Lincoln Electric SVM 117-A User Manual

RETURN TO MAIN INDEX

WIRE-MATIC 250

SVM 117-A

December 1995

For use with machines having Code Numbers:

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 READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.

9799,
9800,

10003,

10004.

VOLTS

WIRE SPEED

20

18

22

16

14

WIRE-MATIC 250

300

250

24

350

200

26

150

28

100

50

1

ON

0

OFF

400

450
500
550

600

View Safety Info View Safety Info View Safety Info View Safety Info

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World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

SERVICE MANUAL

Sales and Service through Subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. [phone]

i

SAFETY

i

WARNING

ARC WELDING can be hazardous.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American W elding Society, P .O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THA T ALLINSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER­FORMED ONLY BY QUALIFIED INDIVIDUALS.

ELECTRIC SHOCK can kill.

1.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.

1.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

1.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

1.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

1.g. Never dip the electrode in water for cooling.

1.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

1.j. Also see Items 4.c. and 6.

2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

2.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

3.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.

3.c. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

3.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

ARC RAYS can burn.

2.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. Headshield and filter lens
should conform to ANSI Z87. I standards.

FUMES AND GASES
can be dangerous.

3.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

vapors

to

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3.e. Also see item 7b.

WIRE-MATIC 250

Apr. ‘93

ii

SAFETY

ii

WELDING SPARKS can
cause fire or explosion.

4.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

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.

4.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

4.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

4.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

4.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

4.f.

Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

4.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.

4.h. Also see item 7c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

5.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

5.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

5.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

5.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

6.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

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Feb. ‘95

WIRE-MATIC 250

iii

SAFETY

iii

FOR ENGINE
powered equipment.

7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes

outdoors.

____________________________________________________

7.c. Do not add the fuel near an open flame
welding arc or when the engine is run­ning. Stop the engine and allow it to cool
before refueling to prevent spilled fuel
from vaporizing on contact with hot
engine parts and igniting. Do not spill
fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until
fumes have been eliminated.

____________________________________________________

7.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.

ELECTRIC AND MAG­NETIC FIELDS
may be dangerous

8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

8d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

8.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

8.d.2. Never coil the electrode lead around your body.

8.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

8.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

8.d.5. Do not work next to welding power source.

____________________________________________________

7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.

7.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

___________________________________________________

7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

Mar. ‘93

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WIRE-MATIC 250

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour

votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

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. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSAStandard
W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

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PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

WIRE-MATIC 250

NOTES

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WIRE-MATIC 250

v

RETURN TO MAIN INDEX

v

TABLE OF CONTENTS

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Select Proper Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Connect Output Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . .B-2

Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Machine Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Using the Wire Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Operating Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C

Replacement Magnum 250L Gun and Cable Assembly . . . . . . . . . . . . . .C-1

K607-1 Spool Gun Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Installing the K607-1 Spool Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Making a Weld with the Spool Gun Adapter (K607-1) Installed . . . . . . . .C-5

Timer Kit (K585-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6

Timer Kit Installation (Optional K585-1) . . . . . . . . . . . . . . . . . . . . . . . . . .C-6

Making Spot and Stitch Welds with Timer Kit Installed . . . . . . . . . . . . . . .C-7

Adjustable Gas Regulator and Hose Kit (K586-1) . . . . . . . . . . . . . . . . . .C-7

Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Drive Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Drop-In Reel Spindle and Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Cable Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Gun Tubes and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Contact Tip and Gas Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Liner Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Liner Removal, Installation, and Trimming Instructions for Magnum 250L D-4

Gun Handle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5

Accessories and Expendable Replacement Parts for

Magnum 250L Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . .D-6

CONTINUED

WIRE-MATIC 250

vi

vi

TABLE OF CONTENTS (continued)

Page

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Power Supply Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

How to use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . .F-2

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-10

Oscilloscope Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-22

Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-218

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WIRE-MATIC 250

INSTALLATION

TABLE OF CONTENTS

- INSTALLATION SECTION -

INSTALLATION SECTION ........................................ Section A

Technical Specifications ...................................................A-1

Safety Precautions...........................................................A-2

Select Proper Location.....................................................A-2

Stacking.......................................................................A-2

Tilting...........................................................................A-2

Input Connections ............................................................A-2

Fuse and Wire Sizes...................................................A-3

Input Power Connections and Ground Connections ...A-3

Connect Shielding Gas................................................A-4

Reconnect Procedure.......................................................A-5

Connect Output Components...........................................A-7

Install the Work Clamp................................................A-7

Output Polarity Connection .........................................A-7

Gun Liner and Contact Tip Installation........................A-7

Wire Size Conversion Parts........................................A-8

Gun and Cable Installation ..........................................A-8

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WIRE-MATIC 250

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Wire-Matic-250

INPUT - SINGLE PHASE/ 60 HERTZ ONLY

Standard Voltage Input Current at Rated Output

208/230/1/60 53/49 Amps

230/460/575 50/25/20 Amps

RATED OUTPUT

Duty Cycle Amps Volts at Rated Amps

100% 145 amps 26

60% 200 amps 28
35% 250 amps 26

OUTPUT

Current Range Maximum Open Circuit Voltage Wire Speed Range

A-1

30A - 250A 40V 50 - 600 IPM

(1.27-15.2 m./minute)

RECOMMENDED INPUT WIRE & FUSE SIZE

Input Voltage/ Fuse (Superlag) Type 750C wire in Type 750C Copper

Frequency or Breaker Size Copper conduit AWG Ground Wire in Conduit

(IEC Sizes)

Runs to Runs over

100ft. (30m.) 100ft. (30m.)

208/60 60 8 (10mm2) 6 (16mm2) 10 (6mm2)
230/60 60 10 (6mm2) 8 (10mm2) 10 (6mm2)
460/60 30 14 (2.5mm2) 12 (4mm2) 10 (6mm2)
575/60 25 14 (2.5mm2) 12 (4mm2) 10 (6mm2)

PHYSICAL DIMENSIONS

HEIGHT Width DEPTH WEIGHT

(W/GUN)

28.2” 18.8” 40.1” 220 lbs.

(719mm) (480mm) (1019mm) (100 Kg.)

