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ELECTRICAL DIAGRAMS
POWER MIG 255
G-4
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WIRING DIAGRAM - ENTIRE MACHINE - CODE 10986 - (L11980)
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
L11980
A
COLOR CODE:
ELECTRICAL SYMBOLS PER E1537
GENERAL INFORMATION
4
5
J7
9
8
7
6
265
263
260
261
U - BLUE
R - RED
W - WHITE
B - BLACK
INDICATES CONNECTOR CAVITY NO.
262
267
264
OUTPUT
CHOKE
POWER FACTOR
ENHANCEMENT
CHOKE
204B
FOR SPOOL GUN OPTION
SECONDARY VOLTAGES SHOWN
ARE NO LOAD RMS VALUES
1
2
3
10
C3C1
205206S
206B
R
1
SCR HEATSINK
ASSEMBLY
THERMOSTAT
116.6V
14.2V
14.2V
28.4V
C2
+++
C1 THRU C3
31,000 MFD
50V
15 OHMS
100 W
+
-
320B
1
J10
J10
390 392
J1
J4
J6
J8
J9
J7
10
J2
J5
1
3
J3
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
251
206
FOR TIMER
OPTION
28.4V
J9
R.F. FILTER
SCR HEATSINK
ASBLY
SCR 2
G1
208S
204S
G2
SCR 1
209S
1
2
3
208S
208
208R
209S
204S
8
7
6
5
4
209R
209
252
WIRE FEED
SPEED
R3
256
8
6
5
1
ARC
VOLTAGE
252254253256
R4
254A
550
551
4
2
7
WIRE FEED
SPEED
3
R3
DISPLAY
BOARD
515
552
500
8
4
7
6
3
5
2
1
ARC
VOLTAGE
WIRE FEED
SPEED
252254253256
R4
254A
DISPLAY
BOARD
500
515
551
552
550
R3
POWER
TRANSFORMER
SCR 1
G1
208S
G2
204S
TO GROUND PER
NATIONAL ELECTRICAL
CODE
SCR 2
ASBLY
SCR HEATSINK
209S
WIRE FEED
SPEED
253
R4
ARC
VOLTAGE
252254256
R3
254A
G2
SCR 1
SCR HEATSINK
ASBLY
SCR 2
204S
209S
G1
208S
SCR 2
ASBLY
SCR HEATSINK
SCR 1
G2
G1
208S
204S
209S
-
+
208R
209R
-
+
254A
R3
252254256
WIRE FEED
SPEED
8
7
6
5
4
3
2
1
ARC
VOLTAGE
DISPLAY
BOARD
253
R4
500
515
550
551
552
209R
+
-
208R
354
J11
1
2
3
4
325
324
325
4
2
GUN
TRIGGER
324
5
2
3
2
4
1
2
3
2
5
5
2
3
4
7
11
6
3
8
9
2
5
4
J8
252
550
254
500
J4
4
7
6
14
11
1
J5
J6
1
1
11
10
9
8
6
GND
X6
X5
515
206B
B
392
2
3
4
7
8
9
10
3
5
206
205
320
326
541A
543
SCI
SCI
515
206A
8
6
14
15
16
6
325A
5
W
206S
207
353
X8
325B
X9
352
4
10
12
13
7
12
354
G2
204
G1
X7
390
325
555
1
J2
6
7
8
9
J1
10
1
515B
324
208
CONTROL BOARD
12
13
1
J3
253
251
552
551
256
209
GND
352
353
252
R4
254A
256 253 254
DISPLAY
BOARD
WIRE FEED
SPEED
R3
8
7
6
5
4
3
1
ARC
VOLTAGE
515
2
551
552
550
500
209R
+
354
208R
-
515B
555
206B
253
R4
254256
254A
ARC
VOLTAGE
254A
POWER
TRANSFORMER
204S
208S
G1
SCR HEATSINK
ASBLY
SCR 2
G2
209S
SNUBBER
BOARD
X2
ASBLY
SCR HEATSINK
D1
R.F. FILTER
209S
X8
D2
BAFFLE
MOUNTED
RECTIFIER
DIODE
BRIDGE
354
+
G1
208S
204S
SCR 2
X3
X4
POWER
TRANSFORMER
G
207
X9
X5
X5
X6
X6
X7
X7
X1
X9
X8
208R
-
209R
TO
WORK
SCR 1
G2
352
353
FAN
MOTOR
TO
WORK
J3
252254253256
TO
WORK
207
R.F. FILTER
500
515
550
551
ARC
VOLTAGE
252254253256
R3R4
DISPLAY
BOARD
254A
552
WIRE FEED
SPEED
8
7
6
5
4
3
2
1
254A
252254253256
R3
R4
ARC
VOLTAGE
WIRE FEED
SPEED
325B
OUTPUT CHOKE
THERMOSTAT
320
J11
**
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
FUTURE APPLICATIONS.
NOTES:
CONDUCTOR STRAP AND WORK STUD.
OFF AND REVERSE LEAD CONNECTIONS AT CABLE
"POSITIVE". TO CHANGE POLARITY, TURN THE UNIT
CURRENT AND DUTY CYCLE OF IMMEDIATE AND
N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
GAS
SOLENOID
CONTROL BOARD
POWER MIG 255 (230/460/575 V)
2
1
5 8
4
1
8
1
9
16
1
3
4
6
8
1
14
7
1
12
7
6
10
6
5
1
CAVITY
1
**
(NON-LEAD SIDE OF CONNECTOR)
2
3
4
NUMBERING SEQUENCE
J11
1
2
3
8
7
6
5
4
W
B
H2
5
4
2
1
3
TO SINGLE PHASE
SUPPLY LINE
H1H3
H4
W
B
H5
H2
L2L1
H1
H1
H3
H4
RECONNECT
PANEL
(SHOWN CONNECTED
FOR 230V)
LINE
SWITCH
S1
L2
L1
H5
H1
H4
H1
H4
H4
H1
H4
H1
WIRE
DRIVE
MOTOR/
GEARBOX
B
W
T
A
C
H
B
R
U
B
R
U
W
B
J12
J12
204