Lincoln Electric SVM 119-A service manual Procedure, Figure F.11 Wire Drive Assembly Removal

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F-30

TROUBLESHOOTING & REPAIR

F-30

 

 

WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT (CONTINUED)

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PROCEDURE

1.Disconnect main input power to the machine.

2.Remove the Case Top and Side Panels.

3.Using the 5/16” Nutdriver remove the gear box top cover.

4.Remove the two sheet metal screws located on the left rear side of the gear box housing using a 5/16” nut- driver.

5.Remove the drive roll. See Figure F.11.

a.Remove the thumb screw, drive hub, and the spacer.

6.Remove the screw holding the gun connector assembly to the Case Front Panel. See Figure F.11.

7.Slide the entire wire drive assembly carefully toward the Case Back and approximately 2” (51 mm) away from the center baffle to gain access to the drive motor and wiring.

a.The gas hose and gun connec- tor leads will limit the travel dis- tance.

8.Disconnect the drive motor from the drive roll assembly.

a.Remove the three large phillips head screws on the outboard side of the drive roll assembly face plate using a phillips head screw driver.

9.Separate the drive roll assembly from the drive motor.

a.Grip the drive motor in one hand and the drive assembly in the other hand.

b.Wiggle the drive motor and drive assembly gently back and forth until the two parts separate.

FIGURE F.11 - Wire Drive Assembly Removal

10.Disconnect molex plugs J15, J12, and J11. See wiring diagram.

11.Remove the drive roll assembly.

a.Remove the two screws mount- ing the drive roll assembly to the insulator board using a 5/16” nut driver.

b.Loosen the set screw using a slot head screwdriver that holds the outgoing guide tube into the drive roll assembly.

c.Remove the drive assembly by sliding it off the out going guide tube and towards the Case Back at the rear of the machine.

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