OPERATING TEMPERATURE

STORAGE OPERATING

±400C -200C to 400C

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WIRE-MATIC 250

A-2

INSTALLATION

A-2

Read entire Installation Section before installing
the WIRE-MATIC 250

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should
install this machine.

• Turn the input power OFF at the dis­connect switch or fuse box before
working on the equipment.

• Do not touch electrically hot parts.

• Always connect the WIRE-MATIC 250 ground­ing terminal to a good electrical earth ground
through the cable plug per the National
Electrical Code.

• Set the Wire-Matic 250 ON/OFF Power switch to
the OFF position when connecting power cord
to input power.

____________________________________

SELECT PROPER LOCATION

Place the WIRE-MATIC 250 where clean, cooling air
can freely circulate in through the case back louvers
and out through the case front louvers. Dirt, dust, or
any foreign material that can be drawn into the
machine case back louvers should be kept at a mini­mum. Not following these precautions can result in the
nuisance shutdown of the machine because of exces­sive operating temperatures.

INPUT CONNECTIONS

WARNING

All input power must be electrically
disconnected before proceeding.

____________________________________

1. Before starting the installation, check with the local
power company to determine if there is any ques­tion about whether your power supply is adequate
for the voltage, amperes, phase, and frequency
specified on the welder nameplate. Be sure the
planned installation will meet the U.S. National
Electrical Code and local code requirements. This
welder may be operated from a single phase line
or from one phase of a two or three phase line.

2. Models that have multiple input voltages specified
on the nameplate (e.g., 208/230) are shipped con­nected for the highest voltage. If the welder is to
be operated at a lower voltage, it must be recon­nected according to the instructions on the inside
of the removable panel (Reconnect Access Door)
near the top left side of the Case Back Assembly.
See the
details on reconnecting the machine to operate at
different voltages.

3. Be sure the voltage, phase, and frequency of the
input power is as specified on the machine rating
plate. See Figure A.1 for the location of the
machine's input cord entry, Reconnect Access
Door, and Reconnect Panel, and Rear Nameplate.

Reconnect Section

of this manual for

STACKING

The WIRE-MATIC 250 cannot be stacked.

TILTING

The Wire-Matic 250 must be placed on a stable, level
surface so it will not topple over. Do not place the
machine on an incline.

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FIGURE A.1 - Case Back Assembly: Input Power
Cable Entry Connections.

WIRE-MATIC 250

A-3

INSTALLATION

A-3

FUSE AND WIRE SIZES

Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the

Specifications

being used. The tripping action of delay type circuit
breakers decreases as the magnitude of the current
increases. They are also called inverse time or ther­mal/magnetic circuit breakers.

DO NOT use fuses or circuit breakers with a lower amp
rating than recommended. This can result in "nui­sance" tripping caused by inrush current even when
machine is not being used for welding at high output
currents.

Use input and grounding wire sizes that meet local
electrical codes or see the
page in this manual.

page of this manual for the machine

Technical Specifications

Technical

INPUT POWER CONNECTIONS AND
GROUND CONNECTIONS

b. Fuse the two hot lines of the receptacle with

super lag type fuses as shown in Figure A.2. A
green wire in the input cord connects this ter­minal to the frame of the welder. This ensures
proper grounding of the welder frame when the
welder plug is inserted into the receptacle.

4. Use proper wire sizes. See the

Specification

cable lengths over 100 feet, larger copper wires
should be used.

table for proper wire sizes. For

Technical

CAUTION

Connect to a system grounding wire. See the
United States National Electrical Code and local
codes for other details and means for proper
grounding.

Connect to hot wires of a three-wire, single phase
system or to one phase of a two or three phase
system.

Have a qualified electrician connect the receptacle or
cable to the input power lines and the system ground
according to the U.S. National Electrical Code and any
applicable local codes.

1. Follow the Input Supply Connection Diagram on
the inside of the Reconnect Panel Access Door.

2. Use a single-phase line or one phase of a three­phase line.

For the 208V/230V/ 60 HZ model WIRE-MATIC 250
shipped with a 10 ft. input cord and plug connected to
the welder, mount the matching receptacle supplied
with the machine.

1. Mount the receptacle in a suitable location using
the screws provided.

2. Locate the receptacle within reach of the 10 ft.
input cord attached to the welder.

3. Mount the receptacle with the grounding terminal
at the top. This allows the power cable to hang
down without bending. See Figure A.2.

____________________________________

FIGURE A.2. - Ground Connections.

a. The center terminal in the receptacle is for the

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grounding connection.

WIRE-MATIC 250

A-4

INSTALLATION

A-4

For the 230/460/575V/ 60 HZ model which is not
equipped with a plug, an input cord, or a receptacle,
the input power supply leads must be connected
directly to the Reconnect Panel as shown in Figure
A.3. Refer to
ning of this chapter for proper wire sizes.

1. Connect the input power leads to terminals L1 and
L2 on the Reconnect Panel Assembly.

a. For input power supply leads of 10 AWG or

b. Strip 1/2" (13mm) of insulation from the input

c. Place ferrule over wire.
d. Torque the terminal screws to 16 in.-lbs.

Technical Specifications

smaller are used, connect leads to Reconnect
Panel using the ferrules (S19117-1) provided.

power supply leads.

(1.8nm).

at the begin-

WARNING

Gas under pressure is explosive.
Always keep gas cylinders in an
upright position and always keep
chained to undercarriage or sta­tionary Y support. See American
National Standard Z-49.1, “Safety
in Welding and Cutting” published

by the American Welding Society.

____________________________________

1. Set the gas cylinder on the rear platform of the
WIRE-MATIC 250.

2. Hook the chain in place to secure cylinder to rear
of welder.

3. Remove the cylinder cap.

4. Inspect the cylinder valves for damaged threads,
dirt, dust, oil or grease.

a. Remove dust and dirt with a clean cloth.

FIGURE A.3 - Input Power Connection For
230/460/575 Volt Models.

CONNECT SHIELDING GAS

Customer must provide cylinder of appropriate type of
shielding gas for gas metal arc welding for the process
being used. See Figure A.4 for the location of the com­ponents used to connect the air supply cylinder.

