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POWER MIG 255C
SERVICE MANUAL
Safety Depends on You
CALIFORNIA PROPOSITION 65 WARNINGS
SAFETY
FOR ENGINE powered equipment
ELECTRIC AND MAGNETIC FIELDS may be dangerous
SAFETY
ELECTRIC SHOCK can kill
ARC RAYS can burn
FUMES AND GASES can be dangerous
SAFETY
FOR ELECTRICALLY powered equipment
WELDING SPARKS can cause fire or explosion
CYLINDER may explode if damaged
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PRÉCAUTIONS DE SÛRETÉ
SAFETY
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MASTER TABLE OF CONTENTS FOR ALL SECTIONS
SECTION A
INSTALLATION
TABLE OF CONTENTS
INSTALLATION SECTION
INSTALLATION
TECHNICAL SPECIFICATIONS - POWER MIG 255C
INPUT - SINGLE PHASE ONLY
PHYSICAL DIMENSIONS
LOCATION
SAFETY PRECAUTIONS
UNCRATING THE POWER MIG 255C
INPUT POWER, GROUNDING AND CONNECTION DIAGRAMS
FIGURE A.1 - DUAL VOLTAGE MACHINE INPUT CONNECTIONS
INSTALLATION
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FIGURE A.2 - TRIPLE VOLTAGE MACHINE INPUT CONNECTIONS
INSTALLATION
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INSTALLATION
GUN AND CABLE INSTALLATION
AUXILIARY POWER RECEPTACLES
SHIELDING GAS
SECTION B
TABLE OF CONTENTS
OPERATION
OPERATION SECTION
ELECTRIC SHOCK can kill
Read entire Operation section before operating the POWER MIG 255C
Observe all safety information throughout this manual
OPERATIONB-2
LIMITATIONS
PRODUCT DESCRIPTION
RECOMMENDED PROCESSES AND EQUIPMENT
WELDING CAPABILITY
OPERATION
WIRE SIZE CONVERSION PARTS
WIRE DRIVE ROLL
DESCRIPTION OF CONTROLS
OPERATION
PROCEDURE FOR CHANGING
WIRE REEL LOADING - READI REELS, SPOOLS OR COILS
DRIVE AND IDLE ROLL SETS
TO START THE WELDER
FEEDING WIRE ELECTRODE
IDLE ROLL PRESSURE SETTING
WIRE DRIVE CONFIGURATION
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OPERATION
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INSTRUCTIONS TO ENTER FAST RUN-IN
SETTING RUN-IN SPEED ON STAN- DARD POWER MIG FEEDER
FAST OR SLOW RUN-IN MODE SELECTION
INSTRUCTIONS TO ENTER SLOW RUN-IN
INPUT LINE VOLTAGE PROTECTION
AVOIDING WIRE FEEDING PROBLEMS
WIRE FEED OVERLOAD PROTECTION
FAN CONTROL
OPERATION
B-10
WELDING THERMAL OVERLOAD PROTECTION
OVERCURRENT PROTECTION
TABLE OF CONTENTS
ACCESSORIES
ACCESSORIES SECTION
SECTION C
MAGNUM GUN CONNECTION KIT
TIMER KIT INSTALLATION Optional K1701-1
DRIVE ROLL KITS
ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES
ACCESSORIES
OPERATING INSTRUCTIONS FOR TIMER KIT
CONNECTING THE SPOOL GUN TO THE POWER MIG 255C
SPOOL GUN
ACCESSORIES
MAKING A WELD WITH THE PRINCE XL SPOOL GUN
MAKING A WELD WITH THE MAGNUM SG SPOOL GUN
FIGURE C.1
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ACCESSORIES
SG Spool Gun Wire Feed Speed
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TABLE OF CONTENTS
MAINTENANCE
MAINTENANCE SECTION
SECTION D
LINER REMOVAL AND REPLACEMENT
GENERAL MAINTENANCE
GUN CABLE CLEANING
CONTACT TIP AND GAS NOZZLE INSTALLATION
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LINER REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM 250L
GUN HANDLE DISASSEMBLY
MAINTENANCE
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MAINTENANCED-4
TABLE D.2 ACCESSORIES AND EXPENDABLE REPLACE
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TABLE OF CONTENTS
THEORY OF OPERATION
THEORY OF OPERATION SECTION
SECTION E
POWER MIG 255C
INPUT LINE VOLTAGE
AND MAIN TRANSFORMER
Diagram are the subject of discussion
POWER MIG 255C
OUTPUT RECTIFICATION AND
