Lincoln Electric SVM 119-A service manual Feeding Electrode

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B-6

OPERATION

B-6

 

 

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To mount a 10 to 44 lb. (4.5 to 20 kg) spools: 8” (200mm) [Use K468 Adapter] and 12” (300mm) diameter:

1.Remove the locking collar and the Readi-Reel Adapter (if installed) on the 2 inch (51mm) diame- ter spindle.

2.If using an 8” (200mm) spool, place the K468 Adapter on the spindle first. The hole in the Adapter arm is to engage the pin on the spindle.

3.Place the spool on the spindle, making certain the brake driving pin enters one of the holes in the back side of the spool. Be certain the wire comes off the reel in a clockwise direction when dereeled from the top of the coil.

4.Replace and tighten the locking collar for several seconds.

FEEDING ELECTRODE

WARNING

When inching, the electrode and drive mechanism are electrically hot to work and ground. The elec- trode remains hot several seconds after the gun trigger is released.

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NOTE: Check that the proper drive rolls and gun parts for the wire size and type are being used.

1.Turn the Readi-Reel or spool until the free end of the electrode is accessible.

2.Tightly holding the electrode, cut off the bent end and straighten the first six inches.

a.If the electrode is not properly straightened, it may not feed properly into the outgoing guide tube or welding gun causing a "birdnest.")

5.Press the gun trigger and push the electrode into the drive roll.

a.If the electrode fails to thread itself into the out- going guide tube of the wire drive

open the quick release idle roll arm

thread the electrode manually

re-close the arm.

6.Inch the electrode through the gun.

NOTE: If using the low speed starting feature, the wire will feed at low speed for 2 seconds while inching, then come up to the set speed. To change run-in mode, see the Changing the Run In Mode Section.

PROPER WIRE FEEDING

Wire feeding problems can be avoided by observing the following gun handling procedures:

Do not kink or pull cable around sharp corners.

Keep the electrode cable as straight as possible when welding or loading electrode through cable.

Do not allow dolly wheels or trucks to run over cables.

Keep cable clean by following maintenance instructions.

Use only clean, rust-free electrode. The Lincoln electrodes have proper surface lubrication.

Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed.

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3.Cut off the first inch.

4.Push the wire through the ingoing guide tube.

WIRE-MATIC 255

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Contents Safety Depends on You WIRE-MATICElectric Shock can kill SafetyARC Rays can burn Fumes and Gases can be dangerousWelding Sparks can cause fire or explosion Cylinder may explode if damagedMay be dangerous Electric and MAG- Netic FieldsIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéWIRE-MATIC Table of Contents Table of Contents Table of Contents Installation Section InstallationTechnical Specifications Wire-Matic-255 Select Proper Location Safety PrecautionsInput Connections StackingFuse and Wire Sizes Connect Shielding GAS Figure A.4 Input Gas Supply Connections Reconnect ProcedureFigure A.5 Reconnect Diagram For 208/230/1/60 Machines Connections Connect Output ComponentsGUN and Cable Installation Wire Size Conversion PartsWIRE-MATIC Operation Table of Contents Operation SectionGeneral Description Safety InstructionsWELDING, Cutting Recommended Processes and Equipment Design Features AdvantagesLimitations Machine CapabilityDuty Cycle Amps Volts Figure B.1 Operator Controls Controls and SettingsFigure B.2 Wire Reel Loading Using the Wire Drive RollFeeding Electrode Operating Steps Setting Idle Roll PressureMaking a Weld WIRE-MATIC Table of Contents Accessories Section AccessoriesMagnum 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 Installation Optional K585-1 Timer KIT K585-164 1.2mm Aluminum Feeding KIT K673-1 Drive Roll KitsK468 8 Spool Adapter K363P READI-REEL AdapterDual Cylinder Mounting KIT K671-1 Table of Contents Maintenance Section MaintenancePerform the following daily Routine and Periodic MaintenanceMaintenance Contact TIP and GAS Nozzle Installation Cable CleaningDrive Rolls and Guide Tubes GUN Tubes and NozzlesFigure D.2 Liner maintenance Liner Removal ReplacementTo open up the handle GUN Handle DisassemblyDescription English Size Metric Size WIRE-MATIC Theory of Operation Table of Contents Theory of Operation SectionTransformer Input Line Voltage and MainFeedback Control Output RectificationFigure E.4 Constant Voltage Output Constant Voltage OutputFeedback Wire Drive MotorThermal Protection Figure E.6 SCR Operation SCR OperationWIRE-MATIC Table of Contents Troubleshooting & Repair Section Troubleshooting & RepairRecommended Course of Action HOW to USE Troubleshooting GuideElectric 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 Trolyte in these capacitors is Liquid elecPerform the Output Rectifier Test Description Main Transformer TestMaterials Needed ON/OFF Power Switch will be hot during these tests Main Transformer Test Test ProcedureLead Plug Location Static SCR Rectifier Assembly Test Leads Figure F.4 SCR 1 Test Points Active SCR Rectifier Assembly Test Leads SCR connections Figure F.7 SCR Tester CircuitWire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test Procedure Test for Feedback Voltage to the Control Board Test for Supply Voltage to TachometerNormal Open Circuit Voltage Waveform Scope SettingsTypical Output Voltage Waveform Machine Loaded Machine Loaded to 250 Amps AT 26 VDC Scope SettingsMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Removal and Replacement Procedure Control PC Board Removal and ReplacementRemoval and REPLACE- Ment Procedure Wire Drive Assembly Removal and Replacement Figure F.11 Wire Drive Assembly Removal ProcedureSCR Output Rectifier Removal & Replacement Disconnection Heat Sink Lead Right side heat sink See Figure F.14Capacitor Bank Removal and Replacement Components Bank Removal ReplacementMain Transformer Removal and Replacement Power Switch FAN Motor and FAN Removal and Replacement Figure F.16 Fan Motor and Fan Removal Components FAN Motor and FAN Removal and Replacement ProcedureTroubleshooting & Repair Open Circuit Voltage Wire Speed RangeInput Volts/Hertz 230/60 375WIRE-MATIC Table of Contents Electrical Diagrams Section WIRE-MATIC Wiring Diagram 208/230 Code Electrical DiagramsWiring Diagram 230/460/575 Code Wire Matic 255 230 / 460Control PC Board G2803 Schematic Control PC Board G2803 Layout Wirematic 255 Control