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Lincoln Electric SVM 117-A - INSTALLATION SECTION -

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INSTALLATION

WIRE-MATIC 250

INSTALLATION SECTION ........................................ Section A

Technical Specifications...................................................A-1

Safety Precautions...........................................................A-2

Select Proper Location.....................................................A-2

Stacking.......................................................................A-2

Tilting...........................................................................A-2

Input Connections ............................................................A-2

Fuse and Wire Sizes...................................................A-3

Input Power Connections and Ground Connections...A-3

Connect Shielding Gas................................................A-4

Reconnect Procedure.......................................................A-5

Connect Output Components...........................................A-7

Install the Work Clamp................................................A-7

Output Polarity Connection.........................................A-7

Gun Liner and Contact Tip Installation........................A-7

Wire Size Conversion Parts........................................A-8

Gun and Cable Installation..........................................A-8

TABLE OF CONTENTS

- INSTALLATION SECTION -

Contents

Main WIRE-MATIC 250 SERVICE MANUAL View Safety Info View Safety Info View Safety Info View Safety Info 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100 SVM 117-A WARNING FUMES AND GASES can be dangerous. CYLINDER may explode if damaged. FOR ELECTRICALLY powered equipment. Feb. 95 ii WELDING SPARKS can cause fire or explosion. ELECTRIC AND MAG- NETIC FIELDS may be dangerous FOR ENGINE powered equipment. iv Mar. 93 WIRE-MATIC 250 PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Page TABLE OF CONTENTS TABLE OF CONTENTS (continued) - INSTALLATION SECTION - TECHNICAL SPECIFICATIONS - Wire-Matic-250 SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. Reconnect Section SELECT PROPER LOCATION STACKING FUSE AND WIRE SIZES Technical Specifications INPUT POWER CONNECTIONS AND GROUND CONNECTIONS Technical Specification Technical Specifications CONNECT SHIELDING GAS Accessories Section RECONNECT PROCEDURE ___________________________________ Page CONNECT OUTPUT COMPONENTS INSTALL THE WORK CLAMP OUTPUT POLARITY CONNECTION GUN LINER AND CONTACT TIP INSTALLATION WIRE SIZE CONVERSION PARTS Acessories Section GUN AND CABLE INSTALLATION Page - OPERATION SECTION - SAFETY INSTRUCTIONS GENERAL DESCRIPTION POWER SOURCE FEATURES: RECOMMENDED PROCESSES AND EQUIPMENT DESIGN FEATURES AND ADVANTAGES UNIT FEATURES: WIRE FEEDER FEATURES: MACHINE CAPABILITY LIMITATIONS CONTROLS AND SETTINGS WIRE-MATIC 250 USING THE WIRE DRIVE ROLL PROCEDURE FOR CHANGING DRIVE ROLL LOADING THE WIRE REEL FEEDING ELECTRODE Changing the Run In Mode Section PROPER WIRE FEEDING SETTING IDLE ROLL PRESSURE OPERATING STEPS ___________________________________ STARTING THE WELDER CHANGING RUN-IN MODE (Later models only) MAKING A WELD Changing Run In Mode Section Page - ACCESSORIES SECTION - K607-1 SPOOL GUN ADAPTER KIT INSTALLING THE