NOTE: For CO2 or Argon blend gas, the optional
K586-1 Adjustable Gas Regulator and Hose Kit should
be used. See

Accessories Section

of this manual.

NOTE: DO NOT ATTACH THE REGULATOR IF OIL,
GREASE OR DAMAGE IS PRESENT! Inform your

gas supplier of this condition. Oil or grease in the pres­ence of high pressure oxygen is explosive.

5. Stand to one side away from the outlet and open
the cylinder valve for an instant to blow away any
dust or dirt which may have accumulated in the
valve outlet.

BE SURE TO KEEP YOUR FACE AWAY FROM THE
VALVE OUTLET WHEN OPENING THE VALVE.

6. Inspect the regulator for damaged threads, dirt,
dust, oil or grease.

a. Remove dust and dirt with a clean cloth.

NOTE: DO NOT USE THE REGULATOR IF OIL,
GREASE OR DAMAGE IS PRESENT! Have an

authorized repair station clean the regulator or repair
any damage.

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WIRE-MATIC 250

A-5

7. Attach the flow regulator to the cylinder valve and
tighten the union nut(s) securely with a wrench.

a. NOTE: If connecting the flow regulator to

100% CO2 cylinder, insert the regulator
adapter provided with the optional K-586-1 Kit
between the regulator and cylinder valve. If
adapter is equipped with a plastic washer, be
sure it is seated properly to connect to the CO2
cylinder.

8. Connect one end of the inlet gas hose to the outlet
fitting of the flow regulator.

9. Connect the other end of the inlet gas hose to the
WIRE-MATIC 250 rear fitting.

10. Tighten both the union nuts securely with a
wrench.

11. Before opening the cylinder valve, turn the regula­tor adjusting knob counter-clockwise until the pres­sure is released from the adjusting spring.

INSTALLATION

A-5

12. Open the cylinder valve slowly a fraction of a turn.
a. When the cylinder pressure gage pointer stops

moving, open the valve fully.

NEVER STAND DIRECTLY IN FRONT OF OR
BEHIND THE FLOW REGULATOR WHEN OPENING
THE CYLINDER VALVE. ALWAYS STAND TO ONE
SIDE.

NOTE: The Optional K586-1 flow regulator is
adjustable. Adjust the flow regulator for the flow rate
recommended for the procedure and process being
used before making the weld.

FIGURE A.4 - Input Air Supply Connections

RECONNECT PROCEDURE

Multiple voltage machines are shipped connected to
the highest input voltage listed on the machine's rating
plate. Before installing the machine, check that the
Reconnect Panel in the Input Box Assembly is con­nected for the proper voltage.

CAUTION

Failure to follow these instructions can cause
immediate failure of components within the
machine.

___________________________________

To reconnect a dual or triple voltage machine to a dif­ferent voltage, change the position of the leads or links
on the Reconnect Panel based on the type of
machine. Follow The Input Supply Connection
Diagram located on the inside of the Case Back
Reconnect Panel Access Door.

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For 208/230/1/60 machine(s), see Figure A.5.
For 230/460/575/1/60 machine(s), see Figure A.6.

WIRE-MATIC 250

A-6

ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHER OF THE TWO
INPUT VOLTAGES LISTED ON THE NAMEPLATE. TO CHANGE VOLTAGE CONNECTION PROCEED AS
FOLLOWS:

1. REMOVE THE OUTER STEEL HEX NUT FROM THE TERMINAL WHERE THE TRANSFORMER
INPUT LEAD IS CONNECTED.

2. SHIFT THE TRANSFORMER INPUT LEAD TO THE TERMINAL THAT THE UNIT IS TO OPERATE
ON AND FASTEN SECURELY WITH THE HEX NUT REMOVED IN STEP1. (MAKE CERTAIN THAT
BRASS NUTS ARE TIGHT.)

INSTALLATION

A-6

FIGURE A.5 - Reconnect Diagram For 208/230/1/60 Machines.

1. ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHEST NAME­PLA TED SINGLE PHASE INPUTVOLTAGE. TO CHANGE CONNECTIONS FOR ADIFFERENT INPUT
VOLTAGE, RECONNECT BOTH COPPER JUMPERS PER DIAGRAM BELOW. ALWAYS CONNECT
JUMPERS BETWEEN OUTER STEEL NUT AND INNER BRASS NUT ON TERMINAL STUDS.

2. CONNECT THE INPUT POWER TO THE INPUTTERMINAL BLOCK, L1 AND L2 AT THE UPPER COR­NER OF THE PANEL. FOR INPUT LEADS 10AWG AND SMALLER USE FERRULES PROVIDED.
TORQUE TO 16 IN-LBS.

3. CONNECT A GROUNDING LEAD TO THE GROUND STUD ( ) ON THE MACHINE NEAR THE TER­MINAL BLOCK.

FIGURE A.6 - Reconnect Diagram For 230/460/575/1/60 Machine.

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WIRE-MATIC 250

A-7

INSTALLATION

A-7

CONNECT OUTPUT COMPONENTS
INSTALL THE WORK CLAMP

Attach the work clamp to the cable which extends from
the front of the machine using the following procedure:

1. Insert the lug on the end of the work cable through
the strain relief hole in the work clamp handle. See
Figure A.7.

2. Slide the work cable through the hole up to the bolt
and nut.

3. Fasten work cable using the bolt and nut provided.

GUN LINER AND CONTACT TIP
INSTALLATION

The Magnum 250L gun and cable provided with the
WIRE-MATIC 250 is factory installed with a liner for a
.035-.045” (0.9-1.2mm) diameter electrode and an
.035” (0.9mm) contact tip.

1. If a .045” diameter wire size is to be used, install
the .045” contact tip (also provided).

2. For other wire sizes, use the following procedure
for contact tip and gas nozzle installation. See
Figure A.8.

a. 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.

b Be sure the nozzle insulator is fully screwed

onto the gun tube and does not block the gas
holes in the diffuser.

FIGURE A.7 - Installing The Work Clamp.

OUTPUT POLARITY CONNECTION

Turn the welder Power Switch OFF before chang­ing output connection.

