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Lincoln Electric POWER MIG 255 SVM144-B Bedienungsanleitung

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Das Wort kommt vom lateinischen „instructio”, d.h. ordnen. Demnach kann man in der Anleitung Lincoln Electric POWER MIG 255 SVM144-B die Beschreibung der Etappen der Vorgehensweisen finden. Das Ziel der Anleitung ist die Belehrung, Vereinfachung des Starts, der Nutzung des Geräts oder auch der Ausführung bestimmter Tätigkeiten. Die Anleitung ist eine Sammlung von Informationen über ein Gegenstand/eine Dienstleistung, ein Hinweis.

Leider widmen nicht viele Nutzer ihre Zeit der Gebrauchsanleitung Lincoln Electric POWER MIG 255 SVM144-B. Eine gute Gebrauchsanleitung erlaubt nicht nur eine Reihe zusätzlicher Funktionen des gekauften Geräts kennenzulernen, sondern hilft dabei viele Fehler zu vermeiden.

Was sollte also eine ideale Gebrauchsanleitung beinhalten?

Die Gebrauchsanleitung Lincoln Electric POWER MIG 255 SVM144-B sollte vor allem folgendes enthalten:
- Informationen über technische Daten des Geräts Lincoln Electric POWER MIG 255 SVM144-B
- Den Namen des Produzenten und das Produktionsjahr des Geräts Lincoln Electric POWER MIG 255 SVM144-B
- Grundsätze der Bedienung, Regulierung und Wartung des Geräts Lincoln Electric POWER MIG 255 SVM144-B
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Der Grund dafür ist die fehlende Zeit und die Sicherheit, was die bestimmten Funktionen der gekauften Geräte angeht. Leider ist das Anschließen und Starten von Lincoln Electric POWER MIG 255 SVM144-B zu wenig. Eine Anleitung beinhaltet eine Reihe von Hinweisen bezüglich bestimmter Funktionen, Sicherheitsgrundsätze, Wartungsarten (sogar das, welche Mittel man benutzen sollte), eventueller Fehler von Lincoln Electric POWER MIG 255 SVM144-B und Lösungsarten für Probleme, die während der Nutzung auftreten könnten. Immerhin kann man in der Gebrauchsanleitung die Kontaktnummer zum Service Lincoln Electric finden, wenn die vorgeschlagenen Lösungen nicht wirksam sind. Aktuell erfreuen sich Anleitungen in Form von interessanten Animationen oder Videoanleitungen an Popularität, die den Nutzer besser ansprechen als eine Broschüre. Diese Art von Anleitung gibt garantiert, dass der Nutzer sich das ganze Video anschaut, ohne die spezifizierten und komplizierten technischen Beschreibungen von Lincoln Electric POWER MIG 255 SVM144-B zu überspringen, wie es bei der Papierform passiert.

Warum sollte man Gebrauchsanleitungen lesen?

In der Gebrauchsanleitung finden wir vor allem die Antwort über den Bau sowie die Möglichkeiten des Geräts Lincoln Electric POWER MIG 255 SVM144-B, über die Nutzung bestimmter Accessoires und eine Reihe von Informationen, die erlauben, jegliche Funktionen und Bequemlichkeiten zu nutzen.

Nach dem gelungenen Kauf des Geräts, sollte man einige Zeit für das Kennenlernen jedes Teils der Anleitung von Lincoln Electric POWER MIG 255 SVM144-B widmen. Aktuell sind sie genau vorbereitet oder übersetzt, damit sie nicht nur verständlich für die Nutzer sind, aber auch ihre grundliegende Hilfs-Informations-Funktion erfüllen.

Inhaltsverzeichnis der Gebrauchsanleitungen

  • Seite 1

    PO WER MIG 255 SVM144-B July , 2006 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE [...]

  • Seite 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC i SAFETY i LN-15 FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventil[...]

  • Seite 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ii SAFETY ii LN-15 ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. [...]

  • Seite 4

    POWER MIG 255 SAFETY iii iii Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and[...]

  • Seite 5

    POWER MIG 255 SAFETY iv iv Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: [...]

