Lincoln Electric SVM144-B service manual Power MIG 255 230/460/575V

Page 99

Section TOC

Master TOC

G-3

ELECTRICAL DIAGRAMS

G-3

WIRING DIAGRAM - ENTIRE MACHINE - CODE 10583 - (L10980)

 

 

POWER MIG 255 (230/460/575V)

to

to

CAVITY NUMBERING SEQUENCE

GENERAL INFORMATION

NOTES:

J10 DISPLAY

ELECTRICAL SYMBOLS PER E1537

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE

BOARD

CURRENT AND DUTY CYCLE OF IMMEDIATE AND

 

 

 

CONTROL BOARD

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FUTURE APPLICATIONS.

352

(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

COLOR CODE:

1

4 3 2

6 5

8 7

 

B - BLACK

N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY

 

 

 

 

 

 

"POSITIVE". TO CHANGE POLARITY, TURN THE UNIT

 

 

 

 

 

 

W - WHITE

 

 

 

 

 

FAN

OFF AND REVERSE LEAD CONNECTIONS AT CABLE

 

 

 

 

 

R - RED

 

 

 

 

 

CONDUCTOR STRAP AND WORK STUD.

552

551

550

515

500

MOTOR

U - BLUE

 

 

INDICATES CONNECTOR CAVITY NO.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

353

253

252

251

552

551

256

550

1

2

3

4

5

6

7

8

J2

1

6

1

7

1

8

J3

 

J2

 

J5

 

7

12

8

14

9

16

 

 

J10

 

 

 

 

 

10

 

1

 

GUNJ11**

TRIGGER

1

324

1

 

 

**

CAVITY

 

 

254A

 

 

 

 

NUMBERING SEQUENCE

 

 

 

 

 

 

 

(NON-LEAD SIDE OF CONNECTOR)

R4

 

 

R3

 

 

 

2

1

2

 

 

 

 

 

 

 

 

 

J11

 

256

253

254

251

252

 

 

J7

J12

J13

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

3

4

 

 

 

 

390

392

265

1

 

 

 

 

ARC

 

 

 

 

 

 

 

 

WIRE FEED

 

263

2

 

 

 

 

VOLTAGE

 

 

SPEED

 

 

 

 

 

 

 

 

 

 

262

3

 

 

 

 

 

 

 

 

 

267

4

 

 

 

 

 

 

 

 

GAS

264

5

 

 

 

 

 

 

 

SOLENOID

260

6

 

 

 

515B

 

 

 

 

 

 

7

 

 

 

 

 

 

 

 

261

8

 

 

 

 

 

 

 

 

 

 

 

 

555

 

 

 

 

 

 

9

 

 

 

206B

 

 

 

 

 

 

10

 

 

 

B

 

 

 

 

 

 

FOR TIMER

 

 

 

W

 

 

 

 

 

 

OPTION

 

 

 

 

 

 

 

 

 

 

254

500

515

206B W

9

10

11

12

13

14

1

2

3

4

5

J4

6

7

8

9

10

1

2

3

2

325

2

325

 

3

 

3

 

4

 

4

324

SNUBBER

1

204

BOARD

 

2

208S

R.F.

3

208

208R

 

 

B 515B 555

325

324

4

5

6

7

8

J1

H5

H2

H4

H3

H1

L1

L2

L1

L2

 

 

5

 

 

 

 

 

 

 

 

2

 

4

 

 

 

 

H1

H4

 

 

1

 

 

 

 

 

 

3

 

 

 

 

 

 

 

RECONNECT

 

 

 

 

H1

 

 

 

 

 

 

 

 

 

PANEL

 

 

 

 

 

LINE

(SHOWN CONNECTED

 

 

 

SWITCH

 

 

FOR 230V)

 

 

 

 

 

 

 

 

 

 

 

 

S1

 

 

 

 

 

 

 

 

 

 

W

 

 

 

 

 

 

TO SINGLE PHASE

 

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SUPPLY LINE

 

 

 

 

 

 

 

 

TO GROUND PER

 

 

 

 

 

 

NATIONAL ELECTRICAL

 

 

 

 

 

 

 

CODE

 

 

 

 

 

 

 

 

 

 

 

CHOKE

 

 

**

 

 

J9

4

 

204S

 

 

 

354 209R

208R

AS’BLY

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

209S

 

SECONDARY VOLTAGES SHOWN

D2

 

 

 

 

J12

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

ARE NO LOAD RMS VALUES

BAFFLE

 

 

 

 

 

 

 

 

7

 

209

 

MOUNTED

-

 

 

 

1

 

 

 

 

 

X8

X8

RECTIFIER

 

 

 

 

B

 

 

 

8

 

209R

 

 

DIODE

 

 

 

 

 

 

 

 

 

 

 

 

 

116.6V

 

BRIDGE

 

 

 

 

2

W

 

 

 

 

 

 

 

X9

X9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X5

+

 

 

 

 

 

 

 

 

 

 

 

 

 

X5

 

 

 

 

 

 

 

 

 

 

 

 

 

14.2V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

X6

X6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

14.2V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

208S

 

 

 

 

 

 

 

 

 

 

 

 

 

X7

X7

 

 

 

 

 

 

 

 

320

 

 

 

H1

X1

 

G1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SCR 1

 

 

 

 

 

 

 

320B

325B

 

 

28.4V

 

 

 

 

 

 

 

 

 

 

 

H2

 

204S

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SCR HEATSINK

 

 

 

 

 

 

 

 

 

 

 

H5

X2

 

 

 

 

 

 

 

 

 

SCR HEATSINK

OUTPUT CHOKE

 

 

 

ASBLY

 

 

J13**

 

 

 

 

 

 

 

 

 

 

W

 

ASSEMBLY

THERMOSTAT

 

 

H3

X3

 

 

SCR 2

 

 

 

THERMOSTAT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

28.4V

 

 

 

 

 

T

 

MOTOR/

 

 

 

H4

X4

 

 

G2

515B

 

R

1

 

P.M.

 

 

 

 

 

 

209S

 

555

U

 

2

 

A

 

GEARBOX

 

 

 

 

 

 

 

206B

B

 

3

 

C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POWER

 

 

 

 

 

 

4

 

H

 

 

 

 

 

 

TRANSFORMER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D1

 

 

 

 

 

 

 

B

 

 

 

TO

 

 

 

 

 

 

 

 

 

 

 

 

 

WORK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

206

206S

205

 

207

+ -

 

206B

FOR SPOOL GUN OPTION

390

392

SCI 325A

543

326

541A SCI

515

206A

209

208

206

206S

205

352

X9

354

325B GND 320 207

353

X8

G2

204

G1

1

2J8

1

2

3

4

5

6J3

7

8

9

10

11

12

1

2

3

4

5

6

7

8

9J5

10

11

12

13

14

15

16

1

2

3

C1

C2

C3

R1

15 OHMS

100 W

 

 

 

 

X7

4

J6

+

+

+

C1 THRU C3

204B

 

 

 

31,000 MFD

 

 

 

50V

 

POWER FACTOR

 

 

 

OUTPUT

ENHANCEMENT

 

 

 

 

 

 

CHOKE

CHOKE

 

 

 

 

 

 

 

X6

X5

5

6

R.F. FILTER

GND

2-23-2001A

L10980

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

Page 98 Page 100
Image 99
Page 98 Page 100
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
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