Welder User Manual

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POWER MIG 255

SVM144-B

July, 2006

Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built

with safety in mind. However,

your overall safety can be

increased by proper installation

. . . and thoughtful operation on

your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS

EQUIPMENT WITHOUT READ-

ING THIS MANUAL AND THE

SAFETY PRECAUTIONS CON-

TAINED THROUGHOUT. And,

most importantly, think before

you act and be careful.

SERVICE MANUAL

For use with machines having Code Number : 10563, 10583,10986, 10990

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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

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Summary of content (108 pages)

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View Safety Info SVM144-B July, 2006 POWER MIG 255 For use with machines having Code Number : 10563, 10583,10986, 10990 Return to Master TOC View Safety Info View Safety Info Safety Depends on You Return to Master TOC Return to Master TOC RETURN TO MAIN MENU Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . . and thoughtful operation on your part.
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Return to Master TOC i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
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Return to Master TOC Return to Master TOC ii ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
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SAFETY Return to Master TOC iii WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
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SAFETY Return to Master TOC a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains. b.
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v v RETURN TO MAIN MENU MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Accessories . . . . . . . . . . . . . . . . . . . . . . . . . .
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Return to Master TOC Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Installation ..............................................................................................................Section A Technical Specifications...............................................................................................A-2 Safety Precautions .......................................................................................................A-3 Uncrating the POWER MIG 255..........
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INSTALLATION Return to Master TOC Return to Section TOC A-2 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 40% 60% 100% Amps 250 Amps 200 Amps 145 Amps Volts at Rated Amperes 26 Volts 28 Volts 26 Volts Return to Master TOC Return to Section TOC OUTPUT Welding Current Range (Conti
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INSTALLATION Return to Master TOC Return to Section TOC A-3 Read entire installation section before starting installation. INPUT POWER, GROUNDING AND CONNECTION DIAGRAMS SAFETY PRECAUTIONS WARNING WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation.
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC A-4 INSTALLATION A-4 FIGURE A.1 — DUAL VOLTAGE MACHINE INPUT CONNECTIONS. 3. The 208/230 volt 60 Hz model POWER MIG is shipped with a 10 ft. input cable and plug connected to the welder. A matching receptacle is supplied with the machine. Mount the receptacle in a suitable location using the screws provided.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC A-5 INSTALLATION FIGURE A.2 — TRIPLE VOLTAGE MACHINE INPUT CONNECTIONS. Return to Section TOC Return to Master TOC Return to Master TOC FIGURE A.3 — RECEPTACLE DIAGRAM. Return to Section TOC A-5 CONNECT TO A SYSTEM GROUNDING WIRE. SEE THE UNITED STATES NATIONAL ELECTRICAL CODE AND/OR LOCAL CODES FOR OTHER DETAILS AND MEANS FOR PROPER GROUNDING.
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INSTALLATION Return to Master TOC Return to Section TOC A-6 GUN AND CABLE INSTALLATION Return to Master TOC Return to Section TOC 2. Unscrew knurled screw on the drive unit front end (inside wire feed compartment) until tip of screw no longer protrudes into gun opening as seen from front of machine. 3. Insert the male end of gun cable into the female casting through opening in front panel. Make sure connector is fully inserted and tighten knurled screw. Return to Master TOC Return to Master TOC 4.
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Return to Master TOC Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Section B-1 Operation ................................................................................................................Section B Product Description......................................................................................................B-3 Recommended Processes and Equipment..................................................................B-3 Welding Capability..........................................