  • Seite 6

    POWER MIG 255 v v MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Operation . . . . . . . . . . . . . . [...]

  • Seite 7

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC X Section A-1 Section A-1 T ABLE OF CONTENTS - INST ALLA TION SECTION - Installation ..............................................................................................................Secti on A T echnical Specifications ..................................[...]

  • Seite 8

    POWER MIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-2 INST ALLA TION A-2 75°C Copper Wire 75°C Copper Wire in Conduit in Conduit Input Ampere A WG (IEC) Sizes A WG (IEC) Sizes Input V oltage/ Fuse or Breaker Rati[...]

  • Seite 9

    POWER MIG 255 INST ALLA TION A-3 A-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT POWER, GROUNDING AND CONNECTION DIAGRAMS ------------------------------------------------------------------------ 1. Before starting th[...]

  • Seite 10

    POWER MIG 255 INST ALLA TION A-4 A-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 4. Using the instructions in Figure A.3 , have a qual- ified electrician connect the receptacle or cable to the input power lines and the sys[...]

  • Seite 11

    POWER MIG 255 INST ALLA TION A-5 A-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A.3 — RECEPT ACLE DIAGRAM. CONNECT TO A SYSTEM GROUNDING WIRE. SEE THE UNITED ST A TES NA TIONAL ELECTRICAL CODE AND/OR LOCAL CODES [...]

  • Seite 12

    POWER MIG 255 INST ALLA TION A-6 A-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GUN AND CABLE INST ALLA TION The Magnum 250L gun and cable provided with the POWER MIG 255 is factory installed with a liner for 0.035-0.045 [...]

  • Seite 13

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 255 Section B-1 Section B-1 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ................................................................................................................Sectio n B Product Description..................................[...]

  • Seite 14

    POWER MIG 255 OPERA TION B-2 B-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Read entire Operation section before operating the POWER MIG 255. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode [...]

  • Seite 15

    POWER MIG 255 OPERA TION B-3 B-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PRODUCT DESCRIPTION The POWER MIG™ 255 is a complete semiautomatic constant voltage DC arc welding machine built to meet NEMA specifications. I[...]

  • Seite 16

    POWER MIG 255 OPERA TION B-4 B-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DESCRIPTION OF CONTROLS Power ON/OFF Switch — Place the lever in the “ON” position to energize the POWER MIG 255. When the power is on, the[...]

  • Seite 17

    POWER MIG 255 OPERA TION B-5 B-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS 1. T urn off the power source. 2. Release the pressure on the idle roll by swinging the adjustabl[...]

  • Seite 18

    POWER MIG 255 OPERA TION B-6 B-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TO ST ART THE WELDER T urn the Power Switch switch to ON. This lights the red LED display lights. With the desired voltage and wire speed selecte[...]

  • Seite 19

    POWER MIG 255 OPERA TION B-7 B-7 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Arc starting characteristics may be effected when using the fast run-in mode since optimum start- ing processes are being overridden. On th[...]

  • Seite 20

    POWER MIG 255 OPERA TION B-8 B-8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 5. Use only clean, rust-free electrode. The Lincoln electrodes have proper surface lubrication. 6. Replace contact tip when the arc starts to bec[...]

  • Seite 21

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 255 Section C-1 Section C-1 T ABLE OF CONTENTS - ACCESSORIES SECTION - Accessories ............................................................................................................Section C Drive Roll Kits .......................................[...]

  • Seite 22

    POWER MIG 255 ACCESSORIES C-2 C-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DRIVE ROLL KITS Refer to T able C.1 for various drive roll kits that are available for the POWER MIG. All items in Bold are supplied standard wi[...]

  • Seite 23

    POWER MIG 255 ACCESSORIES C-3 C-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 3. Using a screwdriver , remove the two screws securing the lower cover panel to the front of the machine. Remove the lower cover panel. 4. Atta[...]

  • Seite 24

    POWER MIG 255 ACCESSORIES C-4 C-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SPOOL GUN ADAPTER KIT Remove all input power to the POWER MIG 255 before proceeding. -----------------------------------------------------------[...]

