Lincoln Electric SVM 119-A service manual Table of Contents Maintenance Section

Page 35

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MAINTENANCE

TABLE OF CONTENTS

- MAINTENANCE SECTION -

MAINTENANCE SECTION	Section D
Safety Precautions	D-1
Routine and Periodic Maintenance	D-1
Component Locations	D-2
Drive Rolls and Guide Tubes	D-3
Cable Cleaning	D-3
Gun Tubes and Nozzles	D-3
Contact Tip and Gas Nozzle Installation	D-3
Liner Removal and Replacement	D-4
Liner Removal, Installation, and Trimming Instructions
for Magnum 250L	D-4
Gun Handle Disassembly	D-5
Accessories and Expendable Replacement Parts for
Magnum 250L Gun and Cable Assemblies	D-6

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 damagedIii Electric and MAG- Netic FieldsMay be dangerous 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 SectionWELDING, Cutting Safety InstructionsGeneral Description Recommended Processes and Equipment Design Features AdvantagesDuty Cycle Amps Volts Machine CapabilityLimitations 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 AccessoriesK672-1 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 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 GuideBoard 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 Trolyte in these capacitors is Liquid elecPerform the Output Rectifier Materials Needed Main Transformer TestTest Description 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