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Return to Master TOC Return to Section TOC B-2 OPERATION Read entire Operation section before operating the POWER MIG 255. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. Return to Master TOC • Always gloves. Return to Section TOC B-2 wear dry insulating FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone.
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Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-3 OPERATION PRODUCT DESCRIPTION The POWER MIG™ 255 is a complete semiautomatic constant voltage DC arc welding machine built to meet NEMA specifications. It combines a constant voltage power source and a constant speed wire feeder with a microcomputer-based controller to form a reliable highperformance welding system.
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OPERATION Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-4 DESCRIPTION OF CONTROLS WIRE DRIVE ROLL 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. 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.
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OPERATION Return to Master TOC Return to Section TOC B-5 PROCEDURE FOR CHANGING DRIVE AND IDLE ROLL SETS 2 IN. O.D. SPINDLE 1. Turn off the power source. 2. Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back of the machine. Lift the cast idle roll assembly and allow it to sit in an upright position. BRAKE HOLDING PIN Return to Master TOC Return to Section TOC 5. Wiggle both the metal idle and drive rolls off of their plastic hubs. 6.
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OPERATION Return to Master TOC Return to Section TOC B-6 TO START THE WELDER Turn the Power Switch switch to ON. This lights the red LED display lights. With the desired voltage and wire speed selected, operate the gun trigger for welder output and to energize the wire feed motor.
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Return to Master TOC Return to Section TOC B-7 OPERATION NOTE: Arc starting characteristics may be effected when using the fast run-in mode since optimum starting processes are being overridden. 5. If welding gas is to be used, turn on the gas supply and set the required flow rate (typically 25-35 CFH; 12-16 liters/min). On the initial trigger closure at power up, no output power or wire feed will be available until the trigger is opened and reclosed, regardless of wire feed speed dial setting. 6.
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OPERATION Return to Master TOC Return to Section TOC B-8 5. Use only clean, rust-free electrode. The Lincoln electrodes have proper surface lubrication. WIRE FEED OVERLOAD PROTECTION 6. Replace contact tip when the arc starts to become unstable or the contact tip end is fused or deformed. The POWER MIG has solid state overload protection of the wire drive motor. If the motor becomes overloaded, the protection circuitry turns off the wire feed speed and gas solenoid.
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Return to Master TOC Section C-1 TABLE OF CONTENTS - ACCESSORIES SECTION - Section C-1 Accessories ............................................................................................................Section C Drive Roll Kits ...............................................................................................................C-2 3/64 in. (1.2 mm) Aluminum Feeding Kit (K1703-1) .....................................................C-2 K363P Readi-Reel Adapter ............................
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ACCESSORIES Return to Master TOC Return to Section TOC C-2 DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that are available for the POWER MIG. All items in Bold are supplied standard with the POWER MIG. TABLE C.1 — AVAILABLE DRIVE ROLL KITS. Wire Solid Steel Return to Master TOC Return to Section TOC Cored Aluminum Size Drive Roll Kit 0.023-0.030 in. (0.6-0.8 mm) KP1696-030S 0.035 in. (0.9 mm) KP1696-035S 0.045 in. (1.2 mm) KP1696-045S 0.035 in. (0.9 mm) 0.045 in. (1.
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ACCESSORIES Return to Master TOC Return to Section TOC C-3 3. Using a screwdriver, remove the two screws securing the lower cover panel to the front of the machine. Remove the lower cover panel. 4. Attach the rectangular 10-pin plug connector on the timer kit wiring harness to the mating receptacle connector located directly behind the removed cover panel. Be sure that the latch on the connector is aligned with the one on the board and insert it until the latch engages.
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ACCESSORIES Return to Master TOC Return to Section TOC C-4 SPOOL GUN ADAPTER KIT WARNING Remove all input power to the POWER MIG 255 before proceeding. -----------------------------------------------------------------------The Spool Gun Adapter Kit provides direct connection and use of the Spool Gun (with remote speed control) with the POWER MIG 255 wire feed welder.