  • Seite 25

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 255 Section D-1 Section D-1 T ABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ...........................................................................................................Section D Safety Precautions .....................................[...]

  • Seite 26

    POWER MIG 255 MAINTENANCE D-2 D-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY PRECAUTIONS • Have a qualified electrician do the maintenance and troubleshooting work. • Disconnect the input power off using the di[...]

  • Seite 27

    POWER MIG 255 MAINTENANCE D-3 D-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE D.1 — COMPONENT LOCA TIONS. CONTROL PC BOARD POWER ENHANCEMENT CHOKE OUTPUT CHOKE MAIN TRANSFORMER SCR RECTIFIER BRIDGE CAPACITOR BANK [...]

  • Seite 28

    POWER MIG 255 MAINTENANCE D-4 D-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONT ACT TIP AND GAS NOZZLE INST ALLA TION 1. Choose the correct size contact tip for the elec- trode being used (wire size is stenciled on the [...]

  • Seite 29

    POWER MIG 255 MAINTENANCE D-5 D-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC GUN HANDLE DISASSEMBL Y The internal parts of the gun handle may be inspected or serviced if necessary . The gun handle consists of two halves t[...]

  • Seite 30

    POWER MIG 255 MAINTENANCE D-6 D-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ACCESSORIES AND EXPENDABLE REPLACEMENT P ARTS FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES * Included with Power MIG 255. ** Requires S19418-1 Gas D[...]

  • Seite 31

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 255 Section E-1 Section E-1 Theory of Operation ...............................................................................................Section E Input Line V oltage and Main T ransformer..............................................................[...]

  • Seite 32

    POWER MIG 255 THEOR Y OF OPERA TION E-2 E-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT LINE VOL T AGE AND MAIN TRANSFORMER The desired single phase input power is connected to the POWER MIG 255 through a line switch[...]

  • Seite 33

    POWER MIG 255 THEOR Y OF OPERA TION E-3 E-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT RECTIFICA TION AND FEEDBACK CONTROL The AC output from the main transformer secondary weld winding is rectified and controlled [...]

  • Seite 34

    POWER MIG 255 THEOR Y OF OPERA TION E-4 E-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONST ANT VOL T AGE OUTPUT The controlled DC output from the SCR rectifier assembly is supplied to the power factor enhancement choke [...]

  • Seite 35

    POWER MIG 255 THEOR Y OF OPERA TION E-5 E-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRE DRIVE MOT OR AND FEEDBACK The wire drive motor is controlled by the control board. A motor speed feedback signal is generated at [...]

  • Seite 36

    POWER MIG 255 THEOR Y OF OPERA TION E-6 E-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THERMAL AND OVERLOAD PROTECTION The POWER MIG 255 has built-in protective ther- mostats that respond to excessive temperatures. One is[...]

  • Seite 37

    POWER MIG 255 THEOR Y OF OPERA TION E-7 E-7 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SCR OPERA TION A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load. An SCR[...]

  • Seite 38

    POWER MIG 255 NOTES E-8 E-8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Seite 39

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 255 Section F-1 Section F-1 T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR SECTION - Tr oubleshooting & Repair Section ........................................................................Section F How to Use T roubleshooting Guide .............[...]

  • Seite 40

    HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician and machine operator and will invalidate your factory warranty . For your safety and to avoid Electrical Shock, please observe all safet[...]

  • Seite 41

    POWER MIG 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-3 F-3 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical co[...]

  • Seite 42

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 POWER MIG 255 CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con- [...]

  • Seite 43

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. POWER MIG 255 CAUTION If for any reason you do not[...]

  • Seite 44

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-6 F-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con- [...]

  • Seite 45

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-7 F-7 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con- [...]

  • Seite 46

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-8 F-8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con- [...]

  • Seite 47

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-9 F-9 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con- [...]

  • Seite 48

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-10 F-10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CAUTION If for any reason you do not understand the test pr ocedures or are unable to perform the test/r epairs safely , con[...]

  • Seite 49

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and pre- cautions detailed t[...]

