Lincoln Electric SVM 119-A Making a Weld with the Spool GUN Adapter K672-1 Installed

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C-2

ACCESSORIES

C-2

 

 

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MAKING A WELD WITH THE SPOOL GUN ADAPTER (K672-1) INSTALLED

CAUTION

In either transfer switch position, closing the gun trigger will cause the electrode of both guns to be electrically "HOT." Be sure unused gun is posi- tioned so the electrode or the tip will not contact metal case or other metal common to the work. A gun holder is provided with the K672-1 kit for this purpose.

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1.The transfer switch in FEEDER position:

a.Disables spool gun trigger, wire feed, and gas output.

b.Closing the feeder gun trigger starts feeder gun welding and makes both electrodes elec- trically "HOT."

2.Transfer switch in SPOOL position:

a.Disables feeder gun wire feed and gas output. However, closing feeder gun trigger will make both electrodes electrically “HOT” and activate spool gun gas output.

b.Closing spool gun trigger starts spool gun welding and makes both electrodes electrical- ly "HOT".

3.Operation with Wire-Matic 255:

a.Turn the Wire-Matic input power ON, and the transfer switch is to be in the SPOOL position.

b.Adjusting the voltage control will increase or decrease your welding Voltage.

c.Adjusting the wire speed control will increase or decrease the spool gun wire feed speed. This represents the set speed for the K469 spool gun and the maximum set speed for the K487 Spool Gun with the remote control in gun handle at maximum.

The remote control turned to minimum will give approximately 50% of the maximum set WFS.

NOTE: The WIRE-MATIC 255 speed calibrated dial markings are not accurate when used for setting the Spool Gun speed.

4.The following procedure settings can be used as initial settings for making test welds to determine final settings:

Wire Diameter

WFS Setting

Arc Voltage

In. (mm)

Wire-Matic 255

Setting

 

 

 

.030” (.8mm)

270

15 V

.035” (.9mm)

250

16 V

3/64” (1.2mm)

210

21 V

 

 

 

5.To return to normal WIRE-MATIC 255 welding, set the transfer switch to FEEDER position and reset feeder gun weld procedure settings.

WIRE-MATIC 255

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Contents Safety Depends on You WIRE-MATICFumes and Gases can be dangerous SafetyElectric Shock can kill ARC Rays can burnWelding 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 Stacking Safety PrecautionsSelect Proper Location Input ConnectionsFuse 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 K585-1K363P READI-REEL Adapter Drive Roll Kits64 1.2mm Aluminum Feeding KIT K673-1 K468 8 Spool AdapterDual Cylinder Mounting KIT K671-1 Table of Contents Maintenance Section MaintenancePerform the following daily Routine and Periodic MaintenanceMaintenance GUN Tubes and Nozzles Cable CleaningContact TIP and GAS Nozzle Installation Drive Rolls and Guide TubesFigure 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 230/60 375 Wire Speed RangeOpen Circuit Voltage Input Volts/HertzWIRE-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