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Return to Master TOC Section D-1 TABLE OF CONTENTS - MAINTENANCE SECTION - Section D-1 Maintenance ...........................................................................................................Section D Safety Precautions ........................................................................................................D-2 Routine and Periodic Maintenance ...............................................................................D-2 Drive Rolls and Guide Tubes ....................
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MAINTENANCE Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC D-2 SAFETY PRECAUTIONS D-2 DRIVE ROLLS AND GUIDE TUBES WARNING • Have a qualified electrician do the maintenance and troubleshooting work. • Disconnect the input power off using the disconnect switch at the main input supply before working inside machine. After every coil of wire, inspect the wire drive mechanism. Clean it as necessary by blowing with low pressure compressed air.
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MAINTENANCE Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC D-3 D-3 FIGURE D.1 — COMPONENT LOCATIONS.
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MAINTENANCE Return to Master TOC Return to Section TOC D-4 CONTACT TIP AND GAS NOZZLE INSTALLATION 1. Choose the correct size contact tip for the electrode being used (wire size is stenciled on the side of the contact tip) and screw it snugly into the gas diffuser. a. Be sure the nozzle insulator is fully screwed onto the gun tube and does not block the gas holes in the diffuser. Return to Master TOC Return to Section TOC 2. Slip or screw the appropriate gas nozzle onto the nozzle insulator.
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MAINTENANCE Return to Master TOC Return to Section TOC D-5 9. Tighten the setscrew on the brass cable connector. The internal parts of the gun handle may be inspected or serviced if necessary. 10. Straighten the cable with the gas nozzle and nozzle insulator removed from the gun tube. The gun handle consists of two halves that are held together with a collar on each end. 11. Trim the liner to the length shown in Figure D.2.
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MAINTENANCE Return to Master TOC Return to Section TOC D-6 ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES TABLE D.2 DESCRIPTION Return to Master TOC Return to Section TOC Return to Master TOC ENGLISH SIZE METRIC SIZE 0.025-0.030 in. 0.035-0.045 in. 3/64 in. (Alum. Wire) 0.6 - 0.8 mm 0.9 - 1.2 mm 1.2 mm (Alum. Wire) KP1934-2 KP1934-1 KP1955-1 Contact Tips Standard Duty KP2020-6B1 KP2020-7B1 KP2020-1B1* KP2020-2B1* 0.025 0.030 0.035 0.
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TABLE OF CONTENTS - THEORY OF OPERATION SECTION - Return to Master TOC Section E-1 Section E-1 Theory of Operation ...............................................................................................Section E Input Line Voltage and Main Transformer.....................................................................E-2 Output Rectification and Feedback Control.................................................................E-3 Constant Voltage Output .........................................
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THEORY OF OPERATION GAS SOLENOID FAN MOTOR WIRE DRIVE MOTOR WIRE SPEED CONTROL BOARD ARC VOLTAGE TACH 115 VAC RECTIFIER DIODE BRIDGE 30 VAC SNUBBER BOARD Return to Master TOC LINE SWITCH Return to Section TOC E-2 FIGURE E.2 — INPUT LINE VOLTAGE AND MAIN TRANSFORMER.
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THEORY OF OPERATION GAS SOLENOID FAN MOTOR WIRE DRIVE MOTOR WIRE SPEED CONTROL BOARD ARC VOLTAGE TACH 115 VAC RECTIFIER DIODE BRIDGE 30 VAC SNUBBER BOARD Return to Master TOC LINE SWITCH Return to Section TOC E-3 FIGURE E.3 — OUTPUT RECTIFICATION AND FEEDBACK.
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THEORY OF OPERATION GAS SOLENOID FAN MOTOR WIRE DRIVE MOTOR WIRE SPEED CONTROL BOARD ARC VOLTAGE TACH 115 VAC RECTIFIER DIODE BRIDGE 30 VAC SNUBBER BOARD Return to Master TOC LINE SWITCH Return to Section TOC E-4 FIGURE E.4 — CONSTANT VOLTAGE OUTPUT.
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THEORY OF OPERATION GAS SOLENOID FAN MOTOR WIRE DRIVE MOTOR WIRE SPEED CONTROL BOARD ARC VOLTAGE TACH 115 VAC RECTIFIER DIODE BRIDGE 30 VAC SNUBBER BOARD Return to Master TOC LINE SWITCH Return to Section TOC E-5 FIGURE E.5 — WIRE DRIVE MOTOR AND FEEDBACK.
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC E-6 THEORY OF OPERATION E-6 OVERCURRENT PROTECTION THERMAL AND OVERLOAD PROTECTION The POWER MIG 255 has built-in protective thermostats that respond to excessive temperatures. One is located on the output choke. The other thermostat is located on the SCR heat sink assembly.
