Lincoln Electric SVM 119-A service manual Drive Roll Kits, 64 1.2mm Aluminum Feeding KIT K673-1

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C-4

ACCESSORIES

C-4

 

 

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MAKING SPOT AND STITCH WELDS WITH TIMER KIT INSTALLED

TO MAKE SPOT PLUG WELDS:

The SPOT WELD MODE is used to make spot plug welds when continuous welds are not needed or to hold thin sheet metal together prior to stitch welding or continuous welding.

Plug welds are made by using a punch to make a 3/16" (5mm) diameter hole in the top sheet and arc welding through the hole into the back sheet.

1.Punch 3/16" (5mm) holes in the top sheet.

2.Set the SPOT/STITCH ON-TIME control to approximately 1.2 seconds.

3.Set the procedure for the metal thickness to be welded.

4.Install spot weld nozzle (if available) on gun and press it against the top sheet so the top and bot- tom sheets are tight together.

5.Close trigger and hold it closed until the arc goes out.

a.If a spot weld nozzle is not used, smoother welds will result by moving the welding wire in a small circle during the weld.

TO MAKE A STITCH WELD:

The STITCH WELD MODE is used to weld thin mater- ial when warpage and burn through are a problem. Proper adjustment of the Spot/Stitch On-Time, Stitch Off-Time, and arc travel speed permits welding thin sheet metal with small welds, minimum distortion, and no burnthrough.

1.The SPOT/STITCH ON-TIME KNOB sets welding time.

a.Start with a dial setting of 0.5 seconds. Raise setting to increase penetration and weld size. Lower setting to reduce burnthrough and dis- tortion.

2.The STITCH OFF-TIME KNOB sets off time between welds.

a.Start with a dial setting of 0.5 seconds. Raise setting to reduce burnthrough. Lower setting to make weld flatter and smoother.

3.Set the procedure for the metal thickness to be welded.

4.Close trigger and hold it closed for length of seam.

a.Hold gun in one place during ON time and move gun just beyond edge of molten metal during OFF time.

NOTE: For smoothest welds on thinner metal, point gun slightly toward the direction of travel.

DRIVE ROLL KITS

The following drive rolls and Magnum 250L gun and cable parts are available to feed different sizes and types of electrodes.

Steel Wire Sizes:

Part Number

.025 - .035" (0.6-0.9mm)

KP674-035S

.030 - .045" (0.8-1.2mm)

KP674-045S

.045" Cored (1.2mm)

KP674-045C

 

 

Aluminum Wire Sizes:

 

3/64" (1.2mm)

KP674-3/64A

 

 

3/64” (1.2mm) ALUMINUM FEEDING KIT (K673-1)

Provides gun and wire drive conversion parts to weld with 3/64” (1.2mm) aluminum wire. 5356 alloy alu- minum wire is recommended for best push feeding performance.

Kit includes drive roll and incoming guide tube for the wire drive, and 450 gun tube, liner and two contact tips for the gun, along with S21529 installation instructions.

K468 8” SPOOL ADAPTER

The K468 Spool Adapter permits the use of 8” Spools on the Wire-Matic 255 spindle.

K363P READI-REEL ADAPTER

The K363P Readi-Reel Adapter mounts to the 2” spin- dle. It is needed to mount the 22-20 lb. Readi-Reels.

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 damagedElectric and MAG- Netic Fields May be dangerousIii 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 SectionSafety Instructions General DescriptionWELDING, Cutting Recommended Processes and Equipment Design Features AdvantagesMachine Capability LimitationsDuty 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 AccessoriesOPTIONS/ACCESSORIES Magnum GUN Connection KIT Optional K466-6K672-1 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 GuidePC Board Troubleshooting Procedures Electric Shock can killBoard 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 Main Transformer Test Test DescriptionMaterials 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
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