____________________________________

The welder is shipped from the factory connected for
electrode positive (+) polarity . This is the normal polar­ity for GMA welding.

If negative (-) polarity is required, interchange the con­nection of the two cables located in the wire drive com­partment near the front panel. The negative lead is the
lead closest to the front panel (where the leads come
out of the floor of the compartment) and should be
reconnected to the brass conductor tube of the gun
connector. The positive lead is stamped (+) on its ter­minal and should be reconnected to the work lead ter­minal.

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WARNING

c. Slip the appropriate gas nozzle onto the noz-

zle insulator. Either a standard .50" (12.7mm)
or optional .62” (15.9mm) I.D. slip-on gas noz­zle may be used and should be selected
based on the welding application.

d. Adjust the gas nozzle for the GMAW process

to be used.

For the short-circuiting transfer process, the contact tip
end should be flush to extended to .12" (3.2mm). See
Figure A.8.

For the spray transfer process, the contact tip should
be flush to recessed .12" (3.2mm). See Figure A.8.

FIGURE A.8 - Contact Tip and Electrode
Connections.

WIRE-MATIC 250

A-8

INSTALLATION

WIRE SIZE CONVERSION PARTS

The Wire-Matic 250 is rated to feed .025" through .045"
(0.6-1.2mm) solid or cored electrode sizes. For vari­ous drive roll kits refer to

Acessories Section

.

GUN AND CABLE INSTALLATION

WARNING

Turn the welder Power Switch OFF before chang­ing output connection.

____________________________________

1. Lay the cable out straight.

2. Locate the wing screw on conductor block inside
wire feed compartment. Unscrew it until the tip of
the screw no longer protrudes into gun opening as
seen from front of machine.

A-8

3. Insert the brass connector on the end of the gun
cable into conductor block through opening in the
front panel. Make sure the connector is fully insert­ed and tighten wing screw.

4. Connect the gun trigger connector from the gun
and cable to the mating receptacle on the front
panel. Make sure that the keyways are aligned,
insert and tighten retaining ring.

NOTE: If a gun and cable other than the Magnum
250L is used, it must conform to connector specifica­tions and the gun trigger switch must be capable of
switching 5 milliamps at 15 volts DC -resistive.

CAUTION

The gun trigger switch connected to the gun trig­ger control cable must be a normally open,
momentary switch. The terminals of the switch
must be insulated from the Welding circuit.
Improper operation of or damage to the WIRE­MATIC 250 might result if this switch is common to
an electrical circuit other than the WIRE-MA TIC 250
trigger circuit.

____________________________________

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WIRE-MATIC 250

NOTES

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WIRE-MATIC 250

OPERATION

TABLE OF CONTENTS

- OPERATION SECTION -

OPERATION SECTION ............................................ Section B

Safety Instructions ............................................................B-1

General Description..........................................................B-1

Recommended Processes and Equipment ......................B-2

Design Features and Advantages....................................B-2

Unit Features ...............................................................B-2

Power Source Features...............................................B-2

Wire Feeder Features .................................................B-3

Machine Capability...........................................................B-3

Limitations........................................................................B-3

Controls and Settings.......................................................B-4

Using the Wire Drive Roll.................................................B-5

Procedure for Changing Drive Roll .............................B-5

Loading the Wire Reel.................................................B-5

Feeding Electrode.......................................................B-6

Proper Wire Feeding...................................................B-6

Setting Idle Roll Pressure............................................B-7

Operating Steps ...............................................................B-7

Starting the Welder......................................................B-7

Changing Run-In Mode...............................................B-7

Enter Fast Run-In Mode .........................................B-7

Enter Slow Run-In Mode.........................................B-7

Making a Weld.............................................................B-8

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WIRE-MATIC 250

B-1

OPERATION

B-1

Read and understand this entire section before operat­ing your WIRE-MATIC 250.

SAFETY INSTRUCTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live
parts such as output terminals
or internal wiring.

• Insulate yourself from the work
and ground.

• Always wear dry insulating
gloves.

____________________________________

FUMES AND GASES
can be dangerous.

CAUTION

When using a Wire-Matic 250 power source there
will be a small spark if the electrode contacts the
work or ground within several seconds after
releasing the trigger.

____________________________________

GENERAL DESCRIPTION

The WIRE-MATIC 250 is a complete semiautomatic
constant voltage DC arc welding machine built to meet
NEMA specifications. It combines a constant voltage
power source, a constant speed wire feeder, and a
microcomputer-based controller to form a reliable high­performance welding system.

Simple controls, consisting of continuous full range cal­ibrated voltage control and wire feed speed control,
provide versatility with ease of use.

• Keep your head out of fumes.

• Use ventilation or exhaust to
remove fumes from breathing
zone.

____________________________________

WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion

• Keep flammable material away.

• Do not weld, cut or gouge on
containers that have held
combustibles.

____________________________________

ARC RAYS
can burn.

• Wear eye, ear and body
protection.

____________________________________

Only qualified personnel should operate this equip­ment. Observe all safety information throughout this
manual.

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WIRE-MATIC 250

B-2

OPERATION

B-2

RECOMMENDED PROCESSES AND
EQUIPMENT

The WIRE-MA TIC 250 is recommended for GMAweld­ing processes using 10 to 30 lb. (4.5 to 13.6 kg) 2"
(51mm) I.D. spools or Readi-Reel coils (with optional
adapter) of:

.025" through .045" (0.6-1.2mm) solid steel.
.035" (0.9mm) stainless steel.
3/64" (1.2mm) aluminum.
.045" (1.2mm) Outershield.
.035" (0.9mm) and .045" (1.2mm) Innershield self­shielding electrodes.

The WIRE-MATIC 250 is factory equipped to feed
.035" (0.9mm) and .045" (1.2mm) electrodes. It
includes a 12 ft. (3.6m) GMAW gun and cable assem­bly equipped for these wire sizes with a duty cycle rat­ing of 200A, 60% or 250A, 35%. Using GMAW
processes requires use of the optional gas regulator
and a supply of shielding gas.