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THEORY OF OPERATION E-7 FIGURE E.6 — SCR OPERATION. Return to Master TOC Return to Section TOC E-7 INPUT CATHODE OUTPUT NOTE: AS THE GATE PULSE IS APPLIED LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED. ANODE Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC GATE SCR OPERATION A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC E-8 NOTES POWER MIG 255 E-8
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Return to Master TOC Section F-1 TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR SECTION - Section F-1 Troubleshooting & Repair Section ........................................................................Section F How to Use Troubleshooting Guide..............................................................................F-2 PC Board Troubleshooting Procedures and Replacement...........................................F-3 Troubleshooting Guide ..........................................................
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-2 TROUBLESHOOTING & REPAIR F-2 HOW TO USE TROUBLESHOOTING GUIDE CAUTION Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
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Return to Master TOC Return to Section TOC F-3 TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-4 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-4 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major Physical or Electrical Damage 1. Contact your local Lincoln 1.
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-5 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-5 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS (Continued) No open circuit voltage output but 1. Check the input voltage at the 1.
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Return to Master TOC Return to Section TOC F-6 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-6 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS (Continued) The output voltage and wire feed is 1. Remove the gun. If the problem 1.
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Return to Master TOC Return to Section TOC F-7 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-7 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS No control of arc voltage. Wire feed- 1. The arc voltage control poten- 1. The arc voltage control potening is normal. tiometer may be dirty. Rotate tiometer may be faulty. Check or several times and check if probreplace.
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Return to Master TOC Return to Section TOC F-8 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-8 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WIRE FEEDING PROBLEMS No control of wire feed speed. Other 1. The wire feed speed control 1. The Wire Speed Control potenmachine functions are normal may be dirty. Rotate several tiometer may be faulty. Check or times and check if problem is replace.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-9 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-9 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS The arc is unstable and or “hunting”. 1. Check for worn or melted con- 1. Check for loose connections at tact tip. the output terminals, the chokes, the capacitor bank and 2.
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Return to Master TOC Return to Section TOC F-10 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) F-10 Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS (Continued) The contact tip seizes in the gas diffuser. 1. The tip being over heated due to 1. Make sure tip is tight in diffuser. excessive current and/or high duty cycle welding.
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Return to Master TOC Return to Section TOC F-11 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
PAGE 50
Return to Master TOC Return to Section TOC F-12 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST (continued) FIGURE F.1 — G3521 CONTROL PC BOARD AND M19248 SNUBBER PC BOARD MAIN TRANSFORMER TEST POINTS. X5 (6J6) J6 J5 #206 (3J5) Return to Master TOC X6 (5J6) X7 (4J6) X9 (8J5) Return to Section TOC F-12 X8 (16J5) #209S (6J9) J3 J8 J9 #208S (2J9) J1 J4 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC J2 TEST PROCEDURE WARNING 4.
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Return to Master TOC Return to Section TOC F-13 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST (continued) 6. Connect main input power to the machine. 7. Turn the POWER MIG 255 ON/OFF POWER SWITCH to ON. 8. Carefully make the following voltage tests at plug J6. Return to Master TOC Return to Section TOC a. Turn the machine OFF between each test. b. Carefully insert the meter probes into the back of each Molex plug pin cavity to perform the test.
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Return to Master TOC Return to Section TOC F-14 TROUBLESHOOTING AND REPAIR MAIN TRANSFORMER TEST (continued) 14. Locate the following leads on plug J9 on the M19248 snubber PC board and on plug J5 on the G3521 control PC board. See Figure F.1. G3521: LEAD PLUG LOCATION 206 3J5 Return to Master TOC Return to Section TOC M19248: LEAD PLUG LOCATION 208S 209S 2J9 6J9 Return to Master TOC Return to Master TOC d. If ALL the voltages tested are incorrect or missing, go to step 16. 17.