  • Seite 50

    POWER MIG 255 F-12 F-12 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR 4. Locate plug J5 and plug J6 on the G3521 control PC board, and J9 on the M19248 snubber PC board. See Figure F .1. NOTE: T[...]

  • Seite 51

    POWER MIG 255 F-13 F-13 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR 11 .T urn the machine ON. 12. Make the following voltage tests at plug J5. a. T urn the machine OFF between each test. b. Ca[...]

  • Seite 52

    POWER MIG 255 TROUBLESHOOTING AND REP AIR F-14 F-14 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC c. If any of the voltages tested are incorrect, check for loose or broken leads between the test points and the main transform[...]

  • Seite 53

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-15 F-15 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC RECTIFIER DIODE BRIDGE TEST Service and repair should only be performed by Lincoln Electric factory trained personnel. Unaut[...]

  • Seite 54

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-16 F-16 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Leads #208R, #209R, and #354 are connected to the rectifier diode bridge (D2). See Figure F .2. Lead #206 is connected at th[...]

  • Seite 55

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-17 F-17 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 9. Make the following voltage test: a. T urn the machine OFF between each test. b. Carefully connect the meter probes to the[...]

  • Seite 56

    POWER MIG 255 NOTES F-18 F-18 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Seite 57

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-19 F-19 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ST A TIC SCR RECTIFIER ASSEMBL Y TEST Service and repair should only be performed by Lincoln Electric factory trained person[...]

  • Seite 58

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-20 F-20 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 4. V erify that the capacitors have completely discharged with a volt- ohmmeter . 5. Disconnect plugs J6 from the G3521 cont[...]

  • Seite 59

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-21 F-21 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .5 — SCR 1 TEST POINTS. 9. T est for high or infinite resistance from the cathode to the anode of SCR 1 by revers[...]

  • Seite 60

    POWER MIG 255 NOTES F-22 F-22 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Seite 61

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-23 F-23 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ACTIVE SCR RECTIFIER ASSEMBL Y TEST Service and repair should only be performed by Lincoln Electric factory trained personne[...]

  • Seite 62

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-24 F-24 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 4. V erify that the capacitors have completely discharged with a volt- ohmmeter . 5. Disconnect plugs J6 from the G3521 cont[...]

  • Seite 63

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-25 F-25 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 8. Use a commercial SCR tester or con- struct the tester circuit shown in Figure F .8. One 6-volt lantern battery can be use[...]

  • Seite 64

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-26 F-26 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 15. Reconnect the tester leads. See Figure F .8. a. Connect tester lead (A) to the cathode. b. Connect tester lead (C) to th[...]

  • Seite 65

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-27 F-27 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRE DRIVE MOTOR AND T ACHOMETER FEEDBACK TEST Service and repair should only be performed by Lincoln Electric factory train[...]

  • Seite 66

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-28 F-28 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 3. Locate plug J1 on the G3521 control PC board. See Figure F .9. 4. Locate the following leads on plug J1: 5. Connect the m[...]

  • Seite 67

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-29 F-29 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 2. Locate plug J1 on the G3521 control PC board. See Figure F .9. 3. Locate the following leads on Plug J1: 4. Connect main [...]

  • Seite 68

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-30 F-30 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC c. T urn the machine ON and pull the gun trigger to conduct the voltage test. 6. If the 1.5 to 3.5 VDC is present, the tacho[...]

  • Seite 69

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-31 F-31 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 0 VOLTS 20.0 V 2.5 ms This is a typical DC output voltage waveform generated from a properly operating machine. Note that ea[...]

  • Seite 70

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-32 F-32 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 0 VOLTS 20.0 V 5 ms MACHINE LOADED TO 250 AMPS A T 26 VDC TYPICAL OUTPUT VOL T AGE W A VEFORM - MACHINE LOADED This is a typ[...]

  • Seite 71

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-33 F-33 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 0 VOLTS 20.0 V 5 ms MACHINE LOADED TO 220 AMPS A T 22 VDC ABNORMAL OUTPUT VOL T AGE W A VEFORM - MACHINE LOADED ONE OUTPUT S[...]