DESIGN FEATURES AND
ADVANTAGES

POWER SOURCE FEATURES:

10 Ft. (3.0m) Input Power Cable - Includes plug and

mating receptacle for 208/230V unit. Convenient rear
reconnect panel allows easy access for 208V re-con­nection.

Power Switch - Front panel toggle switch turns input
power on and off.

Pilot Light - Indicates when power is applied to
machine.

Thermostatically-Controlled Fans - Cools trans­former and other components only when required. The
fan motors stays off when used intermittently or at low
current procedures, reducing the amount of dust and
dirt drawn into the machine. This also reduces power
consumption.

Electronic Overload Protection - Protects machine
from short circuit or high current overloading.

Power Source Line Voltage Regulation - Precise
SCR phase control circuit holds the voltage setting at a
constant level to maintain weld quality even when the
input voltage fluctuates +/- 10%.

UNIT FEATURES:

Continuous Voltage and Wire Speed Control -

Large, easy to use control knobs provide continuous
full-range calibrated control of both wire speed and
voltage. A "ready-reference Procedure Chart” is pro­vided on the inside of the wire drive section door giving
suggested settings for popular welding processes and
plate thickness. Wire speed control has fine resolution
calibrated dial for repeatable and precise setting.

Undercarriage for Hand Mobility - Heavy duty 10"
(254mm) wheels and 4" (102mm) casters are factory
installed. The handle can be used for storing the weld­ing gun and work cable.

Gas cylinder Platform - Factory installed on the
undercarriage, it permits platform mounting and sup­port of a single gas cylinder. It is not necessary to
completely lift the gas cylinder when placing it on the
platform.

Easy Accessibility - The innovative, small door on the
wire feeder enclosure protects wire and wire drive from
dirt, dust, and damage. However, the door allows
easy top access for convenient "drop-in" wire reel load­ing or to service the wire drive.

Solid State Contactor -Output is turned on and off by
SCR's instead of a mechanical contactor providing
extra long life in highly repetitive welding applications.

Output Terminals - Easily accessible in wire drive
compartment for quick cable connection and polarity
reversal.

Work Cable - 10 ft. (3.0m) long with work clamp.

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WIRE-MATIC 250

B-3

OPERATION

B-3

WIRE FEEDER FEATURES:

Drop-in Wire Loading - The innovative spindle snaps

into the Readi-Reel adapter (optional) or most any 2"
(51mm) I.D. wire spool. The wire spindle drops into the
top-loading WIRE-MATIC 250 case design.
Accommodating standard 12" (305mm) and 8"
(203mm) diameter coils, the unique spindle and sup­port design automatically provides appropriate de-reel­ing drag to prevent wire reel overrun and loop-offs
without manual brake adjustment.

Tachometer Controlled Wire Drive - Precision con­trol of permanent magnet motor provides proper wire
feed acceleration and speed accuracy , independent of
fluctuations in line voltage and wire loading. This gives
reliable arc starting and weld consistency.

Low Speed Start - When the trigger is pulled, the wire
feeder feeds wire at low speed regardless of the set
wire feed speed until welding current is drawn or 2 sec­onds has expired. This feature enhances starting and
makes setting stickout easy. The 2 second limit per­mits high speed loading of the gun and cable. In later
versions of the WIRE-MATIC 250, a user selectable
feature allows the wire feeder to feed wire directly at
the set speed, thus bypassing the 2 second slow start.

MACHINE CAPABILITY

The WIRE-MATIC 250 is rated on the following duty
cycles based on a 10-minute time period (i.e., for 60%
duty cycle, it is 6 minutes on and 4 minutes off).

Duty Cycle

100%

60%
35%

Amps.

145
200
250

Volts

26
28
26

LIMITATIONS

The WIRE-MATIC 250 may not operate satisfactorily if
powered with a portable or in-plant generating system.

Solid State Overload Protection - No circuit breaker
to reset. Simply pull the trigger to resume welding
once the overload condition has been cleared.

Unique Drive Roll and Guide Tube Design ­Precisely aligned guide tubes and drive rolls provide
long life. The design also permits quick reload by sim­ply starting wire into ingoing guide tube. Adjustable
tension setting minimizes 'birdnesting', eliminates
milling through the wire, and gives positive feeding.
The double groove, reversible drive roll included with
the WIRE-MATIC 250 allows use of .030" (0.8mm)
through .045" (1.2mm) diameter wire. Drive roll kits for
other sizes and types of wire are also available.

Quick-Connect Welding Gun - Gun connector has
integrated welding power and gas connection with sep­arate front-panel twist-lock trigger connection mount.

Gun and Cable - A12 ft. (3.6m) GMAW gun and cable
assembly , rated 200 amps 60% duty, or 250 amps 35%
duty, is provided with the WIRE-MATIC 250. A liner,
diffuser and contact tips for .035" (0.9mm) and .045"
(1.2mm) electrodes are included.

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WIRE-MATIC 250

B-4

OPERATION

CONTROLS AND SETTINGS

All operator controls are located on the Front
Panel/Nameplate of the machine. See Figure B.1 for
the location of each control.

B-4

Figure B.1 - Operator Controls.

1. POWER SWITCH: Toggle switch to turn input

power ON and OFF. Place the lever in the ON
position to turn the WIRE-MATIC 250 ON.

2. PILOT LIGHT: The red LED pilot light located next
to the POWER SWITCH is lit when the power is
ON.

3. VOL TAGE CONTROL POTENTIOMETER KNOB:

Provide continuous adjustment of power source
output voltage over the rated 12 to 28 volt range.
Voltage can be adjusted while welding.

4. WIRE SPEED CONTROL POTENTIOMETER
KNOB: Controls the wire speed from 50 to 600

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LINCOLN

ELECTRIC

WIRE-MATIC 250

ON

OFF

inches per minute (1.2 to 15.2 m/min). The control
can be preset on the dial to the setting specified on
the Procedure Decal on the inside of the wire com­partment door. Wire speed is not affected when
changes are made in the voltage control.

NOTE: When the trigger is pulled, the wire feeder
feeds wire at low speed regardless of the wire feed
speed set on the control until the welding arc starts or
2 seconds has elapsed. This feature enhances start­ing and makes it easier to set the stickout. The 2 sec­ond limit permits high speed loading of the gun and
cable.