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Return to Master TOC Return to Section TOC F-15 TROUBLESHOOTING & REPAIR RECTIFIER DIODE BRIDGE TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-16 TROUBLESHOOTING & REPAIR RECTIFIER DIODE BRIDGE TESTING (continued) FIGURE F.2 — G3521 RECTIFIER DIODE BRIDGE LOCATION. RECTIFIER DIODE BRIDGE (D2) TEST PROCEDURE LEAD 1. Disconnect the main AC input power to the machine. Return to Master TOC 2. Remove the case top and side panels with a 3/8 in. nutdriver. Return to Section TOC F-16 3.
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Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR RECTIFIER DIODE BRIDGE TESTING (continued) 6. Turn the POWER MIG 255 ON/OFF POWER SWITCH to ON. 7. Carefully make the following voltage tests: a. Turn the machine OFF between each test. b. Carefully connect the meter plugs to the exposed lead connections. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC c. Turn the machine ON to conduct the voltage test.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-18 NOTES POWER MIG 255 F-18
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Return to Master TOC Return to Section TOC F-19 TROUBLESHOOTING & REPAIR STATIC SCR RECTIFIER ASSEMBLY TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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Return to Master TOC Return to Section TOC F-20 TROUBLESHOOTING & REPAIR F-20 STATIC SCR RECTIFIER ASSEMBLY TEST (continued) FIGURE F.3 — REMOVE PLUGS J6 AND J9 TO PERFORM STATIC RECTIFIER ASSEMBLY TEST. J6 Return to Master TOC Return to Section TOC J5 J3 J8 J9 J1 J4 Return to Master TOC Return to Section TOC J2 TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Remove the case top and side panels with a 3/8 in. nutdriver. Return to Master TOC Return to Section TOC 3.
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TROUBLESHOOTING & REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-21 STATIC SCR RECTIFIER ASSEMBLY TEST (continued) FIGURE F.4 — LOCATION OF LEADS X2 AND X3. Return to Section TOC Return to Master TOC Return to Master TOC FIGURE F.5 — SCR 1 TEST POINTS. NEGATIVE CAPACITOR BANK BUSS BAR LEADS X2 AND X3 CONNECTION 9. Test for high or infinite resistance from the cathode to the anode of SCR 1 by reversing the meter leads. See Figure F.5. 6.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-22 NOTES POWER MIG 255 F-22
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Return to Master TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR ACTIVE SCR RECTIFIER ASSEMBLY TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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Return to Master TOC Return to Section TOC F-24 TROUBLESHOOTING & REPAIR F-24 ACTIVE SCR RECTIFIER ASSEMBLY TEST (continued) FIGURE F.6 — CONTROL BOARD MOLEX PLUG LOCATIONS FOR G3521 PC CONTROL BOARD. J6 Return to Master TOC Return to Section TOC J5 J3 J8 J9 J1 J4 Return to Master TOC Return to Section TOC J2 TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Remove the case top and side panels with a 3/8 in. nutdriver. Return to Master TOC Return to Section TOC 3.
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TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-25 ACTIVE SCR RECTIFIER ASSEMBLY TEST (continued) 6. Disconnect leads X2 and X3 (braided copper strap) from the negative capacitor bank buss bar using a 1/2 in. open end wrench. See Figure F.7. FIGURE F.7 — LOCATION OF LEADS X2 AND X3. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 8. Use a commercial SCR tester or construct the tester circuit shown in Figure F.8.
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Return to Master TOC Return to Section TOC F-26 TROUBLESHOOTING & REPAIR F-26 ACTIVE SCR RECTIFIER ASSEMBLY TEST (continued) 9. Connect the tester to the SCR 1 as shown in Figure F.8. 15. Reconnect the tester leads. See Figure F.8. a. Connect tester lead (A) to the anode. a. Connect tester lead (A) to the cathode. b. Connect tester lead (C) to the cathode. b. Connect tester lead (C) to the anode. c. Connect tester lead (G) to the gate. c. Disconnect test lead (G) from the gate. 10.
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Return to Master TOC Return to Section TOC F-27 TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST WARNING Service and repair should only be performed by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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Return to Master TOC Return to Section TOC F-28 TROUBLESHOOTING & REPAIR F-28 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) FIGURE F.9 — PLUG J1 LOCATION ON G3521 PC CONTROL BOARD. J6 J3 Return to Master TOC Return to Section TOC J5 B J8 (4J1) #555 (6J1) W J1 (2J1) #515B (5J1) #206B (1J1) J4 Return to Master TOC Return to Section TOC J2 3. Locate plug J1 on the G3521 control PC board. See Figure F.9. TEST PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS.