  • Seite 72

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-34 F-34 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 0 VOLTS 20.0 V 5 ms ABNORMAL OPEN CIRCUIT VOL T AGE OUTPUT CAP ACIT OR BANK NOT FUNCTIONING This is NOT the typical DC outpu[...]

  • Seite 73

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-35 F-35 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 0 VOLTS 2.00 V 5 ms TYPICAL SCR GA TE VOL T AGE W A VEFORM This is a typical SCR gate pulse voltage waveform. The machine wa[...]

  • Seite 74

    POWER MIG 255 NOTES F-36 F-36 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

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    POWER MIG 255 F-37 F-37 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REP AIR Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on t[...]

  • Seite 76

    POWER MIG 255 F-38 F-38 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REP AIR CONTROL PC BOARD REMOV AL AND REPLACEMENT PROCEDURE (Continued) REMOV AL AND REPLACEMENT PROCEDURE 1. Disconnect main input po[...]

  • Seite 77

    POWER MIG 255 F-39 F-39 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING AND REP AIR CONTROL PC BOARD REMOV AL AND REPLACEMENT PROCEDURE (Continued) 7. When re-installing the control PC board carefully secure bo[...]

  • Seite 78

    POWER MIG 255 NOTES F-40 F-40 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Seite 79

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-41 F-41 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on[...]

  • Seite 80

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-42 F-42 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 6. Disconnect the wire connectors J13 and J12 to the motor/gearbox assem- bly . See Wiring Diagram. 7. Use a 3/4 in. wrench [...]

  • Seite 81

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-43 F-43 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 15. Grasp the motor/gearbox assembly and wiggle the motor/gearbox assembly gently back and forth until it separates from the[...]

  • Seite 82

    POWER MIG 255 NOTES F-44 F-44 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Seite 83

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-45 F-45 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on[...]

  • Seite 84

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-46 F-46 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 3. Disconnect lead #204 and heavy alu- minum choke lead from the middle heat sink with a 1/2 in. socket wrench and 1/2 in. o[...]

  • Seite 85

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-47 F-47 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 8. Clear the leads and carefully remove the SCR rectifier assembly . NOTE: When installing the SCR rectifier assembly , appl[...]

  • Seite 86

    POWER MIG 255 NOTES F-48 F-48 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Seite 87

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-49 F-49 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC The liquid electrolite in the capacitors is toxic. Do not touch the capacitors with any part of your body . ----------------[...]

  • Seite 88

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-50 F-50 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC tive capacitor bank buss bar using a 1/2 in. open end wrench. 6. Remove the choke lead and lead 204B from the positive capac[...]

  • Seite 89

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-51 F-51 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on[...]

  • Seite 90

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-52 F-52 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 6. Remove the two transformer secondary leads X2 and X3 (braided copper strap) from the negative capacitor bank buss bar usi[...]

  • Seite 91

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-53 F-53 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 11 . Unplug and label leads X5, X6, X7, X8, and X9. These leads have connectors near the trans- former which can be disconne[...]

  • Seite 92

    POWER MIG 255 NOTES F-54 F-54 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Seite 93

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-55 F-55 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on[...]

  • Seite 94

    POWER MIG 255 TROUBLESHOOTING & REP AIR F-56 F-56 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC a. Loosen and remove the two nuts and lock washers from the motor mounting bracket using a 1 1/32 in. open end wrench. b. Wh[...]

  • Seite 95

    POWER MIG 255 TROUBLESHOOTING AND REP AIR F-57 F-57 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT IDLE AMPS AND W A TTS WIRE SPEED RANGE OPEN CIRCUIT VOL T AGE RETEST AFTER REP AIR Maximum Idle W atts Maximum Idle Amps[...]

  • Seite 96

    POWER MIG 255 NOTES F-58 F-58 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Seite 97

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER MIG 255 Section G-1 Section G-1 T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams ...............................................................................................Section G Wiring Diagram - Entire Machine - Code 10563 - (L109[...]

