Lincoln Electric 11519 Service Manual page 108

G-4
SchEmaTic - cOmPLETE machiNE (G4752-1)
ENGINEERING CONTROLLED
MANUFACTURER:
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
1 3
1
J1
J8 J6
J9
J12
4 6
2
1 6
1
J3 J2
7 12
8
J10
10
THIS SECTION APPEARS ON 208V/230V MACHINE ONLY
TO SINGLE PHASE
SUPPLY LINE
TO GROUND PER
NATIONAL ELECTRICAL
CODE
TO SINGLE PHASE
SUPPLY LINE
TO GROUND PER
NATIONAL ELECTRICAL
CODE
THIS SECTION APPEARS ON 230V/460V/575V MACHINE ONLY
LIMITATION
The Power MIG 255C WILL NOT operate satisfactorily if
powered with a portable or in-plant generating system,
including engine welders.
CHANGE DETAIL: RELEASED A.02 FROM "X".
No
NOTES:
GENERAL INFORMATION
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
ELECTRICAL SYMBOLS PER E1537
CURRENT AND DUTY CYCLE OF IMMEDIATE AND
COLOR CODE: FUTURE APPLICATIONS.
B - BLACK
N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
1 4 1 5 W - WHITE
"POSITIVE". TO CHANGE POLARITY, TURN THE UNIT
J4 R - RED
OFF AND REVERSE LEAD CONNECTIONS AT CABLE
J7 U - BLUE
CONDUCTOR STRAP AND WORK STUD.
5 8 6 10
N.C. THIS MACHINE IS WIRED TO USE A PRINCE XL SPOOL GUN
INDICATES CONNECTOR CAVITY NO.
DIRECTLY. A K2445-1 ADAPTER IS NEEDED TO USE A
MAGNUM SPOOL GUN.
7 1 8 **
J5 CAVITY
14 9 16 NUMBERING SEQUENCE
(NON-LEAD SIDE OF CONNECTOR)
1 2
1
J11
3 4
Automatically SENSES if board is present.
Adjustable SPOT TIME from 0 to 5 sec.
Adjustable BURNBACK TIME from 0 to 250 msec.
Adjustable RUN-IN speed from 50 to 250 IPM
Convenient 4 STEP TRIGGER INTERLOCK
Receptacle is intended for non-complex
loads (i.e. lights, drills, saws, grinders, tool
battery chargers).
115V
TIMER PC BOARD
Case Back
Top Rear
403
402A
15A FACTORY INSTALLED
CIRCUIT BREAKER
TIMER ASSEMBLY
Case Back
H3
Top Rear
L2
L1
H2
H3 H4 H2 L2 L1 401A
230V 208V
115VAC
H1 H4 H4 H4 H4
W
X9
X9
H1
B
H1 H1 H1 H1
LINE X8
RECONNECT PANEL
POWER X8
Case Back SWITCH X7
TRANSFORMER X7
S1
G Rear Left Case Front
208V/230V 14-15VAC
X6
Middle Left X6
14-15VAC
X5
X5
SECONDARY
VOLTAGES SHOWN
ARE NO LOAD RMS
VALUES
X2
28-30VAC
28-30VAC
ACROSS
X1 TABS
X4
36-40VDC
H4
FROM
28-30VAC + TAB TO
COMMON
L2 H3 X3
L1
H5
H4 H3 H1 H1
H2 L2 L1 H5 Bottom
H5
Front
H2 H4 H3 H1
H2
H1 H4 H4 H4 H4
W H1
B
POWER
RECONNECT PANEL LINE
TRANSFORMER
(SHOWN CONNECTED FOR 230V) SWITCH 230V/460V/575V
Case Back S1
G Case Front
Rear Left
Middle Left
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELEcTricaL DiaGramS
POWER MIG 255XT
CODE 11519, 11520
TIMER BD FEATURES
ARC
254 254A
VOLTAGE
10K
10K
PRESET 10-28.5V
WIRE FEED
R3
R4
SPEED
0 to 5 VDC PRESET
0 to 5 VDC
50-700 IN/MIN
252
251
256 253
1 2 3 4 5 6 7 8
265
263
262
LOCATED IN CASE
267
FRONT ASSEMBLY
264
260
261A 261
TIMER SWITCH
OPEN = 9 VDC **
CLOSED= 0 VDC
J11
1 324 4 324
GUN 2 325 3
TRIGGER
3 2 325
4 1
Located inside
control box
1 2 3 4 5 6 8 7
204
SCR
HEATSINK
Bottom
X1 ASSEMBLY
208R
208 Left Rear
G1 G2
209
354 D2 209R
X4
Mounted
on Lower SCR 1 SCR 2
TOROID
Baffle Left
209R Side D1
TACH RANGE
115Hz @ 50 IPM
to
1600Hz @ 700 IPM
POWER FACTOR
ENHANCEMENT
Above Main
Bottom Right CHOKE
Xfmr
Side Rear
"DIAMOND CORE"
OUTPUT CHOKE
204B
C1 THRU C3 15 OHMS
Bottom
31,000 MFD 100 W
C1 C2 C3
50V Front
Bottom Right
206B
Side Rear -
206S 205
206
PC BD
COMMON
CLEVELAND, OHIO U.S.A.
Enhanced Diagram
OUTPUT RATING
PROCEDURES
The POWER MIG 255C is rated at 250 amps @ 26 volts, Weld procedures are listed on the hinged flip up door of
at a 40% duty cycle based on a ten minute cycle time. It the machine, or consult Procedure Chart G3681.
is capable of higher duty cycles at lower output currents
and capable of up to 300 Amps at lower duty cycles.
