Lincoln Electric SVM144-B Power MIG 255 208/230V, Wiring Diagram Entire Machine Code 10563 L10979

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Section TOC

Master TOC

G-2

ELECTRICAL DIAGRAMS

G-2

WIRING DIAGRAM - ENTIRE MACHINE - CODE 10563 - (L10979)

 

 

POWER MIG 255 (208/230V)

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CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P.C. BOARD)

 

 

1

3

1

4

1

5

J8

1

J6

 

J1

 

J4

 

2

 

J9

 

J7

 

 

 

 

 

 

 

 

4

6

5

8

6

10

1

 

6

 

1

7

1

8

J3

 

 

J2

 

 

J5

 

7

 

12

 

8

14

9

16

 

 

 

J10

 

 

1

 

 

 

 

 

10

 

 

GUNJ11**

TRIGGER

1

324

1

 

2

325

2

325

3

 

3

 

4

 

4

324

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE:

B - BLACK

W - WHITE

R - RED

U - BLUE

INDICATES CONNECTOR CAVITY NO.

** CAVITY NUMBERING SEQUENCE

(NON-LEAD SIDE OF CONNECTOR)

2

1

2

J12

J11

 

J13

 

 

 

1

3

4

NOTES:

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS.

N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY "POSITIVE". TO CHANGE POLARITY, TURN THE UNIT OFF AND REVERSE LEAD CONNECTIONS AT CABLE CONDUCTOR STRAP AND WORK STUD.

515B

555

206B

B

W

 

 

J10

DISPLAY

 

 

 

 

 

 

BOARD

 

 

 

 

 

8 7 6 5 4 3 2 1

 

 

 

 

552

551

550

515

500

 

 

 

 

254A

 

 

 

 

R4

 

 

 

 

R3

 

256

253

254

251

 

252

 

 

 

ARC

 

 

 

 

 

390

392

 

 

 

 

 

WIRE FEED

 

 

VOLTAGE

 

 

 

 

SPEED

 

GAS

SOLENOID

SNUBBER

BOARD 1 2

352

FAN

MOTOR

353

 

J7

265

1

2

263

262

3

267

4

 

264

5

 

2606

7

2618

9

10

FOR TIMER

OPTION

204

208S

CONTROL BOARD

253

1

 

252

2

 

251

3

 

4

 

552

 

5

 

551

 

6

 

256

 

7

 

 

J2

550

8

 

 

 

254

9

 

50010

11

12

13

51514

1

2

3

4

5

6J4

7

8

9

10

206B1

W2

3

B

4

J1

515B

5

 

555

6

 

325

7

 

324

8

 

Return to Section TOC

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L1

L2

H3

H4

H2

L1

L2

 

TO SINGLE PHASE

 

 

 

 

 

SUPPLY LINE

 

 

 

 

 

230V

208V

 

 

H1

H4

W

 

 

 

 

 

 

 

 

B

 

 

 

 

H1

 

RECONNECT

 

 

 

 

 

 

 

 

PANEL

 

 

LINE

G

 

 

 

 

 

 

 

 

SWITCH

 

 

 

 

 

S1

TO GROUND PER

NATIONAL ELECTRICAL

CODE

 

 

 

 

 

R.F.

 

 

 

 

 

 

 

 

CHOKE

 

**

 

 

 

354 209R

208R

AS’BLY

 

J12

 

SECONDARY VOLTAGES SHOWN

D2

 

 

 

 

ARE NO LOAD RMS VALUES

BAFFLE

 

 

 

 

 

MOUNTED

-

 

 

1

 

X8

X8

RECTIFIER

 

 

 

B

 

 

DIODE

 

 

 

 

 

 

116.6V

 

BRIDGE

 

 

 

2

W

 

X9

X9

 

 

 

 

 

 

 

 

 

 

 

 

X5

+

 

 

 

 

 

 

X5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14.2V

 

 

 

 

 

 

 

 

X6

X6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14.2V

 

208S

 

 

 

 

 

 

X7

X7

 

 

 

 

 

H1

X1

 

G1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SCR 1

 

 

 

 

 

28.4V

204S

 

SCR HEATSINK

 

 

 

 

 

 

 

 

 

 

 

 

X2

 

 

ASBLY

 

 

J13**

H2

X3

 

 

SCR 2

 

 

 

 

 

 

 

 

28.4V

 

 

 

 

 

X4

 

 

G2

515B

R

1

T

 

 

 

555

U

2

A

H3

 

 

209S

 

 

 

 

 

206B

B

3

C

 

 

 

 

 

 

POWER

 

 

 

 

 

4

H

 

TRANSFORMER

 

 

 

 

 

 

 

 

 

 

D1

 

 

 

 

 

3

4

J95

6

7

8

 

320

 

 

 

 

320B

325B

 

SCR HEATSINK

OUTPUT CHOKE

 

ASSEMBLY

THERMOSTAT

 

W

THERMOSTAT

 

 

P.M. MOTOR/

GEARBOX

B

208

208R

204S

209S

209

209R

TO WORK

FOR SPOOL GUN OPTION

390

1

J8

392

2

 

SCI

1

 

325A

2

 

543

3

 

326

4

 

 

 

541A

5

 

6

J3

SCI

7

 

 

8

 

515

9

 

206A

10

 

11

 

 

 

 

12

 

209

1

 

208

2

 

206

 

3

 

206S

 

4

 

205

 

5

 

 

 

352

6

 

7

 

X9

8

J5

354

9

 

325B

10

 

GND

11

 

320

12

 

to Section TOC

to Master TOC

 

 

 

 

 

206

 

 

 

206S

205

 

 

 

 

+ -

 

 

 

 

 

206B

 

C1

C2

C3

 

R1

15 OHMS

 

100 W

 

 

 

 

 

+

+

+

C1 THRU C3

204B

 

 

 

 

31,000 MFD

 

 

 

 

50V

 

 

POWER FACTOR

 

 

 

 

OUTPUT

ENHANCEMENT

 

 

 

 

CHOKE

CHOKE

 

 

 

 

 

207

R.F. FILTER

GND

20713

14

353

15

 

X8

16

 

G2

1

 

204

2

 

G1

 

3

J6

X7

4

 

X6

 

5

 

X5

 

6

 

2-23-2001A

L10979

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

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 dangerousWelding Capability OperationProduct Description LimitationsDescription of Controls Procedure for Changing Drive and Idle Roll Sets Wire Reel Loading READI-REELS, SPOOLS, or CoilsIdle Roll Pressure Setting Feeding Wire ElectrodeSetting RUN-IN Speed on STAN- Dard Power MIG Feeder To Start the WelderAvoiding Wire Feeding Problems Making a WeldFAN Control Input Line Voltage ProtectionAccessories Section Section CK363P READI-REEL Adapter AccessoriesDrive Roll Kits 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 Retest After Repair Troubleshooting and RepairWire Speed Range 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
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