WIRE-MATIC 250

B-5

OPERATION

B-5

USING THE WIRE DRIVE ROLL

The drive roll provided with the WIRE-MATIC 250 has
two grooves, one for.030-.035" (0.8-0.9mm) solid steel
electrode, and the other for .045" (1.2mm) solid steel
electrode. The welder is shipped with the drive roll
installed in the .030-.035" (0.8-0.9mm) position as indi­cated by the stenciling on the exposed side of the drive
roll. If .045" (1.2mm) electrode is to be used or one of
the optional drive rolls is required, then the drive roll
must be reversed or changed per the following instruc­tions. This information also appears on the Procedure
Decal on the door inside the wire compartment.

PROCEDURE FOR CHANGING DRIVE
ROLL

Different wire sizes may require changing the drive roll.
The applicable wire sizes are stamped on the drive roll.
Dual groove rolls must be installed so the side with the
proper wire size stamp faces out.

1. Turn POWER SWITCH to OFF.

4. Position the Readi-Reel so that it will rotate in a
counterclockwise direction (as viewed from retain­ing spring side of Adapter) when wire is dereeled
from the top of the coil as shown in Figure B.2.

FIGURE B.2 - Wire Reel Loading.

2. Release the pressure on the idle roll by swinging
the pressure arm off the idle roll arm.

3. Remove the wire from the drive system.

4. Remove the wing screw from the drive roll.

5. Turn the drive roll over or change to another roll as
required.

6. Replace the wing screw.

7. Check that the gun liner and contact tip are prop­erly sized for wire being used.

LOADING THE WIRE REEL

T o mount a 22-30 lb. (10-14 kg) Readi-Reel package
using the optional Readi-Reel Adapter (K363P):

1. Pull the spindle up out of the WIRE-MATIC 250
spindle mounting clips (V-brackets).

2. Snap the spindle into the Readi-Reel adapter so
the spindle drive pin is engaged with the hole pro­vided in the Adapter.

3. Rotate the spindle and adapter so the retaining
spring is at the 12 o'clock position.

5. Set one of the Readi-Reel inside cage wires on the
slot in the retaining spring tab.

6. Lower the Readi-Reel to depress the retaining
spring and align the other inside cage wires with
the grooves in the molded adapter.

7. Slide the cage all the way onto the adapter until the
retaining spring "pops" up fully.

WARNING

Check to be sure the retaining spring has fully
returned to the locking position and has securely
locked the Readi-reel cage in place. Retaining
spring must rest on the cage not the welding elec­trode.

____________________________________

8. Check that the mating surfaces of the spindle hubs
and spindle mounting clips (V-brackets) are clear
of dirt and debris, and that the adapter is fully
engaged onto the spindle.

9. Lower the loaded spindle into the spindle mounting
clips (V-brackets) so wire dereels from top of coil
toward wire drive.

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WIRE-MATIC 250

B-6

OPERATION

B-6

NOTE: The retaining spring side of the adapter should
be facing the center (inner) panel of the WIRE-MATIC

250.

10. Remove Readi-Reel from Adapter by depressing
the retaining spring tab with thumb while pulling
the Readi-Reel cage from the molded adapter with
both hands. Do not remove adapter from spindle.

To mount 10 to 30 lb. spools (8" and 12" diameter):

1. Remove the optional Readi-Reel adapter from the
2 inch dia. spindle, if installed.

2. Check the mating surfaces of the spindle hubs and
spindle mounting clips (V-brackets) to be sure they
are clear of dirt and debris.

3. Place the spool on the spindle. Make certain the
brake driving pin enters one of the holes in the
back side of the spool.

4. Lower the loaded spindle into the spindle mount­ing clips (V-brackets) so the wire dereels from the
top of the reel toward the wire drive.

NOTE: The WIRE-MATIC 250 Spindle was designed
to mount 12" (300mm) and 8" (200mm) diameter
spools meeting international spool size specifications.
If the spool being used is too narrow to keep the brake
driving pin* engaged with the spool pin hole, a 2"
(51mm) I.D. shim washer could be used between the
spool and the spindle retaining clip to take up the
space.

2. Tightly holding the electrode, cut off the bent end
and straighten the first six inches.

a. If the electrode is not properly straightened, it

may not feed properly into the outgoing guide
tube or welding gun causing a "birdnest.")

3. Cut off the first inch.

4. Push the wire through the ingoing guide tube.

5. Press the gun trigger and push the electrode into
the drive roll.

a. If the electrode fails to thread itself into the out-

going guide tube of the wire drive

• open the quick release idle roll arm

• thread the electrode manually

• re-close the arm.

6. Inch the electrode through the gun.

NOTE: Due to the low speed starting feature of the
WIRE-MATIC 250, the wire will feed at low speed for 2
seconds while inching, then come up to the set speed.
To change run-in mode, see the

Mode Section

.

Changing the Run In

PROPER WIRE FEEDING

Wire feeding problems can be avoided by observing
the following gun handling procedures:

* Later spindle design uses a longer D-shaped pin to
assure engagement.

FEEDING ELECTRODE

When inching, the electrode and drive mechanism
are electrically hot to work and ground. The elec­trode remains hot several seconds after the gun
trigger is released.

____________________________________

NOTE: Check that the proper drive rolls and gun parts
for the wire size and type are being used.

1. Turn the Readi-Reel or spool until the free end of
the electrode is accessible.

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WARNING

• Do not kink or pull cable around sharp corners.

• Keep the electrode cable as straight as possible
when welding or loading electrode through cable.

• Do not allow dolly wheels or trucks to run over
cables.

• Keep cable clean by following maintenance
instructions.

• Use only clean, rust-free electrode. The Lincoln
electrodes have proper surface lubrication.

• Replace contact tip when the arc starts to become
unstable or the contact tip end is fused or
deformed.

• Keep drop-in spindle and spindle mounting clip
contacting surfaces clear of dirt and debris.

