Lincoln Electric SVM 119-A service manual Timer KIT K585-1, Timer KIT Installation Optional K585-1

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C-3

ACCESSORIES

C-3

 

 

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TIMER KIT (K585-1)

The Timer Kit provides selectable 4-step trigger inter- lock, spot and stitch functions, and manual adjustment of burnback time. This kit installs easily using only a screwdriver. It replaces the blank upper panel on Case Front. It offers the following mode selections:

The Normal Welding mode provides welding power only while gun trigger is pressed.

The 4-Step Trigger mode eliminates the need to hold gun trigger while welding. It operates in 4 steps:

1.Close trigger and establish welding arc.

2.Release trigger and continue welding.

3.Re-close trigger near end of weld.

4.Release trigger again to stop welding.

The Spot Weld mode allows a single timed weld cycle each time the gun trigger is held closed. Duration is set with SPOT/STITCH ON TIME knob.

The Stitch Weld mode allows repeated timed weld cycles while gun trigger is held closed. Weld on- time is set with SPOT/STITCH ON TIME knob, and weld off time is set with STITCH OFF TIME knob.

The BURNBACK TIME knob is used to manually set arc power delay at the end of any above selected weld mode to prevent wire sticking in the weld. With the Timer Kit not installed, a preselected delay is automat- ically set by the machine.

TIMER KIT INSTALLATION (OPTIONAL K585-1)

WARNING

Remove all input power to the WIRE-MATIC 255 before proceeding.

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1.Verify that the following items have been included in the kit:

a.Timer Board and Panel Assembly.

b.Two sheet metal screws.

c.Wiring harness.

2.Turn the POWER SWITCH to OFF.

3.Disconnect AC input power to the machine.

4.Remove the Cover Plate Assembly from the front of the machine by removing the two screws which fasten it using a screwdriver, a 5/16" (8mm) nut dri- ver, or other suitable tool.

5.Reach through the exposed panel opening and attach the rectangular 8-pin plug connector on the Timer Kit wiring harness to the available mating receptacle connector on the upper left corner of the Control Board inside the machine.

a.Be sure that the latch on the connector is aligned with that on the Control Board and insert it until the latch engages.

b.Check that the remaining connector on the opposite end of the wiring harness is firmly attached to the mating connector on the PC Board on the Timer Kit panel, and that the latch is engaged.

6.Align the Timer Kit panel so you can carefully insert the printed circuit board and wiring harness through the opening in the front panel.

a.Make sure the wiring harness is not pinched between panels or between printed circuit board and front panel.

7.Fasten the Timer Kit assembly with either the two supplied screws or with the original screws to com- plete the installation.

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 ConnectionsWire 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