FEEDBACK CONTROL
Diagram are the subject of discussion
THEORY OF OPERATION
CONSTANT VOLTAGE OUTPUT
Diagram are the subject of discussion
POWER MIG 255C
POWER MIG 255C
WIRE DRIVE MOTOR
AND FEEDBACK
Diagram are the subject of discussion
OVERCURRENT PROTECTION
WIRE FEED OVERLOAD PROTECTION
THERMAL AND OVERLOAD PROTECTION
THEORY OF OPERATION
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SCR OPERATION
THEORY OF OPERATION
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TROUBLESHOOTING AND REPAIR
TROUBLESHOOTING AND REPAIR SECTION
TABLE OF CONTENTS
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F-2TROUBLESHOOTING AND REPAIRF-2
HOW TO USE TROUBLESHOOTING GUIDE
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TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
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MISADJUSTMENTS
TROUBLESHOOTING GUIDE
PROBLEMS
SYMPTOMS
MISADJUSTMENTS
TROUBLESHOOTING AND REPAIR
PROBLEMS
SYMPTOMS
MISADJUSTMENTS
TROUBLESHOOTING AND REPAIR
PROBLEMS
SYMPTOMS
SYMPTOMS
FUNCTION PROBLEMS
TROUBLESHOOTING AND REPAIR
PROBLEMS
SYMPTOMS
WIRE FEEDING PROBLEMS
TROUBLESHOOTING AND REPAIR
PROBLEMS
SYMPTOMS
WELDING PROBLEMS
TROUBLESHOOTING AND REPAIR
PROBLEMS
SYMPTOMS
F-10
TROUBLESHOOTING AND REPAIR
PROBLEMS
TEST DESCRIPTION
TEST PROCEDURES
F-11
MAIN TRANSFORMER TEST
TROUBLESHOOTING AND REPAIR
TEST PROCEDURE
F-12
MAIN TRANSFORMER TEST continued
MAIN TRANSFORMER TEST continued
F-13
TROUBLESHOOTING AND REPAIR
F-13
MAIN TRANSFORMER TEST continued
F-14
TROUBLESHOOTING AND REPAIR
F-14
F-15
F-15
RECTIFIER DIODE BRIDGE TEST
TROUBLESHOOTING AND REPAIR
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F-16TROUBLESHOOTING AND REPAIRF-16
RECTIFIER DIODE BRIDGE TESTING continued
TEST PROCEDURE
F-17
F-17
TROUBLESHOOTING AND REPAIR
RECTIFIER DIODE BRIDGE TESTING continued
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F-18
F-18
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F-19
STATIC SCR RECTIFIER ASSEMBLY TEST
F-19
TROUBLESHOOTING AND REPAIR
TEST PROCEDURE
STATIC SCR RECTIFIER ASSEMBLY TEST continued
F-20
TROUBLESHOOTING AND REPAIR
F-21
F-21
TROUBLESHOOTING AND REPAIR
STATIC SCR RECTIFIER ASSEMBLY TEST continued
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F-22
F-22
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F-23
ACTIVE SCR RECTIFIER ASSEMBLY TEST
F-23
TROUBLESHOOTING AND REPAIR
TEST PROCEDURE
ACTIVE SCR RECTIFIER ASSEMBLY TEST continued
F-24
TROUBLESHOOTING AND REPAIR
F-25
F-25
TROUBLESHOOTING AND REPAIR
ACTIVE SCR RECTIFIER ASSEMBLY TEST continued
F-26
F-26
TROUBLESHOOTING AND REPAIR
ACTIVE SCR RECTIFIER ASSEMBLY TEST continued
F-27
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST
F-27
TROUBLESHOOTING AND REPAIR
TEST PROCEDURE
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continued
F-28
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continued
F-29
TEST FOR SUPPLY VOLTAGE TO TACHOMETER
TROUBLESHOOTING AND REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST continued
F-30
TEST FOR FEEDBACK VOLTAGE TO CONTROL BOARD
TROUBLESHOOTING AND REPAIR
F-31
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
F-31
TROUBLESHOOTING AND REPAIR
F-32
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
F-32
TROUBLESHOOTING AND REPAIR
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F-33
TROUBLESHOOTING AND REPAIR
F-33
F-34
ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING
F-34
TROUBLESHOOTING AND REPAIR
F-35
TYPICAL SCR GATE VOLTAGE WAVEFORM