WIRE-MATIC 250

B-7

OPERATION

B-7

SETTING IDLE ROLL PRESSURE

The idle roll pressure wing screw is set at the factory
backed out 2-1/2 turns from full pressure. This is an
approximate setting. The optimum idle roll pressure
varies with type of wire, wire diameter, surface condi­tions, lubrication, and hardness. As a general rule,
hard wires may require greater pressure, and soft, or
aluminum wire, may require less pressure than the fac­tory setting. The optimum idle roll setting can be deter­mined as follows:

1. Push the end of gun against a solid object that is
electrically isolated from the welder output.

2. Press the gun trigger for several seconds.
a. If the wire "birdnests", jams, or breaks at the

drive roll, the idle roll pressure is too great.
Back the wing screw out 1/2 turn, run new wire
through gun, and repeat steps 1 and 2.

b. If the drive roll slips, loosen the wing screw on

the conductor block and pull the gun cable for­ward about 6" (15 cm). There should be a
slight waviness in the exposed wire. If there is
no waviness, the pressure is too low. Tighten
the wing screw 1/4 turn, reinstall the gun
cable, and repeat steps 1 and 2.

NOTE: When the POWER SWITCH is ON, the fan
motor is thermostatically controlled to provide cooling
for the transformer and other components only when
the machine needs cooling. When the machine does
not require fan cooling the fan does not run, such as
when first turned on, when welding at low current, or at
low duty cycle procedures.

CHANGING RUN-IN MODE (Later models
only)

The WIRE-MATIC 250 is factory set for slow run-in
mode. This means the machine will initially feed wire
at 50 IPM until output current is sensed or for 2.0 sec­onds, whichever occurs first. After which it will accel­erate to the preset wire feed speed.

In the Fast run-in mode, the machine will accelerate
directly to the preset wire feed speed.

ENTER FAST RUN-IN MODE

1. Turn POWER SWITCH to OFF on front panel of
WIRE-MATIC 250.

2. Turn the WIRE SPEED CONTROL POTEN­TIOMETER KNOB fully clockwise to maximum.

3. Close the gun trigger switch and turn the POWER
SWITCH to ON.

OPERATING STEPS

WARNING

Before operating the machine, be sure you have all
the materials needed to perform the work. Be sure
you are familiar with and have taken all possible
safety precautions before starting the work. It is
important that you follow these operating steps
each time you use the machine.

___________________________________

STARTING THE WELDER

1. Turn the POWER switch to ON. This illuminates
the red LED pilot light.

2. Select the correct voltage and wire speed for the
welding process required.

3. Operate the gun trigger for welder output and to
energize the wire feeder motor.

a. The gas solenoid will actuate four times to sig-

nal that the unit has entered the fast run-in
mode. The gun trigger need only be closed
until the first gas solenoid actuation is heard.

NOTE: Arc starting characteristics may be effected
when using the fast run-in mode since normal starting
processes are being overridden.

ENTER SLOW RUN-IN MODE

1. Turn POWER SWITCH to OFF on front panel of
WIRE-MATIC 250.

2. Turn the WIRE SPEED CONTROL POTEN­TIOMETER KNOB fully counterclockwise to mini­mum.

3. Close the gun trigger and turn the POWER
SWITCH to ON.

a. The gas solenoid will actuate two times to sig-

nal that the unit has entered the slow run-in
mode. The gun trigger need only be closed
until the first gas solenoid actuation is heard.

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WIRE-MATIC 250

B-8

OPERATION

B-8

NOTE: The unit will remember the run-in mode from
the previous power down and return you to that same
state the next time you power up. Therefore, it is not
necessary to repeat either of the above procedures
each time the unit is powered up. You need only per­form one of the above procedures when you want to
change the run-in mode.

NOTE. When the gun trigger is first closed before turn­ing on the welder, there is no output power or wire feed
until the trigger is opened and re-closed, regardless of
the WIRE SPEED CONTROL POTENTIOMETER
KNOB setting.

MAKING A WELD

1. Check that the electrode polarity is correct for the
process being used.

2. Turn the POWER SWITCH to ON.

3. Set desired arc voltage and wire speed for the
electrode wire, material type and thickness, and
gas (for GMAW) being used.

nate the possibility of the gas nozzle overheating.

7. Connect the work cable to metal to be welded.
Work clamp (if used) must make good electrical
contact to the work. The work must be grounded.

WARNING

When using an open arc process, it is necessary to
use correct eye, head and body protection.

____________________________________

8. Position electrode over joint. End of electrode may
be lightly touching the work.

9. Lower welding helmet, close gun trigger, and begin
welding. Hold the gun so the contact tip to work
distance is about 3/8 inch (10mm) or 3/4" (20mm)
for Outershield.

10. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.

NOTE: Use the Application Chart on the door inside
the wire compartment as a quick reference for some
common welding procedures.

NOTE: If Timer Kit is installed, see the Accessories
Section of this manual to select the desired mode and
for additional welding information Spot and Stitch
modes.

4. Inch the electrode through the gun and cable.

5. Cut the electrode within approximately 3/8"
(10mm) of the end of the contact tip or 3/4" (20mm)
for Outershields.

NOTE: When the trigger is pulled, the wire feeder
feeds wire at low speed regardless of the set wire feed
speed until the welding arc starts or 2 seconds has
elapsed. This feature enhances starting and makes it
easier to set the stickout. The 2 second limit permits
high speed loading of the gun and cable. To change
run-in mode, refer to

6. 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).

Changing Run In Mode Section

11. When no more welding is to be done, close the
valve on gas cylinder (if used), momentarily oper­ate gun trigger to release gas pressure.

12. Turn POWER SWITCH to OFF.

.

