Lincoln Electric SVM144-B service manual Installation, Technical Specifications Power MIG

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A-2

INSTALLATION

A-2

TECHNICAL SPECIFICATIONS – POWER MIG 255

INPUT – SINGLE PHASE ONLY

Standard Voltage/Frequency

Input Current @ 200 Amp Rated Output

Input Current @ 250 Amp Rated Output

208/230/60 Hz

41/37 Amps

50/46

230/460/575/60 Hz

41/20/16 Amps

50/24/19

RATED OUTPUT

Duty Cycle

Amps

Volts at Rated Amperes

40%

250 Amps

26 Volts

60%

200 Amps

28 Volts

100%

145 Amps

26 Volts

OUTPUT

Welding Current Range

Maximum Open Circuit Voltage

Welding Voltage Range

(Continuous)

30 – 300 Amps

40 Volts

10-28 Volts

RECOMMENDED INPUT WIRE AND FUSE SIZES

75°C Copper Wire

75°C Copper Wire

in Conduit

in Conduit

Input Ampere

AWG (IEC) Sizes

AWG (IEC) Sizes

Input Voltage/

Fuse or Breaker

Rating On

(For lengths

(For lengths

Frequency (Hz)

Size (Super Lag)

Nameplate

up to 100 ft)

exceeding 100 ft)

208/60

60

50

8 (10 mm2)

6 (16 mm2)

230/60

60

46

10 (6 mm2)

8 (10 mm2)

460/60

30

24

14 (2.5 mm2)

12 (4 mm2)

575/60

25

19

14 (2.5 mm2)

12 (4 mm2)

NOTE: Use #10 AWG Grounding Wire

PHYSICAL DIMENSIONS

Height

Width

Depth

Weight

31.79 in.

18.88 in.

38.78 in.

220 Ibs

808 mm

480 mm

985 mm

100 kg

WIRE SPEED RANGE

Wire Speed

50 – 700 IPM (1.27 – 17.8 m/minute)

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 MIGLocation Safety PrecautionsUncrating the Power MIG 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 DGUN Tubes and Nozzles MaintenanceRoutine and Periodic Maintenance 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 EMain Transformer Theory of OperationInput Line Voltage Output Rectification Feedback ControlConstant Voltage Output Figure E.4 Constant Voltage OutputWire Drive Motor FeedbackOvercurrent Protection Wire Feed Overload ProtectionThermal and Overload 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 Materials Needed Rectifier Diode Bridge TestTest Description 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