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TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-29 WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) 6. Make the following voltage tests: a. Turn the machine OFF between each test. Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC FROM LEAD TO LEAD EXPECTED VOLTAGE B (4J1) W (2J1) 3-20 VDC (varies depending on wire feed speed) 7.
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Return to Master TOC Return to Section TOC F-30 TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued) TEST FOR FEEDBACK VOLTAGE TO CONTROL BOARD Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC c. Turn the machine ON and pull the gun trigger to conduct the voltage test. 1. Disconnect the main AC input power to the machine. FROM LEAD TO LEAD EXPECTED VOLTAGE 2. Locate plug J1 on the G3521 control PC board.
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TROUBLESHOOTING & REPAIR 0 VOLTS Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC 20.0 V Return to Section TOC F-31 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM Return to Master TOC Return to Section TOC Return to Section TOC F-31 2.5 ms SCOPE SETTINGS This is a typical DC output voltage waveform generated from a properly operating Volts/Div . . . . . . . . . . . . . . . . . . 20 V/Div machine.
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TROUBLESHOOTING & REPAIR Return to Master TOC F-32 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED 0 VOLTS Return to Master TOC Return to Section TOC Return to Section TOC F-32 20.0 V 5 ms Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC MACHINE LOADED TO 250 AMPS AT 26 VDC SCOPE SETTINGS This is a typical DC output voltage waveform generated from a properly operating Volts/Div . . . . . . . . . . . . . . . . . . 20 V/Div machine.
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TROUBLESHOOTING & REPAIR Return to Master TOC F-33 ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED ONE OUTPUT SCR NOT FUNCTIONING 0 VOLTS Return to Master TOC Return to Section TOC Return to Section TOC F-33 20.0 V 5 ms Return to Master TOC Return to Section TOC MACHINE LOADED TO 220 AMPS AT 22 VDC SCOPE SETTINGS This is NOT a typical DC output voltage waveform. One output SCR is not functioning. Note the increased ripple content.
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TROUBLESHOOTING & REPAIR 0 VOLTS Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC 20.0 V Return to Section TOC F-34 ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING Return to Master TOC Return to Section TOC Return to Section TOC F-34 5 ms SCOPE SETTINGS This is NOT the typical DC output voltage waveform. The output capacitors are not Volts/Div . . . . . . . . . . . . . . . . . . 20 V/Div functioning.
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TROUBLESHOOTING & REPAIR 0 VOLTS Return to Master TOC Return to Master TOC 2.00 V Return to Section TOC F-35 TYPICAL SCR GATE VOLTAGE WAVEFORM Return to Master TOC Return to Section TOC Return to Section TOC F-35 5 ms SCOPE SETTINGS This is a typical SCR gate pulse voltage waveform. The machine was in an open Volts/Div . . . . . . . . . . . . . . . . . . 2.0 V/Div circuit condition (no load) and operating properly. Note that each vertical division Horizontal Sweep . . . . . . . . . .
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-36 NOTES POWER MIG 255 F-36
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Return to Master TOC Return to Section TOC F-37 TROUBLESHOOTING AND REPAIR CONTROL PC BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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Return to Master TOC Return to Section TOC F-38 TROUBLESHOOTING AND REPAIR CONTROL PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (Continued) FIGURE F.10 — WIRING HARNESS AND MOLEX PLUG LOCATIONS. J6 REMOVAL AND REPLACEMENT PROCEDURE 1. Disconnect main input power the machine. J5 2. Open the side panels and remove the tool tray using a 5/16 in. nutdriver. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC J3 J8 3.
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Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-39 TROUBLESHOOTING AND REPAIR F-39 CONTROL PC BOARD REMOVAL AND REPLACEMENT PROCEDURE (Continued) FIGURE F.11 — CONTROL BOARD MOUNTING. TOOL TRAY MOUNTING STANDOFF PC CONTROL BOARD Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC NOTE: TOP COVER SHOWN REMOVED FOR CLARITY. 4. Ensure a static electricity grounding strap is used before handling the control PC boards. 7.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-40 NOTES POWER MIG 255 F-40