ERRORS DISPLAYED
"Too HOT" - Thermostat is open; allow machine to cool.
"Too HI" - Input voltage is too high; verify reconnect or obtain lower input voltage.
"Too Lo" - Input voltage is too low; verify reconnect or obtain higher input voltage.
DISPLAY L10952
8 7 6 5 3 2 1
BOARD J10
SCHEM. L10951
Displays show SET and ACTUAL values. After a weld,
actual values are "held" for 5 seconds (while LED
J2
flashes) before returning to set values. When using a
552 4
SPI
Prince XL spool gun, display will show Volts and WFS.
551 5 CKTS
550 8
515
14 +15V
500 10
7 COM
254 9
252 2 44.2K
251 3 COM
253 1
256 6
44.2K
11
COM
12
13
5V = NO BD, 0V = TIMER BD PRESENT
J4
0 - 4.5VDC SPOT TIME POT
OPTION BD SENSE
1
44.2K
SPOT TIME w/ DEADBAND OFF
2 COM
BURNBACK TIME
0 - 4.5VDC BURNBACK TIME POT
3
44.2K
RUN-IN w/ DEADBAND OFF
4
COM
COMMON
0 - 3.7VDC RUN-IN TIME POT
5 COM
4 STEP / NORMAL TRIGGER 44.2K
6
COM
0V= 2 STEP, 15V= 4 STEP
7
8 +15V
9
10
J6
X7 4 OCV GATE
DRIVE G1&G2
X6 5 20.5V @ 180Hz
X5 6
G1 3
204 2 GATE DRIVE
G2 1 CKTS
J1
TRIGGER
0V=OPEN, 9V=CLOSED
324 8
CKT
700
325 7 +15V
515B 6 +15V
5
555
206B 1 COM +V
W 4
3
DRIVE MOTOR
555 ON= 2KHz
2
B CONTROL
515B 206B W B
J12
BRAKE
390
6VDC COM
J8
@
390
R U B W B 333hz 1
MAIN
392 3
21 ohms
2
392
GAS AUTO SENSING 4
SPOOL GUN
SOLENOID
J3
Case Back CONNECTOR
(VIEWED FROM REAR) 1
Upper 77
77 2
SPOOL
76
76 3
D 75 POT CKT
TOROID DIRECT CONNECTION FOR
75
C E 4 4
PRINCE XL SPOOL GUN ,
G
K2445-1 ADAPTER NEEDED 4 7 SPOOL
B F 2
FOR MAGNUM SPOOL GUN A 8 TRIGGER CKT
3218
2 +V
10 +15V
700
3214
T 3218 5
3214
A 6 DRIVE
311
6VDC 9
C +V
WIRE @
311
333hz 11 BRAKE
H DRIVE SPOOL
312 12
MOTOR/
21 ohms
GEARBOX
312
GAS COM
SOLENOID
J5
Case Back
10 THERMAL
325B +15V
Lower +15=NORM 0V=FAULT CKT
320B 320 12
PHASEBACK AT 305-320 AMPS
OUTPUT 207 13
SCR
CHOKE INDUCTANCE SELECT (NOT USED ON 255C)
HEATSINK 14
THERMOSTAT
THERMOSTAT CURRENT
Embedded in 205 4
Center of
50mV=300A FEEDBACK
206S 5
windings
Heatsink CKT
206 3
6 +15V COM
208 2 INPUT
354 9 POWER
1
209
X9 8
X8 16
352 7 FAN DRIVE
353 15 CKT
VOLT SENSE- OCV 21-40VDC 11
207
TO GND
WORK
Mounted on
cap bracket
353 FAN ON DEMAND- FAN
352
STARTS ON TRIGGER
SHUNT FAN
PULL, ENDS 6 MINUTES
50mV = 300A
MOTOR AFTER WELD
115VAC
1550 RPM
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
SCALE:
CONTROL: CLEVELAND EQUIPMENT TYPE:
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. ( ± 0.5 mm) 1:1
ON 3 PLACE DECIMALS IS ± .002 in. ( ± 0.05 mm) DRAWN BY: cstuble
IF PRINTED SUBJECT:
ON ALL ANGLES IS ± .5 OF A DEGREE
@ A1 SIZE
MATERIAL TOLERANCE (" ") TO AGREE t ENGINEER: T. SPEAR
WITH PUBLISHED STANDARDS. UNITS:
MATERIAL
DO NOT SCALE THIS DRAWING APPROVED: - INCH DISPOSITION:
G-4
Upper
Compartment
Left Side
DISPLAY BD
0 - 5 VDC VOLT POT
0 - 5 VDC WFS POT
SCR GATE DRIVES
MAIN TRIGGER INPUT
TACH INPUT 115Hz (50 IPM) to 1600Hz (700 IPM)
MICRO
TACH
MAIN SOLENOID DRIVE
CKT CONTROLLER
SPOOL SENSE
SPOOL INPUT
SPOOL TRIGGER INPUT
CKT
+V
COM
MOTOR
CONTROL
CKT
VOLTAGE
FEEDBACK
CKT
INDUCTANCE
CKT
FAN ON DEMAND
(6 minute cool down time) G4824-1
POWER MIG 255XT 1 1
PAGE ___ OF ___
MACHINE SCHEMATIC DOCUMENT DOCUMENT
NUMBER: REVISION:
G4752-1
REFERENCE: A
APPROVAL PROJECT
UF 6/6/2008 CRM39725
G4752
DATE: NUMBER:
Power miG® 255XT