Lincoln Electric SVM144-B Operation, Product Description, Welding Capability, Limitations

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B-3

OPERATION

B-3

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PRODUCT DESCRIPTION

The POWER MIG™ 255 is a complete semiautomatic constant voltage DC arc welding machine built to meet NEMA specifications. It combines a constant voltage power source and a constant speed wire feeder with a microcomputer-based controller to form a reliable high- performance welding system. A simple control scheme, consisting of continuous full range voltage and wire feed speed controls, provides versatility with ease of use and accuracy.

Other features include a 2 in. (51 mm) O.D. wire reel spindle with adjustable brake, an integral gas cylinder mounting undercarriage, an adjustable CO2 or Argon blend flow regulator with cylinder pressure gauge and inlet hose, a 12 ft (3.6 m) Magnum 250L GMAW gun and cable with fixed (flush) nozzle, a 10 ft (3.0 m) power cable with plug and mating receptacle, and a 10 ft (3.0 m) work cable with clamp.

An Optional Timer kit provides variable burnback con- trol, a spot function, a selectable 4-step trigger inter- lock and adjustable “Run In” for wire starting optimiza- tion. Also optional are a Spool Gun Adapter kit, a Dual Cylinder Mounting Kit and an Aluminum Feeding Kit for push feeding with standard built in feeder.

RECOMMENDED PROCESSES AND EQUIPMENT

The POWER MIG 255 is recommended for GMA welding processes using 10 to 44 lb (4.5 to 20 kg)

2in. (51 mm) I.D. spools or Readi-Reel®coils (with optional adapter) of 0.025 in. through 0.045 in. (0.6 to 1.2 mm) solid steel, 0.035 in. (0.9 mm)

stainless, 3/64 in. (1.2 mm) aluminum and 0.045 in. (1.2 mm) Outershield®; as well as 0.035 in. (0.9 mm) and 0.045 in. (1.2 mm) Innershield® self-shielding electrodes.

The POWER MIG is factory equipped to feed 0.035 in. (0.9 mm) electrodes and provides tip, guide, and drive rolls for 0.045 in. (1.2 mm) electrode. It also includes a 200A, 60% duty cycle (or 250A, 40% duty cycle) rated, 12 ft (3.6 m) GMAW gun and cable assembly equipped for these wire sizes. Use of GMAW processes requires a supply of shielding gas.

WELDING CAPABILITY

The POWER MIG 255 is rated at 250 amps @ 26 volts, at a 40% duty cycle based on a ten minute cycle time. It is capable of higher duty cycles at lower output cur- rents and capable of up to 300 Amps at lower duty cycles.

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LIMITATIONS

The POWER MIG 255 MAY NOT operate satisfactorily if powered with a portable or in-plant generating system.

POWER MIG 255

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Contents Power MIG Safety Electric Shock can kill Welding Sparks can cause fire or explosion SafetySûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Installation Section Table of ContentsTechnical Specifications Power MIG InstallationSafety Precautions Uncrating the Power MIGLocation Power MIG Figure A.2 Triple Voltage Machine Input Connections Shielding GAS GUN and Cable InstallationSection B Operation SectionFumes and Gases can be dangerous OPERATIONB-2Limitations OperationProduct Description Welding CapabilityDescription of Controls Wire Reel Loading READI-REELS, SPOOLS, or Coils Procedure for Changing Drive and Idle Roll SetsTo Start the Welder Feeding Wire ElectrodeSetting RUN-IN Speed on STAN- Dard Power MIG Feeder Idle Roll Pressure SettingMaking a Weld Avoiding Wire Feeding ProblemsInput Line Voltage Protection FAN ControlSection C Accessories SectionDual Cylinder Mounting KIT K1702-1 AccessoriesDrive Roll Kits K363P READI-REEL AdapterOperating Instructions For Timer KIT Spool GUN Adapter KIT Making a Weld with the Spool GUN, Spool GUN InstalledSection D Maintenance SectionMaintenance Routine and Periodic MaintenanceGUN Tubes and Nozzles Figure D.1 Component Locations Liner Removal Replacement Contact TIP and GAS Nozzle InstallationTo open up the handle 5MAINTENANCED-5Description English Size Metric Size Table D.2Section E Theory of Operation SectionTheory of Operation Input Line VoltageMain Transformer Feedback Control Output RectificationFigure E.4 Constant Voltage Output Constant Voltage OutputFeedback Wire Drive MotorWire Feed Overload Protection Thermal and Overload ProtectionOvercurrent Protection Figure E.6 SCR Operation SCR OperationPower MIG Section F Troubleshooting & Repair SectionHOW to USE Troubleshooting Guide Troubleshooting & RepairWorkstations PC Board Troubleshooting ProceduresOutput Problems SCR Rectifier Rectifier Function Problems Wire Feeding Problems Welding Problems Welding Problems Test Description Main Transformer TestMain Transformer Test Test ProcedureFigure F.1 Troubleshooting and Repair Rectifier Diode Bridge Test Test DescriptionMaterials Needed Rectifier Diode Bridge Testing 208R 206 28 VAC 209R Power MIG Static SCR Rectifier Assembly Test Static SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Power MIG Active SCR Rectifier Assembly Test Active SCR Rectifier Assembly Test Figure F.7 Location Leads X2 Open switch SW-1 Wire Drive Motor and Tachometer Feedback Test Wire Drive Motor and Tachometer Feedback Test 515B 206B 15 VDC 5J1 1J1 Test for Supply Voltage to Tachometer555 206B To 3.5 VDC 6J1 1J1 Test for Feedback Voltage to Control BoardVolts Normal Open Circuit Voltage WaveformTypical Output Voltage Waveform Machine Loaded Machine Loaded to 250 Amps AT 26 VDC Scope SettingsMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Power MIG Description Control PC Board Removal and Replacement ProcedureControl PC Board Removal and Replacement ProcedureFigure F.11 Control Board Mounting Power MIG Wire Drive Assembly Removal and Replacement Procedure 41TROUBLESHOOTING & REPAIRF-41Procedure Wire Drive Assembly Removal and ReplacementTOC Power MIG SCR Output Rectifier Removal and Replacement Procedure SCR Output Rectifier Removal and Replacement Figure F.15 Right Heat Sink Lead Disconnection Power MIG Capacitor Bank Removal and Replacement Procedure Capacitor Bank Removal and Replacement Troubleshooting & Repair Main Transformer and Output Choke Removal and ReplacementTOC Power MIG FAN Motor Assembly Removal and Replacement Procedure FAN Motor Assembly Removal and Replacement Open Circuit Voltage Troubleshooting and RepairWire Speed Range Retest After RepairPower MIG Electrical Diagrams Section Wiring Diagram Entire Machine Code 10563 L10979 Power MIG 255 208/230VWiring Diagram Entire Machine Code 10583 L10980 Power MIG 255 230/460/575VWiring Diagram Entire Machine Code 10986 L11980 Power MIG 255 230/460/575Wiring Diagram Entire Machine Code 10990 L11979 Power MIG 255 208/230Control PC Board Schematic G3520-1D1 3521 Control PC Board Assembly G3521-1Powermig Display PC Board Schematic L10951Lincoln Electric CO Display PC Board Assembly L10952-124374 S Snubber PC Board Schematic S2437400 ~.04 Snubber PC Board Assembly M19248-1SVM Error Reporting Form