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Return to Master TOC Return to Section TOC F-41 TROUBLESHOOTING & REPAIR WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-42 F-42 WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT (continued) FIGURE F.12 — WIRE DRIVE ASSEMBLY REMOVAL FOR CODES 10563 & 10583 REFER TO P344-F.2 FOR EXPLODED VIEW OF WIRE DRIVE FOR CODES 10986 AND 10990 - SIMILAR PROCEDURE 2 17 9 4 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 18 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
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Return to Master TOC Return to Section TOC F-43 TROUBLESHOOTING & REPAIR WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT (continued) 10. Rotate the adjustment arm assembly counterclockwise to release the tension on the idle arm. 11. Swing the idle arm up and away from the wire drive assembly. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 12.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-44 NOTES POWER MIG 255 F-44
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Return to Master TOC Return to Section TOC F-45 TROUBLESHOOTING & REPAIR SCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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Return to Master TOC Return to Section TOC F-46 TROUBLESHOOTING & REPAIR SCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove the case side panels using a 3/8 in. nutdriver. 2. Disconnect lead #208S and transformer lead X1 from the heat sink on the left side of the machine using a 1/2 in. socket wrench. See Figure F.13. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC a.
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Return to Master TOC Return to Section TOC F-47 TROUBLESHOOTING & REPAIR F-47 SCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) FIGURE F.15 — RIGHT HEAT SINK LEAD DISCONNECTION. SCR ASSEMBLY SCR DIODE LEAD LEAD #320B Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC LEAD #320 LEAD #209S LEAD X4 5. Remove lead #209S and transformer lead X4 from the right side heat sink using a 1/2 in. socket wrench and 1/2 in. open end wrench. See Figure F.15. 6.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-48 NOTES POWER MIG 255 F-48
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Return to Master TOC Return to Section TOC F-49 TROUBLESHOOTING & REPAIR CAPACITOR BANK REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-50 F-50 CAPACITOR BANK REMOVAL AND REPLACEMENT (continued) FIGURE F.16 — LOCATION OF CAPACITOR BANK REMOVAL AND REPLACEMENT COMPONENTS. LEAD #206 SCR DIODE LEAD CAPACITOR BANK LEAD #206B Return to Master TOC Return to Section TOC SHUNT LEADS X1 AND X2 POWER ENHANCEMENT CHOKE LEAD Return to Master TOC Return to Section TOC OUTPUT CHOKE LEAD tive capacitor bank buss bar using a 1/2 in. open end wrench.
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Return to Master TOC Return to Section TOC F-51 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty.
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TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-52 MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT (continued) FIGURE F.17 — MAIN TRANSFORMER REMOVAL. LEAD X1 OUTPUT CHOKE LEAD Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC OUTPUT CHOKE POSITIVE LEAD NOTE: PLUG-IN LEADS ARE NOT SHOWN FOR CLARITY. LEAD X4 LEADS X2 AND X3 MAIN TRANSFORMER POWER ENHANCEMENT CHOKE PROCEDURE 1. Disconnect main input power to the machine. 2.
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Return to Master TOC Return to Section TOC F-53 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER AND OUTPUT CHOKE REMOVAL AND REPLACEMENT (continued) 11. Unplug and label leads X5, X6, X7, X8, and X9. These leads have connectors near the transformer which can be disconnected. 14. Remove the four nuts and washers mounting the transformer to the floor of the machine using a 1/2 in. wrench. 12. Disconnect the output choke lead from the positive capacitor bank buss using two 1/2 in. open end wrenches. 15.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-54 NOTES POWER MIG 255 F-54
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Return to Master TOC Return to Section TOC F-55 TROUBLESHOOTING & REPAIR FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
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TROUBLESHOOTING & REPAIR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-56 FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT (continued) FIGURE F.18 — FAN MOTOR ASSEMBLY REMOVAL. Return to Master TOC Return to Section TOC FAN BLADE LEAD #353 LEAD #352 FAN MOTOR PROCEDURE 1. Disconnect main input power to the machine. 1. Remove the case side panels using a 3/8 in. nutdriver. 2. Disconnect the fan motor leads #352 and #352. See Figure F.18.
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TROUBLESHOOTING AND REPAIR Return to Master TOC Return to Section TOC F-57 RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS Input Volts/Hertz Maximum Idle Amps Maximum Idle Watts 230/60 7.0 400 OPEN CIRCUIT VOLTAGE Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 35-40 VDC Return to Section TOC F-57 WIRE SPEED RANGE 50 - 700 IPM (1.27 - 17.
