Wire-Matic | Lincoln Electric SVM 119-A instruction

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WIRE-MATIC 255

NOTES

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Lincoln Electric SVM 119-A service manual Wire-Matic

Contents

WIRE-MATIC Safety Depends on You ARC Rays can burn SafetyElectric Shock can kill Fumes and Gases can be dangerous Cylinder may explode if damaged Welding Sparks can cause fire or explosion Electric and MAG- Netic Fields May be dangerousIii Précautions DE Sûreté Sûreté Pour Soudage a L’Arc WIRE-MATIC Table of Contents Table of Contents Installation Table of Contents Installation Section Technical Specifications Wire-Matic-255 Input Connections Safety PrecautionsSelect Proper Location Stacking Fuse and Wire Sizes Connect Shielding GAS Reconnect Procedure Figure A.4 Input Gas Supply Connections Figure A.5 Reconnect Diagram For 208/230/1/60 Machines Connect Output Components Connections Wire Size Conversion Parts GUN and Cable Installation WIRE-MATIC Table of Contents Operation Section Operation Safety Instructions General DescriptionWELDING, Cutting Design Features Advantages Recommended Processes and Equipment Machine Capability LimitationsDuty Cycle Amps Volts Controls and Settings Figure B.1 Operator Controls Using the Wire Drive Roll Figure B.2 Wire Reel Loading Feeding Electrode Setting Idle Roll Pressure Operating Steps Making a Weld WIRE-MATIC Accessories Table of Contents Accessories Section OPTIONS/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 K585-1 Timer KIT Installation Optional K585-1 K468 8 Spool Adapter Drive Roll Kits64 1.2mm Aluminum Feeding KIT K673-1 K363P READI-REEL Adapter Dual Cylinder Mounting KIT K671-1 Maintenance Table of Contents Maintenance Section Routine and Periodic Maintenance Perform the following daily Maintenance Drive Rolls and Guide Tubes Cable CleaningContact TIP and GAS Nozzle Installation GUN Tubes and Nozzles Liner Removal Replacement Figure D.2 Liner maintenance GUN Handle Disassembly To open up the handle Description English Size Metric Size WIRE-MATIC Table of Contents Theory of Operation Section Theory of Operation Input Line Voltage and Main Transformer Output Rectification Feedback Control Constant Voltage Output Figure E.4 Constant Voltage Output Wire Drive Motor Feedback Thermal Protection SCR Operation Figure E.6 SCR Operation WIRE-MATIC Troubleshooting & Repair Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Recommended Course of Action PC 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 Liquid elec Trolyte in these capacitors is Perform the Output Rectifier Main Transformer Test Test DescriptionMaterials Needed Main Transformer Test Test Procedure ON/OFF Power Switch will be hot during these tests Lead Plug Location Static SCR Rectifier Assembly Test Leads Figure F.4 SCR 1 Test Points Active SCR Rectifier Assembly Test Leads Figure F.7 SCR Tester Circuit SCR connections Wire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test Test Procedure Test for Supply Voltage to Tachometer Test for Feedback Voltage to the Control Board Scope Settings Normal Open Circuit Voltage Waveform Machine Loaded to 250 Amps AT 26 VDC Scope Settings Typical Output Voltage Waveform Machine Loaded Machine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Control PC Board Removal and Replacement Removal and Replacement Procedure Removal and REPLACE- Ment Procedure Wire Drive Assembly Removal and Replacement Procedure Figure F.11 Wire Drive Assembly Removal SCR Output Rectifier Removal & Replacement Right side heat sink See Figure F.14 Disconnection Heat Sink Lead Capacitor Bank Removal and Replacement Bank Removal Replacement Components Main Transformer Removal and Replacement Power Switch FAN Motor and FAN Removal and Replacement FAN Motor and FAN Removal and Replacement Procedure Figure F.16 Fan Motor and Fan Removal Components Troubleshooting & Repair Input Volts/Hertz Wire Speed RangeOpen Circuit Voltage 230/60 375 WIRE-MATIC Table of Contents Electrical Diagrams Section WIRE-MATIC Electrical Diagrams Wiring Diagram 208/230 Code Wire Matic 255 230 / 460 Wiring Diagram 230/460/575 Code Control PC Board G2803 Schematic Wirematic 255 Control Control PC Board G2803 Layout