K607-1 SPOOL GUN ADAPTER KIT OPTIONS/ACCESSORIES REPLACEMENT MAGNUM 250L GUN AND CABLE ASSEMBLY SPOOL GUN MODULE BOARD INSTALLATION SPOOL GUN CONNECTION BOX INSTALLATION Installation Chapter SPOOL GUN PREPARATION SPOOL GUN CONNECTION MAKING A WELD WITH THE SPOOL GUN ADAPTER (K607-1) INSTALLED MAKING THE WELD: TIMER KIT (K585-1) TIMER KIT INSTALLATION (OPTIONAL K585-1) MAKING SPOT AND STITCH WELDS WITH TIMER KIT INSTALLED TO MAKE SPOT PLUG WELDS: TO MAKE A STITCH WELD: ADJUSTABLE GAS REGULATOR AND HOSE KIT (K586-1) DRIVE ROLL KITS - MAINTENANCE SECTION - SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE Perform the following daily: Perform Periodically: Page DRIVE ROLLS AND GUIDE TUBES DROP-IN REEL SPINDLE AND CLIPS CABLE CLEANING GUN TUBES AND NOZZLES CONTACT TIPAND GAS NOZZLE INSTALLATION LINER REMOVALAND REPLACEMENT LINER REMOVAL, INSTALLATION, AND TRIMMING INSTRUCTIONS FOR MAGNUM 250L GUN HANDLE DISASSEMBLY ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES Page - THEORY OF OPERATION SECTION - INPUT LINE VOLTAGE AND MAIN TRANSFORMER INPUT LINE VOLTAGE AND MAIN TRANSFORMER OUTPUT RECTIFICATION AND FEEDBACK CONTROL SCR Operation OUTPUT RECTIFICATION AND FEEDBACK CONSTANT VOLTAGE OUTPUT WIRE DRIVE MOTOR AND FEEDBACK WIRE DRIVE MOTOR AND FEEDBACK THERMAL PROTECTION SCR OPERATION Page - TROUBLESHOOTING & REPAIR SECTION - Step 1. LOCATE PROBLEM(SYMPTOM). Step 2. PERFORM EXTERNAL TESTS. Step 3. RECOMMENDED COURSE OF ACTION HOW TO USE TROUBLESHOOTING GUIDE _______________________________ PC BOARD TROUBLESHOOTING PROCEDURES Page Main Transformer Test Page Page Wire Drive Motor and Tach Feedback test Wire Drive Motor and Tach Feedback Test Page Output Rectifier Bridge Test. MAIN TRANSFORMER TEST MAIN TRANSFORMER TEST (CONTINUED) __________________________ Page STATIC SCR RECTIFIER ASSEMBLY TEST STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED) LEADS X2 AND X3 NEGATIVE CAPACITOR BANK BUSS BAR Page ACTIVE SCR RECTIFIER ASSEMBLYTEST ACTIVE SCR RECTIFIER ASSEMBLYTEST (CONTINUED) LEADS X2 AND X3 NEGATIVE CAPACITOR BANK BUSS BAR Page Page Page WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (CONTINUED) NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED ONE OUTPUT SCR NOT FUNCTIONING ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING TYPICAL SCR GATE VOLTAGE WAVEFORM CONTROL PC BOARD REMOVALAND REPLACEMENT REMOVALAND REPLACEMENT PROCEDURE MATERIALS NEEDED CONTROL PC BOARD REMOVALAND REPLACEMENT (CONTINUED) REMOVALAND REPLACE- MENT PROCEDURE WIRE DRIVE ASSEMBLYREMOVAL AND REPLACEMENT WIRE DRIVE ASSEMBLYREMOVAL AND REPLACEMENT (CONTINUED) SCR OUTPUT RECTIFIER REMOVAL & REPLACEMENT SCR OUTPUT RECTIFIER REMOVAL & REPLACEMENT (CONTINUED) CAPACITOR BANK REMOVALAND REPLACEMENT CAPACITOR BANK REMOVALAND REPLACEMENT (CONTINUED) MAIN TRANSFORMER REMOVALAND REPLACEMENT MAIN TRANSFORMER REMOVALAND REPLACEMENT (CONTINUED) FAN MOTOR AND FAN REMOVAL AND REPLACEMENT Page FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED) Page Page Page Page ELECTRICAL DIAGRAMS Wiring Diagram (230/460/575) Code 10004 S1 266 } } 267 GUN TRIGGER S2 } } } 2-5-93 L9078 TO SPOOL GUN OPTION } } GUN TRIGGER S2 G } } G-5 G-6 Control PC Board (G2332) Schematic 2/16/93 MJH CAPS. = ufd (.022/50V UNLESS OTHERWISE SPECIFIED) DIODES = 1A, 400V (UNLESS OTHERWISE SPECIFIED) Control PC Board (G2332) Layout