Lincoln Electric SVM144-B - Manual

Lincoln Electric SVM144-B

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Table of Contents:

  • Page 2 – SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
  • Page 3 – ii; ELECTRIC SHOCK can kill.
  • Page 4 – iii
  • Page 5 – iv; PRÉCAUTIONS DE SÛRETÉ
  • Page 6 – MASTER TABLE OF CONTENTS FOR ALL SECTIONS; RETURN TO MAIN MENU
  • Page 7 – TABLE OF CONTENTS
  • Page 8 – INSTALLATION; TECHNICAL SPECIFICATIONS – POWER MIG 255
  • Page 9 – Before starting the installation, check with the; SAFETY PRECAUTIONS
  • Page 10 – FIGURE A.1 — DUAL VOLTAGE MACHINE INPUT CONNECTIONS.
  • Page 11 – OUTPUT POLARITY CONNECTIONS; FIGURE A.2 — TRIPLE VOLTAGE MACHINE INPUT CONNECTIONS.
  • Page 12 – GUN AND CABLE INSTALLATION
  • Page 14 – OPERATION
  • Page 15 – PRODUCT DESCRIPTION
  • Page 16 – DESCRIPTION OF CONTROLS; — Place the lever in the “ON”; Voltage Control; — This is a continuous control that; Wire Speed Control; — This controls the wire feed; WIRE DRIVE ROLL; Procedure for; WIRE SIZE CONVERSION PARTS; Accessories; FIGURE B.1 — OPERATOR CONTROLS; LINCOLN
  • Page 17 – CAUTION
  • Page 18 – TO START THE WELDER; INSTRUCTIONS TO ENTER SLOW RUN-IN
  • Page 19 – MAKING A WELD
  • Page 20 – electrodes have proper surface lubrication.; FAN CONTROL; Welding Procedure Information
  • Page 22 – ACCESSORIES; DRIVE ROLL KITS; Wire; English Wire
  • Page 24 – SPOOL GUN ADAPTER KIT; WFS Setting
  • Page 26 – MAINTENANCE; • Have a qualified electrician do the maintenance; Perform the following daily:
  • Page 29 – GUN HANDLE DISASSEMBLY; To open up the handle:
  • Page 30 – METRIC SIZE
  • Page 31 – FIGURE E.1 – BLOCK LOGIC DIAGRAM
  • Page 32 – THEORY OF OPERATION; NOTE: Unshaded areas of Block Logic; FIGURE E.2 — INPUT LINE VOLTAGE AND MAIN TRANSFORMER.
  • Page 33 – FIGURE E.3 — OUTPUT RECTIFICATION AND FEEDBACK.
  • Page 34 – CONSTANT VOLTAGE OUTPUT
  • Page 35 – FIGURE E.5 — WIRE DRIVE MOTOR AND FEEDBACK.
  • Page 36 – OVERCURRENT PROTECTION
  • Page 37 – SCR OPERATION; INPUT
  • Page 38 – NOTES
  • Page 39 – Test Procedures
  • Page 40 – HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; The; Step 3. PERFORM COMPONENT TESTS
  • Page 41 – PC board can be damaged by static electricity.; PC BOARD TROUBLESHOOTING PROCEDURES
  • Page 42 – TROUBLESHOOTING GUIDE; Observe Safety Guidelines; OUTPUT PROBLEMS
  • Page 45 – FUNCTION PROBLEMS
  • Page 46 – WIRE FEEDING PROBLEMS
  • Page 47 – WELDING PROBLEMS
  • Page 49 – MAIN TRANSFORMER TEST; TEST DESCRIPTION; This procedure will determine if the correct voltages are being:; MATERIALS NEEDED
  • Page 50 – TEST PROCEDURE; FIGURE F.1 — G3521 CONTROL PC BOARD AND M19248 SNUBBER PC BOARD; PLUG
  • Page 52 – TROUBLESHOOTING AND REPAIR
  • Page 53 – RECTIFIER DIODE BRIDGE TEST; This test will determine if the correct voltages are being:; MATERIALS NEEDED
  • Page 54 – Connect main input power to the; Disconnect the main AC input power to; RECTIFIER DIODE BRIDGE TESTING (continued); LEAD; RECTIFIER
  • Page 57 – STATIC SCR RECTIFIER ASSEMBLY TEST
  • Page 58 – Ve r i f y t h a t t h e c a p a c i t o r s h a v e; Disconnect main AC input power to the; STATIC SCR RECTIFIER ASSEMBLY TEST (continued)
  • Page 59 – FIGURE F.4 — LOCATION OF
  • Page 61 – ACTIVE SCR RECTIFIER ASSEMBLY TEST
  • Page 62 – ACTIVE SCR RECTIFIER ASSEMBLY TEST (continued)
  • Page 63 – a. Test the voltage level of the battery.; FIGURE F.8 — SCR TESTER CIRCUIT; Separate leads X2 and X3 from the
  • Page 65 – WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST
  • Page 66 – Locate the following leads on plug J1:; Disconnect main input power to the; FIGURE F.9 — PLUG J1 LOCATION ON G3521 PC CONTROL BOARD.; WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (continued)
  • Page 69 – VOLTS; Scope probes connected at; SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
  • Page 70 – MACHINE LOADED TO 250 AMPS AT 26 VDC; TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
  • Page 71 – MACHINE LOADED TO 220 AMPS AT 22 VDC
  • Page 73 – TYPICAL SCR GATE VOLTAGE WAVEFORM
  • Page 75 – DESCRIPTION; Static electricity grounding strap
  • Page 76 – CONTROL PC BOARD; REMOVAL AND REPLACEMENT PROCEDURE (Continued); Disconnect main input power the; FIGURE F.10 — WIRING HARNESS
  • Page 77 – NOTE: TOP COVER SHOWN
  • Page 79 – Large slot head screwdriver
  • Page 80 – PROCEDURE; WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT (continued)
  • Page 84 – FIGURE F.14 — MIDDLE HEAT SINK; Remove the case side panels using a; FIGURE F.13 — LEFT HEAT SINK; SCR OUTPUT RECTIFIER REMOVAL AND REPLACEMENT (continued)
  • Page 85 – FIGURE F.15 — RIGHT HEAT SINK LEAD DISCONNECTION.
  • Page 87 – Wiring diagram
  • Page 88 – CAPACITOR BANK REMOVAL AND REPLACEMENT (continued)
  • Page 89 – Wire cutters
  • Page 90 – FIGURE F.17 — MAIN TRANSFORMER REMOVAL.; MAIN TRANSFORMER AND OUTPUT CHOKE
  • Page 93 – Slot head screwdriver
  • Page 94 – FIGURE F.18 — FAN MOTOR ASSEMBLY REMOVAL.; FAN MOTOR ASSEMBLY REMOVAL AND REPLACEMENT (continued)
  • Page 95 – INPUT IDLE AMPS AND WATTS; RETEST AFTER REPAIR; Maximum Idle Watts
  • Page 98 – ELECTRICAL DIAGRAMS
  • Page 106 – SNUBBER BOARD
  • Page 107 – SNUBBER
  • Page 108 – SVM ERROR REPORTING FORM; Please give detailed description below:
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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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• 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.

RETURN TO MAIN MENU

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Summary

Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC i SAFETY i LN-15 FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. __________________________________________...

Page 3 - ii; ELECTRIC SHOCK can kill.

Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ii SAFETY ii LN-15 ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and fi...

Page 4 - iii

POWER MIG 255 SAFETY iii iii Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the ...

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