English dropdown-ico

Lincoln Electric SVM144-B manual

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108

Go to page of

Similar user manuals

A good user manual

The rules should oblige the seller to give the purchaser an operating instrucion of Lincoln Electric SVM144-B, along with an item. The lack of an instruction or false information given to customer shall constitute grounds to apply for a complaint because of nonconformity of goods with the contract. In accordance with the law, a customer can receive an instruction in non-paper form; lately graphic and electronic forms of the manuals, as well as instructional videos have been majorly used. A necessary precondition for this is the unmistakable, legible character of an instruction.

What is an instruction?

The term originates from the Latin word „instructio”, which means organizing. Therefore, in an instruction of Lincoln Electric SVM144-B one could find a process description. An instruction's purpose is to teach, to ease the start-up and an item's use or performance of certain activities. An instruction is a compilation of information about an item/a service, it is a clue.

Unfortunately, only a few customers devote their time to read an instruction of Lincoln Electric SVM144-B. A good user manual introduces us to a number of additional functionalities of the purchased item, and also helps us to avoid the formation of most of the defects.

What should a perfect user manual contain?

First and foremost, an user manual of Lincoln Electric SVM144-B should contain:
- informations concerning technical data of Lincoln Electric SVM144-B
- name of the manufacturer and a year of construction of the Lincoln Electric SVM144-B item
- rules of operation, control and maintenance of the Lincoln Electric SVM144-B item
- safety signs and mark certificates which confirm compatibility with appropriate standards

Why don't we read the manuals?

Usually it results from the lack of time and certainty about functionalities of purchased items. Unfortunately, networking and start-up of Lincoln Electric SVM144-B alone are not enough. An instruction contains a number of clues concerning respective functionalities, safety rules, maintenance methods (what means should be used), eventual defects of Lincoln Electric SVM144-B, and methods of problem resolution. Eventually, when one still can't find the answer to his problems, he will be directed to the Lincoln Electric service. Lately animated manuals and instructional videos are quite popular among customers. These kinds of user manuals are effective; they assure that a customer will familiarize himself with the whole material, and won't skip complicated, technical information of Lincoln Electric SVM144-B.

Why one should read the manuals?

It is mostly in the manuals where we will find the details concerning construction and possibility of the Lincoln Electric SVM144-B item, and its use of respective accessory, as well as information concerning all the functions and facilities.

After a successful purchase of an item one should find a moment and get to know with every part of an instruction. Currently the manuals are carefully prearranged and translated, so they could be fully understood by its users. The manuals will serve as an informational aid.

Table of contents for the manual

  • Page 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 [...]

  • Page 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[...]

  • Page 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. [...]

  • Page 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[...]

  • Page 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: [...]

  • Page 6

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

  • Page 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 ..................................[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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 [...]

  • Page 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 [...]

  • Page 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..................................[...]

  • Page 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 [...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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 .......................................[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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. -----------------------------------------------------------[...]

  • Page 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 .....................................[...]

  • Page 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[...]

  • Page 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 [...]

  • Page 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 [...]

  • Page 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[...]

  • Page 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[...]

  • Page 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..............................................................[...]

  • Page 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[...]

  • Page 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 [...]

  • Page 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 [...]

  • Page 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 [...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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 .............[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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- [...]

  • Page 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[...]

  • Page 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- [...]

  • Page 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- [...]

  • Page 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- [...]

  • Page 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- [...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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 [...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 75

    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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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 [...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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 . ----------------[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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[...]

  • Page 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-[...]

  • Page 108

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. W e 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 w[...]