable Installation Auxiliary Power ReceptaclesShielding GAS Table of Contents Operation Section OperationOPERATIONB-2 Wear eye, ear and body protec- tionWelding Capability Product DescriptionRecommended Processes and Equipment LimitationsWire Size Conversion Parts Wire Drive RollDescription of Controls Procedure for Changing Wire Reel Loading Readi REELS, Spools or CoilsDrive and Idle Roll Sets 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 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 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