Lincoln Electric SVM 119-A - ACCESSORIES SECTION -

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ACCESSORIES

WIRE-MATIC 255

ACCESSORIES SECTION ....................................... Section C

Other Available Magnum 250LGun and

Cable Assembly ..........................................................C-1

Magnum Gun Connection Kit (Optional K466-6).............C-1

K672-1 Spool Gun Adapter Kit.........................................C-1

Making a Weld with the Spool Gun Adapter and

Spool Gun (K672-1) Installed......................................C-1

Making a Weld with the Spool Gun Adapter (K672-1)

Installed.......................................................................C-2

Timer Kit (K585-1)............................................................C-3

Timer Kit Installation (Optional K585-1)...........................C-3

Making Spot and Stitch Welds with Timer Kit Installed...C-4

Drive Roll Kits ..................................................................C-4

3/64” Aluminum Feeding Kit (K673-1)..............................C-4

K468 8” Spool Adapter.....................................................C-4

K363P Readi-Reel Adapter..............................................C-4

Dual Cylinder Mounting (K671-1).....................................C-5

TABLE OF CONTENTS

- ACCESSORIES SECTION -

Contents

Main WIRE-MATIC 255 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 119-A ARC RAYS can burn. ELECTRIC SHOCK can kill. ARC WELDING can be hazardous. 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 255 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-255 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 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 255 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 FAST OR SLOW RUN-IN MODE SELECTION INSTRUCTIONS TO ENTER SLOW RUN-IN MODE INSTRUCTIONS TO ENTER FAST RUN-IN MODE MAKING A WELD Changing Run In Mode Section Page - ACCESSORIES SECTION - MAKING A WELD WITH THE SPOOL GUN ADAPTER AND SPOOL GUN (K672-1) INSTALLED MAGNUM GUN CONNECTION KIT (Optional K466-6) K672-1 SPOOL GUN ADAPTER KIT OPTIONS/ACCESSORIES OTHER AVAILABLE MAGNUM 250L GUN AND CABLE ASSEMBLY MAKING A WELD WITH THE SPOOL GUN ADAPTER (K672-1) INSTALLED 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: DRIVE ROLL KITS 3/64 (1.2mm) ALUMINUM FEEDING KIT (K673-1) Page - MAINTENANCE SECTION - SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE Perform the following daily: Perform Periodically: Page DRIVE ROLLS AND GUIDE TUBES 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 COUNTER- CLOCKWISE 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 __________________________ MAIN TRANSFORMER TEST (CONTINUED) 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 (208/230) Code 10166 C-RW J16 J13 WIRE - MATIC 255 (230 / 460 / 575V) J21 R.F. CHOKE AS'BLY BB WW R.F. R.F. CHOKE CHOKE AS'BLY AS'BLY Control PC Board (G2803) Schematic G-5 Control PC Board (G2803) Layout 2803 G2803 G THE LINCOLN ELECTRIC CO.