Lincoln Electric SVM 119-A Safety Instructions, General Description, WELDING, Cutting

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B-1

OPERATION

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Read and understand this entire section before operat- ing your WIRE-MATIC 255.

SAFETY INSTRUCTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

Insulate yourself from the work and ground.

Always wear dry insulating gloves.

CAUTION

When using a Wire-Matic 255 power source there will be a small spark if the electrode contacts the work or ground within several seconds after releasing the trigger.

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GENERAL DESCRIPTION

The WIRE-MATIC 255 is a complete semiautomatic constant voltage DC arc welding machine built to meet NEMA specifications. It combines a constant voltage power source, a constant speed wire feeder, and a microcomputer-based controller to form a reliable high- performance welding system.

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FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

Use ventilation or exhaust to remove fumes from breathing zone.

Simple controls, consisting of continuous full range cal- ibrated voltage control and wire feed speed control, provide versatility with ease of use.

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WELDING, CUTTING and

GOUGING SPARKS

can cause fire or explosion

Keep flammable material away.

Do not weld, cut or gouge on containers that have held combustibles.

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ARC RAYS can burn.

Wear eye, ear and body protection.

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Only qualified personnel should operate this equip- ment. Observe all safety information throughout this manual.

WIRE-MATIC 255

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Contents WIRE-MATIC Safety Depends on YouSafety Electric Shock can killARC Rays can burn Fumes and Gases can be dangerousCylinder may explode if damaged Welding Sparks can cause fire or explosionIii Electric and MAG- Netic FieldsMay be dangerous Précautions DE Sûreté Sûreté Pour Soudage a L’ArcWIRE-MATIC Table of Contents Table of Contents Installation Table of Contents Installation SectionTechnical Specifications Wire-Matic-255 Safety Precautions Select Proper LocationInput Connections StackingFuse and Wire Sizes Connect Shielding GAS Reconnect Procedure Figure A.4 Input Gas Supply ConnectionsFigure A.5 Reconnect Diagram For 208/230/1/60 Machines Connect Output Components Connections Wire Size Conversion Parts GUN and Cable InstallationWIRE-MATIC Table of Contents Operation Section OperationWELDING, Cutting Safety InstructionsGeneral Description Design Features Advantages Recommended Processes and EquipmentDuty Cycle Amps Volts Machine CapabilityLimitations Controls and Settings Figure B.1 Operator ControlsUsing the Wire Drive Roll Figure B.2 Wire Reel LoadingFeeding Electrode Setting Idle Roll Pressure Operating StepsMaking a Weld WIRE-MATIC Accessories Table of Contents Accessories SectionK672-1 Spool GUN Adapter KIT OPTIONS/ACCESSORIESMagnum GUN Connection KIT Optional K466-6 Making a Weld with the Spool GUN Adapter K672-1 Installed Timer KIT K585-1 Timer KIT Installation Optional K585-1Drive Roll Kits 64 1.2mm Aluminum Feeding KIT K673-1K468 8 Spool Adapter K363P READI-REEL AdapterDual Cylinder Mounting KIT K671-1 Maintenance Table of Contents Maintenance SectionRoutine and Periodic Maintenance Perform the following dailyMaintenance Cable Cleaning Contact TIP and GAS Nozzle InstallationDrive Rolls and Guide Tubes GUN Tubes and NozzlesLiner Removal Replacement Figure D.2 Liner maintenanceGUN Handle Disassembly To open up the handleDescription English Size Metric Size WIRE-MATIC Table of Contents Theory of Operation Section Theory of OperationInput Line Voltage and Main TransformerOutput Rectification Feedback ControlConstant Voltage Output Figure E.4 Constant Voltage OutputWire Drive Motor FeedbackThermal Protection SCR Operation Figure E.6 SCR OperationWIRE-MATIC Troubleshooting & Repair Table of Contents Troubleshooting & Repair SectionHOW to USE Troubleshooting Guide Recommended Course of ActionBoard can be dam- aged by static electricity PC Board Troubleshooting ProceduresElectric Shock can kill Main Transformer Rectifier Assembly Test To Section TOC SCR Rectifier Perform the Wire Drive Motor Liquid elec Trolyte in these capacitors isPerform the Output Rectifier Materials Needed Main Transformer TestTest Description Main Transformer Test Test Procedure ON/OFF Power Switch will be hot during these testsLead Plug Location Static SCR Rectifier Assembly Test Leads Figure F.4 SCR 1 Test Points Active SCR Rectifier Assembly Test Leads Figure F.7 SCR Tester Circuit SCR connectionsWire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test Procedure Test for Supply Voltage to Tachometer Test for Feedback Voltage to the Control BoardScope Settings Normal Open Circuit Voltage WaveformMachine 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 & Repair Typical SCR Gate Voltage Waveform Control PC Board Removal and Replacement Removal and Replacement ProcedureRemoval and REPLACE- Ment Procedure Wire Drive Assembly Removal and Replacement Procedure Figure F.11 Wire Drive Assembly RemovalSCR Output Rectifier Removal & Replacement Right side heat sink See Figure F.14 Disconnection Heat Sink LeadCapacitor Bank Removal and Replacement Bank Removal Replacement ComponentsMain Transformer Removal and Replacement Power Switch FAN Motor and FAN Removal and Replacement FAN Motor and FAN Removal and Replacement Procedure Figure F.16 Fan Motor and Fan Removal ComponentsTroubleshooting & Repair Wire Speed Range Open Circuit VoltageInput Volts/Hertz 230/60 375WIRE-MATIC Table of Contents Electrical Diagrams Section WIRE-MATIC Electrical Diagrams Wiring Diagram 208/230 CodeWire Matic 255 230 / 460 Wiring Diagram 230/460/575 CodeControl PC Board G2803 Schematic Wirematic 255 Control Control PC Board G2803 Layout