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Lincoln Electric POWER MIG 255 SVM144-B User Manual

Lincoln Electric POWER MIG 255 SVM144-B
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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
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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• Sales and Service through Subsidiaries and Distributors Worldwide •
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 •
Copyright © 2006 Lincoln Global Inc.

Table of Contents

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Lincoln Electric POWER MIG 255 SVM144-B Specifications

General IconGeneral
BrandLincoln Electric
ModelPOWER MIG 255 SVM144-B
CategoryWelding System
LanguageEnglish

Summary

Safety Information

California Proposition 65 Warnings

Warnings regarding chemicals known to cause cancer, birth defects, or reproductive harm.

General Safety Precautions

Key safety guidelines for operation, electrical hazards, fumes, and arc exposure.

Installation Procedures

Installation Safety Precautions

Essential safety measures to follow before and during equipment installation.

Uncrating and Location

Instructions for safely uncrating the machine and selecting an appropriate location.

Input Power, Grounding, and Connections

Detailed guidance on connecting input power, grounding, and wiring diagrams.

Output Polarity Connections

How to set and understand electrode polarity for optimal welding.

Gun and Cable Installation

Steps for properly installing the welding gun and associated cables.

Operation Guide

Operation Safety Warnings

Critical safety warnings related to electric shock, fumes, sparks, and arc rays during operation.

Product Description and Capabilities

Overview of the machine's features, welding capabilities, and limitations.

Description of Controls

Explanation of the function of each control on the machine's panel.

Drive Roll and Wire Loading

Procedures for changing drive rolls and loading wire reels, spools, or coils.

Starting and Welding Procedures

Step-by-step instructions for starting the welder and making a weld.

Accessories and Options

Drive Roll Kits

Details on available drive roll kits for different wire sizes and types.

Gun and Cable Assemblies

Available gun and cable assemblies for enhanced performance.

Timer Kit Installation

Instructions for installing the optional timer kit for added functionality.

Spool Gun Adapter Kit

Information regarding the adapter for using spool guns with the welder.

Maintenance Procedures

Maintenance Safety Precautions

Safety guidelines to follow before performing any maintenance tasks.

Routine and Periodic Maintenance

Recommended daily and periodic cleaning and inspection tasks.

Drive Rolls and Cable Cleaning

Procedures for cleaning drive rolls, guide tubes, and cable liners.

Gun Tubes and Nozzles Maintenance

Guidelines for maintaining gun tubes and nozzles, including tip replacement.

Liner Removal and Replacement

Procedures for removing, replacing, and trimming the gun liner.

Theory of Operation

Input Line Voltage and Main Transformer

Explanation of how input voltage is processed by the main transformer.

Output Rectification and Feedback Control

How AC output is rectified and controlled using SCRs and feedback signals.

Constant Voltage Output

The process of filtering DC output to achieve a constant voltage.

Wire Drive Motor and Feedback

How the control board manages the wire drive motor speed using feedback.

Thermal and Overload Protection

Details on the machine's built-in protective systems against overheating and overloads.

SCR Operation

Explanation of how Silicon Controlled Rectifiers (SCRs) function in controlling output.

Troubleshooting and Repair

How to Use Troubleshooting Guide

Instructions on how to effectively use the troubleshooting guide to diagnose issues.

PC Board Troubleshooting Procedures

Guidelines for troubleshooting and replacing PC boards, including static precautions.

Troubleshooting Guide: Common Problems

Guides for output, function, wire feeding, and welding problems.

Component Testing Procedures

Tests for transformer, rectifier, SCRs, and wire drive motor.

Oscilloscope Waveforms

Visual representations of normal and abnormal waveforms for diagnostic purposes.

Component Replacement Procedures

Steps for replacing PC boards, wire drive, SCRs, capacitors, transformer, and fan.

Retest After Repair

Guidelines and specifications for retesting the machine after repairs.

Electrical Diagrams

Wiring Diagram - Code 10563

Complete wiring diagram for machines with Code 10563.

Wiring Diagram - Code 10583

Complete wiring diagram for machines with Code 10583.

Wiring Diagram - Code 10986

Complete wiring diagram for machines with Code 10986.

Wiring Diagram - Code 10990

Complete wiring diagram for machines with Code 10990.

Control PC Board Diagrams

Schematic and assembly diagrams for the control PC board.

Display PC Board Diagrams

Schematic and assembly diagrams for the display PC board.

Snubber PC Board Diagrams

Schematic and assembly diagrams for the snubber PC board.

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