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Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-58 NOTES POWER MIG 255 F-58
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Return to Master TOC Section G-1 TABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Section G-1 Electrical Diagrams ...............................................................................................Section G Wiring Diagram - Entire Machine - Code 10563 - (L10979) . . . . . . . . . . . . . . . . . . . .G-2 Wiring Diagram - Entire Machine - Code 10583 - (L10980) . . . . . . . . . . . . . . . . . . . .G-3 Wiring Diagram - Entire Machine - Code 10986 - (L11980) . . . . . . . . . . . . . . . . .
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WIRING DIAGRAM - ENTIRE MACHINE - CODE 10563 - (L10979) POWER MIG 255 (208/230V) NOTES: GENERAL INFORMATION 12 7 ** 8 1 1 515 2 256 J13 3 1 253 254 251 Return to Master TOC 392 265 263 262 264 260 515B 261 206B ** 2 W SNUBBER 324 4 BOARD X5 14.2V X6 14.
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WIRING DIAGRAM - ENTIRE MACHINE - CODE 10583 - (L10980) POWER MIG 255 (230/460/575V) NOTES: GENERAL INFORMATION CAVITY NUMBERING SEQUENCE R4 256 J13 J12 3 253 254 251 4 390 WIRE FEED SPEED 392 2 325 L2 L1 H1 L2 H2 H5 H1 H3 H4 4 H4 X8 9 10 1 204 2 208S 208 206B 1 W 2 J12 - 1 ** 2 208R 4 J9 5 B 7 209 8 209R W + 320 G1 320B 28.
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POWER MIG 255 (230/460/575 V) NOTES: GENERAL INFORMATION CAVITY NUMBERING SEQUENCE COLOR CODE: (COMPONENT SIDE OF P.C. BOARD) 3 J1 J9 J12 J6 4 2 1 6 6 1 5 4 8 1 J3 J4 J7 5 6 10 1 7 J2 7 1 B - BLACK W - WHITE R - RED U - BLUE INDICATES CONNECTOR CAVITY NO. 8 10 (NON-LEAD SIDE OF CONNECTOR) Return to Master TOC 3 4 254 252 251 390 WIRE FEED SPEED 392 265 263 262 267 264 260 261 1 324 2 325 J11 3 4 4 J12 324 14.
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POWER MIG 255 (208/230 V) NOTES: GENERAL INFORMATION CAVITY NUMBERING SEQUENCE COLOR CODE: (COMPONENT SIDE OF P.C. BOARD) 3 J1 J9 J12 J6 4 2 1 6 7 12 6 4 1 5 8 1 J3 J4 J7 1 5 6 10 7 J2 14 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. B - BLACK W - WHITE R - RED U - BLUE INDICATES CONNECTOR CAVITY NO.
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Return to Master TOC ELECTRICAL DIAGRAMS G-6 CONTROL PC BOARD SCHEMATIC - (G3520-1D1) Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-6 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric.
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CONTROL PC BOARD ASSEMBLY - (G3521-1) 3521-1 Return to Master TOC G-7 ELECTRICAL DIAGRAMS G Return to Section TOC G-7 ITEM REQ’D PART NO. IDENTIFICATION S16668-5 18 C1,C2,C8,C9,C14,C20,C29 .022/50 C36,C37,C38,C39,C43,C44 C48,C52,C53,C55,C56 C3,C4,C11 3 C5,C6,C18,C19,C35,C51,C54 7 C7 1 C10,C22,C23,C24,C25,C30 16 S13490-42 1.0/35 T11577-52 .0047 OR .005/1400 S13490-73 20/50 S16668-11 .1/50 C31,C32,C33,C34,C40,C41 C45,C46,C57,C58 ~.
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G-8 ELECTRICAL DIAGRAMS 18 20 f 1 Rx 8 /ENABLE DATA OUT 9 10 7 9 10 DISP1 10 R11 L 10951 SHT. NO. SUP’S’D’G. POWERMIG 255 SCHEMATIC, DISPLAY PCB EARTH GROUND CONNECTION COMMON CONNECTION FRAME CONNECTION VOLTAGE NET POWER SUPPLY SOURCE POINT CHK. 1.50K DR.
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4.7/35 S13490-39 18/15 C3,C4,C10 3 S16668-11 .1/50 C7,C8,C9 3 S16668-6 4700pF/50 D1 1 T12199-1 1N4004 DISP1,DISP2,DISP3,DISP5 6 S17395-2 DISPLAY J10 1 S20380-8 RT ANGLE HEADER LED3 1 T13657-6 RED LED R1,R2,R3,R4,R13,R14 6 S19400-2210 221 1/4W R5,R6,R7 3 S19400-1002 10K 1/4W R8,R9,R10 3 S19400-4750 475 1/4W R11,R12 2 S19400-1501 1.5K 1/4W X1 1 S15128-5 +5V REG. X3,X4 2 S20496-1 IC,MC14489,CMOS,DRIVER,LED,CC,MCU(SS) X5 1 S17900-8 14 PIN I.C.
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204 1 208S 2 J1 J1 208 3 208R 4 400V R1 J1 5W 10 J1 204S 5 209S 6 J1 5W 10 J1 7 C2 .68 400V J1 209R 8 Return to Master TOC Return to Section TOC C1 .68 R2 Return to Master TOC J1 Return to Master TOC Return to Section TOC SNUBBER PC BOARD SCHEMATIC - (S24374) 209 NOTES : LABELS GENERAL INFORMATION N.A.
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Return to Master TOC G-11 ELECTRICAL DIAGRAMS SNUBBER PC BOARD ASSEMBLY - (M19248-1) M 19248-1 Return to Section TOC G-11 .20 4.00 REQ’D ITEM 1.80 IDENTIFICATION PART NO. C1,C2 2 T11577-68 J1 1 S18248-8 0.68 MFD /400 WVDC CAPACITOR HEADER R1,R2 2 T14648-25 10 5W ~.04 3.80 SNUBBER J1 Return to Master TOC R1 CAPACITORS = MFD/VOLTS R2 C2 Return to Master TOC Return to Section TOC Return to Section TOC M19248-1 C1 .20 Return to Master TOC Return to Section TOC 0 0 2.
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We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three column troubleshooting chart, please share this information with us. Please include the machine’s code number and how the problem was resolved. Thank You, Technical Services Group Lincoln Electric Co. 22801 St. Clair Ave.