Lincoln Electric SVM 119-A service manual Machine Capability, Limitations, Duty Cycle Amps Volts

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B-3

OPERATION

B-3

 

 

WIRE FEEDER FEATURES:

MACHINE CAPABILITY

 

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Wire Loading - Adjustable brake spindle mounts Readi-Reel® Adapter, included with WIRE-MATIC 255, or most any 2" (51mm) I.D. wire spool. Accommodating standard 12" (305mm) and 8" (203mm) diameter coils, the spindle’s adjustable brake provides appropriate dereeling drag to prevent wire reel overrun and loop-offs.

Tachometer Controlled Wire Drive - Precision con- trol of permanent magnet motor provides proper wire feed acceleration and speed accuracy, independent of fluctuations in line voltage and wire loading. This gives reliable arc starting and weld consistency.

Selectable Run-In Start-Up - A user selectable fea- ture allows the wire feeder to feed wire directly at the selected speed, (factory selected), or when the trigger is pulled the wire feeder feeds wire at slow speed regardless of the set wire feed speed until welding cur- rent is drawn or 2 seconds has expired. This feature enhances starting and makes setting stick out a snap The 2 second limit permits high speed loading of the gun and cable.

Solid State Overload Protection - No circuit breaker to reset. Simply pull the trigger to resume welding once the overload condition has been cleared.

Unique Drive Roll and Guide Tube Design - Precisely aligned guide tubes and drive rolls provide long life. The design also permits quick reload by sim- ply starting wire into ingoing guide tube. Adjustable tension setting minimizes 'birdnesting', eliminates milling through the wire, and gives positive feeding. The double groove, reversible drive roll included with the WIRE-MATIC 255 allows use of .030" (0.8mm) through .045" (1.2mm) diameter wire. Drive roll kits for other sizes and types of wire are also available.

Quick-Connect Welding Gun - Gun connector has integrated welding power and gas connection with sep- arate front-paneltwist-lock trigger connection mount.

Gun and Cable - A 12 ft. (3.6m) GMAW gun and cable assembly, rated 200 amps 60% duty, or 250 amps 35% duty, is provided with the WIRE-MATIC 255. A liner, diffuser and contact tips for .035" (0.9mm) and .045" (1.2mm) electrodes are included.

The WIRE-MATIC 255 is rated on the following duty cycles based on a 10-minute time period (i.e., for 60% duty cycle, it is 6 minutes on and 4 minutes off).

Duty Cycle

Amps.

Volts

 

 

 

100%

145

26

60%

200

28

35%

250

26

 

 

 

LIMITATIONS

The WIRE-MATIC 255 may not operate satisfactorily if powered with a portable or in-plant generating system.

WIRE-MATIC 255

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Contents WIRE-MATIC Safety Depends on YouARC Rays can burn SafetyElectric Shock can kill Fumes and Gases can be dangerousCylinder may explode if damaged Welding Sparks can cause fire or explosionMay be dangerous Electric and MAG- Netic FieldsIii 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 Input Connections Safety PrecautionsSelect Proper Location 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 ConnectionsWire Size Conversion Parts GUN and Cable InstallationWIRE-MATIC Table of Contents Operation Section OperationGeneral Description Safety InstructionsWELDING, Cutting Design Features Advantages Recommended Processes and EquipmentLimitations Machine CapabilityDuty Cycle Amps Volts 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 SectionMagnum GUN Connection KIT Optional K466-6 OPTIONS/ACCESSORIESK672-1 Spool GUN Adapter KIT Making a Weld with the Spool GUN Adapter K672-1 Installed Timer KIT K585-1 Timer KIT Installation Optional K585-1K468 8 Spool Adapter Drive Roll Kits64 1.2mm Aluminum Feeding KIT K673-1 K363P READI-REEL AdapterDual Cylinder Mounting KIT K671-1 Maintenance Table of Contents Maintenance SectionRoutine and Periodic Maintenance Perform the following dailyMaintenance Drive Rolls and Guide Tubes Cable CleaningContact TIP and GAS Nozzle Installation 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 ActionElectric Shock can kill PC Board Troubleshooting ProceduresBoard can be dam- aged by static electricity 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 Test Description Main Transformer TestMaterials Needed 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 Input Volts/Hertz Wire Speed RangeOpen Circuit Voltage 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