F-35
TROUBLESHOOTING AND REPAIR
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F-36
F-36
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DESCRIPTION
COMPONENT REPLACEMENT PROCEDURES
CONTROL PC BOARD REMOVAL AND REPLACEMENT
F-37
F-38
CONTROL PC BOARD REMOVAL AND REPLACEMENT continued
REMOVAL AND REPLACEMENT
PROCEDURE
F-39
CONTROL PC BOARD REMOVAL AND REPLACEMENT continued
F-39
TROUBLESHOOTING AND REPAIR
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F-40
F-40
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F-41
WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT
F-41
TROUBLESHOOTING AND REPAIR
F-42
WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT continued
F-42
TROUBLESHOOTING AND REPAIR
PROCEDURE
F-43
TROUBLESHOOTING AND REPAIR
WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT continued
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F-44
F-44
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F-45
SCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT
F-45
TROUBLESHOOTING AND REPAIR
PROCEDURE
SCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT continued
F-46
TROUBLESHOOTING AND REPAIR
F-47
F-47
TROUBLESHOOTING AND REPAIR
SCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT continued
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F-48
F-48
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F-49
CAPACITOR BANK REMOVAL AND REPLACEMENT
F-49
TROUBLESHOOTING AND REPAIR
PROCEDURE
CAPACITOR BANK REMOVAL AND REPLACEMENT continued
F-50
TROUBLESHOOTING AND REPAIR
F-51
MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT
F-51
TROUBLESHOOTING AND REPAIR
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F-52TROUBLESHOOTING AND REPAIRF-52
MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT continued
PROCEDURE
F-53
F-53
TROUBLESHOOTING AND REPAIR
MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT continued
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F-54
F-54
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F-55
FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT
F-55
TROUBLESHOOTING AND REPAIR
PROCEDURE
FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT continued
F-56
TROUBLESHOOTING AND REPAIR
OPEN CIRCUIT VOLTAGE
WIRE SPEED RANGE
RETEST AFTER REPAIR
F-57
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TABLE OF CONTENTS
ELECTRICAL DIAGRAMS SECTION
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ELECTRICAL DIAGRAMS
WIRING DIAGRAM - ENTIRE MACHINE - CODE 11192 L12464
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WIRING DIAGRAM - ENTIRE MACHINE CODE 11218 L12506
ELECTRICAL DIAGRAMS
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SCHEMATIC - ENTIRE MACHINE - G4752
ELECTRICAL DIAGRAMS
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SCHEMATIC - CONTROL PC BOARD - G4823-2D1 SHEET
ELECTRICAL DIAGRAMS
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ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD - G4823-2D1 SHEET
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ELECTRICAL DIAGRAMS
SCHEMATIC - CONTROL PC BOARD - G4823-2D1 SHEET
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PC BOARD ASSEMBLY - CONTROL - G4824-2D1
ELECTRICAL DIAGRAMS
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SCHEMATIC - DISPLAY PC BOARD L10951
ELECTRICAL DIAGRAMS
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G-10
PC BOARD ASSEMBLY - DISPLAY - L10952
G-10
ELECTRICAL DIAGRAMS
SVM ERROR REPORTING FORM