  • Seite 98

    G-2 ELECTRICAL DIAGRAMS POWER MIG 255 WIRING DIAGRAM - ENTIRE MACHINE - CODE 10563 - (L10979) 392 325 515B 209S ** 204S 209R 209 209S W 254 256 551 254A 552 COLOR CODE: ELECTRICAL SYMBOLS PER E1537 GENERAL INFORMATION POWER MIG 255 (208/230V) 206B G2 4 5 J7 4 5 6 2 7 8 J11 GUN TRIGGER 2 325 4 3 4 J12 325 324 H4 H1 9 6 8 7 7 5 4 L1 7 2 1 5 6 265 263[...]

  • Seite 99

    G-3 ELECTRICAL DIAGRAMS POWER MIG 255 WIRING DIAGRAM - ENTIRE MACHINE - CODE 10583 - (L10980) G-3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 209 555 B W 515 254 262 207 P.M. 208S J9 B T A C H D1 ASBLY 2-23-2001A 11 1 28[...]

  • Seite 100

    G-4 ELECTRICAL DIAGRAMS POWER MIG 255 G-4 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRING DIAGRAM - ENTIRE MACHINE - CODE 10986 - (L1 1980) NOTE: This diagram is for reference only . It may not be accurate for all machi[...]

  • Seite 101

    G-5 ELECTRICAL DIAGRAMS POWER MIG 255 G-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRING DIAGRAM - ENTIRE MACHINE - CODE 10990 - (L1 1979) NOTE: This diagram is for reference only . It may not be accurate for all machi[...]

  • Seite 102

    G-6 ELECTRICAL DIAGRAMS POWER MIG 255 CONTROL PC BOARD SCHEMA TIC - (G3520-1D1) G-6 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level t[...]

  • Seite 103

    G-7 ELECTRICAL DIAGRAMS POWER MIG 255 CONTROL PC BOARD ASSEMBL Y - (G3521-1) Ch’ge. Sht. No. 3521-1 XE-RW A POWER MIG 255 CONTROL P.C. BOARD ASSEMBLY C.S./ FULL 3521-1 12-18-98 G2803-1 THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. EQUIP. TYPE SCALE DR DATE CHK REF. SUBJECT SUP’S’D’G SHT. NO. G G 5.80 .20 3-12-99 7-9-99H 7-28-2000J 10-5-20[...]

  • Seite 104

    G-8 ELECTRICAL DIAGRAMS POWER MIG 255 G-8 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DISPLA Y PC BOARD SCHEMA TIC - (L10951) 500 475 R10 DISP2 2 1 4 9 5 10 7 6 8 3 LED3 X5 12 13 J10 4 DISP3 2 1 4 9 5 10 7 6 8 3 14 3 Rx Vd[...]

  • Seite 105

    G-9 ELECTRICAL DIAGRAMS POWER MIG 255 G-9 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC DISPLA Y PC BOARD ASSEMBL Y - (L10952-1) 10952-1 Ch’ge. Sht. No. XA 3-12-99 A B POWER MIG 255 R.T. FULL 10952-1 5-20-98 THE LINCOLN EL[...]

  • Seite 106

    G-10 ELECTRICAL DIAGRAMS POWER MIG 255 SNUBBER PC BOARD SCHEMA TIC - (S24374) 204S J1 1 J1 8 5W 10 R1 J1 6 J1 2 J1 3 J1 4 400V .68 C2 J1 5 J1 7 5W 10 R2 24374 209R SNUBBER BOARD NONE .022/50V MFD UNLESS OTHERWISE SPECIFIED) POWER SUPPLY SOURCE POINT POWERMIG 255 N.A. OF A COMPLETE ( CONTROLS HAVING A COMMON CODE NUMBER. NOTES : BOARD. SHOW THE EXAC[...]

  • Seite 107

    G-11 ELECTRICAL DIAGRAMS POWER MIG 255 G-11 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SNUBBER PC BOARD ASSEMBL Y - (M19248-1) 19248-1 Ch’ge. Sht. No. XB 3-12-99 B SP WELDERS SNUBBER P.C. BOARD AS’BLY R.T. FULL 19248-[...]

  • Seite 108

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information wi[...]