Lincoln Electric SVM170-A service manual MAINTENANCED-4, English Metric Description

Page 32

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D-4

MAINTENANCED-4

TABLE D.2

ACCESSORIES AND EXPENDABLE REPLACE-

MENT PARTS FOR MAGNUM 250L GUN AND

CABLE ASSEMBLIES

 

 

English

Metric

Description

Part No.

Size

Size

 

 

 

 

CABLE LINER

 

 

 

For 15'

KP1934-2

.025 – .030"

0.6 – 0.8 mm

(4.5 m) or

KP1934-1

.035 – .045"

0.9 – 1.2 mm

shorter cable

KP1955-1

3/64"

1.2 mm

 

 

(Alum. wire)

(Alum. wire)

 

 

 

 

CONTACTS TIPS

 

 

 

 

 

 

Standard Duty

KP2020-6B1

.025"

0.6 mm

 

KP2020-7B1

.030"

0.8 mm

 

KP2020-1B1*

.035"

0.9 mm

 

KP2020-2B1*

.045"

1.2 mm

Heavy Duty

KP2021-1B1

.035"

0.9 mm

 

KP2021-2B1

.045"

1.2 mm

Tapered

KP2021-5B1

.025"

0.6 mm

 

KP2021-6B1

.030"

0.8 mm

 

KP2022-1B1

.035"

0.9 mm

 

KP2022-2B1

.045"

1.2 mm

Notched (For Alum.)

KP2010-5B1

3/64"

1.2 mm

 

 

(Alum. Wire)

(Alum. Wire.)

 

 

 

 

GAS NOZZLES

 

 

 

Fixed (Flush)

KP1931-1

3/8"

9.5 mm

 

KP1931-2*

1/2"

12.7 mm

 

KP1931-3

5/8"

15.9 mm

Fixed (Recessed)

KP1930-1

3/8"

9.5 mm

 

KP1930-2

1/2"

12.7 mm

 

KP1930-3

5/8"

15.9 mm

Requires: Gas

 

 

 

Diffuser as’bly

KP2026-3 *

.025 – .045"

0.6 – 1.2 mm

Adjustable Slip On

KP1935-2

1/2"

12.7 mm

 

KP1935-1

5/8"

15.9 mm

Requires:

 

 

 

Nozzle Insulator

KP2025-1

 

 

Requires:

 

 

 

Gas diffuser

KP2026-2

.025 – .030"

0.6 – 0.8 mm

As’bly

KP2026-1

.035 – .045"

0.9 – 1.2 mm

Gasless nozzle

KP1947-1∆

 

 

(For Innershield)

 

 

 

 

 

 

 

GUN TUBE ASSEMBLIES

 

 

 

Standard (60°)

KP2015-1 *

 

 

45°

KP2041-1

 

 

 

 

 

 

*Included with POWER MIG 255C Requires KP2026-1 Gas Diffuser

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 Shielding GAS GUN and Cable InstallationAuxiliary Power Receptacles Table of Contents Operation Section OperationOPERATIONB-2 Wear eye, ear and body protec- tionProduct Description Recommended Processes and EquipmentWelding 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 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 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 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
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