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Welding System
Lincoln Electric
SVM 119-A
service manual
Wire-Matic
Models:
SVM 119-A
1
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Install
Electrical Diagrams
Timer KIT K585-1
Wire-Matic
Maintenance
Options/Accessories
GUN Handle Disassembly
Reconnect Procedure
Controls and Settings
Cable Cleaning
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WIRE-MATIC
255
NOTES
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Contents
WIRE-MATIC
Safety Depends on You
ARC Rays can burn
Safety
Electric Shock can kill
Fumes and Gases can be dangerous
Cylinder may explode if damaged
Welding Sparks can cause fire or explosion
May be dangerous
Electric and MAG- Netic Fields
Iii
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 Precautions
Select 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
General Description
Safety Instructions
WELDING, Cutting
Design Features Advantages
Recommended Processes and Equipment
Limitations
Machine Capability
Duty 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
Magnum GUN Connection KIT Optional K466-6
OPTIONS/ACCESSORIES
K672-1 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 Kits
64 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 Cleaning
Contact 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
Electric Shock can kill
PC Board Troubleshooting Procedures
Board 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
Test Description
Main Transformer Test
Materials 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 Range
Open 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
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