Lincoln Electric SVM144-B service manual Description of Controls

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B-4

OPERATION

B-4

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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 red LED display lights illuminate.

Voltage Control — This is a continuous control that gives full range adjustment of power source output volt- age. It can be adjusted while welding over its 10 to 28 volt range.

Wire Speed Control — This controls the wire feed speed from 50 to 700 inches per minute (1.2 to

17.8m/min). The wire speed control can be preset on the dial to the setting specified on the Procedure Decal located inside the wire compartment door. Wire speed is not affected when changes are made in the voltage control.

WIRE DRIVE ROLL

The drive rolls installed with the POWER MIG each have two grooves, both for 0.030-0.0035 in. (0.8-0.9 mm) solid steel electrode. Drive roll size is indi- cated by the stencilling on the exposed side of the drive roll. If feeding problems occur, then the drive roll may be reversed or changed. See Procedure for Changing Drive Roll in this section. This information also appears on the Procedure Decal on the door inside the wire compartment. An additional drive roll set is provided for 0.045 in. (1.2 mm) solid steel electrode, packaged standard with each machine.

WIRE SIZE CONVERSION PARTS

The POWER MIG 255 is rated to feed 0.025 through 0.045 in. (0.6 to 1.2 mm) solid or cored electrode sizes.

The drive roll kits and Magnum 250L gun and cable parts are available to feed different sizes and types of electrodes. See Accessories section.

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FIGURE B.1 — OPERATOR CONTROLS

WIRE SPEED

VOLTS

 

 

 

 

ON

LINCOLN

POWER MIG 255

ELECTRIC

 

OFF

 

POWER

 

POWER MIG 255

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Contents Power MIG Safety Electric Shock can kill Safety Welding Sparks can cause fire or explosionPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation SectionInstallation Technical Specifications Power MIGUncrating the Power MIG Safety PrecautionsLocation Power MIG Figure A.2 Triple Voltage Machine Input Connections GUN and Cable Installation Shielding GASOperation Section Section BOPERATIONB-2 Fumes and Gases can be dangerousOperation Product DescriptionWelding Capability LimitationsDescription of Controls Procedure for Changing Drive and Idle Roll Sets Wire Reel Loading READI-REELS, SPOOLS, or CoilsFeeding Wire Electrode Setting RUN-IN Speed on STAN- Dard Power MIG FeederIdle Roll Pressure Setting To Start the WelderAvoiding Wire Feeding Problems Making a WeldFAN Control Input Line Voltage ProtectionAccessories Section Section CAccessories Drive Roll KitsK363P READI-REEL Adapter Dual Cylinder Mounting KIT K1702-1Operating Instructions For Timer KIT Making a Weld with the Spool GUN, Spool GUN Installed Spool GUN Adapter KITMaintenance Section Section DRoutine and Periodic Maintenance MaintenanceGUN Tubes and Nozzles Figure D.1 Component Locations Contact TIP and GAS Nozzle Installation Liner Removal Replacement5MAINTENANCED-5 To open up the handleTable D.2 Description English Size Metric SizeTheory of Operation Section Section EInput Line Voltage Theory of OperationMain Transformer Output Rectification Feedback ControlConstant Voltage Output Figure E.4 Constant Voltage OutputWire Drive Motor FeedbackThermal and Overload Protection Wire Feed Overload ProtectionOvercurrent Protection SCR Operation Figure E.6 SCR OperationPower MIG Troubleshooting & Repair Section Section FTroubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures WorkstationsOutput Problems SCR Rectifier Rectifier Function Problems Wire Feeding Problems Welding Problems Welding Problems Main Transformer Test Test DescriptionTest Procedure Main Transformer TestFigure F.1 Troubleshooting and Repair Test Description Rectifier Diode Bridge TestMaterials 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 Test for Supply Voltage to Tachometer 515B 206B 15 VDC 5J1 1J1Test for Feedback Voltage to Control Board 555 206B To 3.5 VDC 6J1 1J1Normal Open Circuit Voltage Waveform VoltsMachine Loaded to 250 Amps AT 26 VDC Scope Settings Typical Output Voltage Waveform Machine LoadedMachine Loaded to 220 Amps AT 22 VDC Scope Settings Troubleshooting & Repair Typical SCR Gate Voltage Waveform Power MIG Control PC Board Removal and Replacement Procedure DescriptionRemoval and Replacement Procedure Control PC BoardFigure F.11 Control Board Mounting Power MIG 41TROUBLESHOOTING & REPAIRF-41 Wire Drive Assembly Removal and Replacement ProcedureWire Drive Assembly Removal and Replacement ProcedureTOC 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 Removal and Replacement Main Transformer and Output ChokeTOC Power MIG FAN Motor Assembly Removal and Replacement Procedure FAN Motor Assembly Removal and Replacement Troubleshooting and Repair Wire Speed RangeRetest After Repair Open Circuit VoltagePower MIG Electrical Diagrams Section Power MIG 255 208/230V Wiring Diagram Entire Machine Code 10563 L10979Power MIG 255 230/460/575V Wiring Diagram Entire Machine Code 10583 L10980Power MIG 255 230/460/575 Wiring Diagram Entire Machine Code 10986 L11980Power MIG 255 208/230 Wiring Diagram Entire Machine Code 10990 L11979Control PC Board Schematic G3520-1D1 Control PC Board Assembly G3521-1 3521Display PC Board Schematic L10951 PowermigDisplay PC Board Assembly L10952-1 Lincoln Electric COSnubber PC Board Schematic S24374 24374 SSnubber PC Board Assembly M19248-1 00 ~.04SVM Error Reporting Form