NOTE: When using Innershield electrode, the gas
nozzle may be removed from the insulation on the end
of the gun. This will give improved visibility and elimi-

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WIRE-MATIC 250

NOTES

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WIRE-MATIC 250

ACCESSORIES

TABLE OF CONTENTS

- ACCESSORIES SECTION -

ACCESSORIES SECTION ....................................... Section C

Replacement Magnum 250L Gun and

Cable Assembly ..........................................................C-1

K607-1 Spool Gun Adapter Kit.........................................C-1

Installing the K607-1 Spool Adapter Kit...........................C-1

Spool Gun Module Board Installation .........................C-2

Spool Gun Connection Box Installation ......................C-3

Spool Gun Preparation................................................C-4

Spool Gun Connection................................................C-4

Making a Weld with the Spool Gun Adapter (K607-1)

Installed.......................................................................C-5

Timer Kit (K585-1)............................................................C-6

Timer Kit Installation (Optional K585-1)...........................C-6

Making Spot and Stitch Welds with Timer Kit Installed ...C-7

Adjustable Gas Regulator and Hose Kit (K586-1)...........C-7

Drive Roll Kits ..................................................................C-7

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WIRE-MATIC 250

C-1

ACCESSORIES

C-1

OPTIONS/ACCESSORIES
REPLACEMENT MAGNUM 250L

GUN AND CABLE ASSEMBL Y

The following GMAW gun and cable assemblies are
available for use with the WIRE-MATIC 250. Each is
rated 200 amps 60% duty cycle or 250 amps 35% duty
cycle. The gun and cable assemblies are equipped
with the integrated connector, twist-lock trigger con­nector, and includes a liner, diffuser, and contact tips
for the wire sizes specified:

LENGTH PART NO.

10' (3.0 m)
12' (3.6 m)
15’ (4.5 m)

10' (3.0 m)
12' (3.6 m)
15’ (4.5 m)

K533-1
K533-2*
K533-3

K533-4
K533-5
K533-6

WIRE SIZE

.035-.045”

(0.9-1.2mm)

.025-.030”

(0.6-0.8mm)

spool gun gas supply hose, as well as up-front easy
connection of the spool gun gas line, control plug, and
electrode lead (using the T wist-Mate plug provided with
the kit). An Installation and Operation Manual is includ­ed with the kit.

* Included with the K578-1.

K607-1 SPOOL GUN ADAPTER KIT

The K607-1 Spool Gun Adapter Kit provides "up front"
direct connection of the K487 Spool Gun (with remote
speed control) or the K469 Spool Gun (requiring K518
Connection Adapter) for use with the WIRE-MATIC

250.
It also provides single switch transfer between the

machine's feeder gun or the spool gun for same polar­ity welding with different wire and gas processes.

The kit includes a spool gun module board and a con­nection box assembly with connecting plug and lead
harnesses, mounting hardware, installation instruc­tions, and operating instructions.

INSTALLING THE K607-1 SPOOL
GUN ADAPTER KIT

The spool gun module mounts inside the control sec­tion of the machine. It provides control and inter-con­nection between the machine's control board and the
spool gun kit connection box.

The connection box mounts to the front of the
machine's base. It provides for inlet connection of the

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WIRE-MATIC 250

C-2

ACCESSORIES

C-2

SPOOL GUN MODULE BOARD
INSTALLATION

NOTE: The K607-1 Spool Gun Adapter Kit is designed
for use with WIRE-MATIC 250 model codes above

9900. Model Codes below 9900 may be used with
addition of holes to the case as described in the instal­lation instructions below.

WARNING

Do not operate with covers removed. Disconnect
AC input power before servicing. Do not touch
electrically live parts. Only qualified electricians
should install, use. or service this equipment.

____________________________________

1. Disconnect AC input power to the machine before
installing the Spool Gun Module Board.

2. Remove the six screws from the Left Case Side
and Door and Hinge Assembly.

5. Position the Spool Gun Module Board over the
snap-mount fasteners with the lead plug connec­tors at the top.

6. Gently press the board onto the fasteners, making
sure all the fasteners snap into place.

7. Remove the hex-head screw from beneath the gas
connector on the wire drive side of the machine to
release the small metal cover. See Figure C.2.

3. Lift the Left Case Side and Door and Hinge
Assembly up and over the lip of the center divider
panel while pulling the case side away from the
unit. Slide it out of the slots in the base.

4. Locate the four snap-mount fasteners mounted to
the side panel of the P.C. board compartment. See
Figure C.1.

FIGURE C.2 - Spool Gun Installation.

8. Slide the metal cover out from behind the motor
bracket.

9. Turn the cover over so the screw hole is in the top
right corner, then reinstall as a spacer plate with
the hex-head screw. See Figure C.2.

10. Locate the panel receptacle lead harness included
in the kit. See Figure C.1.

11. Insert the panel receptacle into the hole on the
control board side of the panel, making sure the
panel receptacle mounting plate is positioned so
the grounding screw is in the lower left corner of
the plate. See Figure C.1.

FIGURE C.1 - Spool Gun Module Board Installation.

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NOTE: For model codes below 9900, small notches
may need to be filed at top and bottom of panel hole to
allow clearance of the plastic mounting ears.

WIRE-MATIC 250

C-3

CAUTION

ACCESSORIES

SPOOL GUN CONNECTION BOX
INSTALLATION

C-3

Collect metal filings with a rag to protect against
possible metal contamination of the control board
or other internal electrical components.

____________________________________

12. Fasten the panel receptacle to the case with the
three #6-32 x 3/8" self tapping screws provided.

a. Insert the screws from wire drive side, through

the sheet metal, and into the receptacle
mounting plate holes.

13. Plug the 10-pin, 8-pin, and 6-pin connector plugs
from the other end of the receptacle lead harness
into the 10-pin, 8-pin, and 6-pin connectors (Molex
plugs J12, J11, and J13) at the top of the Spool
Gun Module Board.

a. Plug the 8-pin connector at the opposite end of

this harness into the unused 8-pin connector
on the WIRE-MATIC 250 control board (Molex
plug J4).

14. Disconnect the 4-pin gas solenoid plug from the
receptacle (Molex plug J8) on the upper right cor­ner of the Control Board as shown Figure C.1.
Reconnect this plug to the 4-pin receptacle (Molex
plug J14) on the top of the Spool Gun Module
Board.

15. Plug the 4 pin connector plug, included with the
panel receptacle harness connected in step 13
above, into the Control Board receptacle (J8), dis­connected in step 14 above.

16. Using the cable tie included in the kit, tie the two
harnesses together approximately 3.50 inches
(88.9 mm) from the end of the lead plugs as shown
in Figure C.1.

17. Replace the Case into the slots in the base. Make
sure the lip of the case side is lifted over the top
edge of the center panel during installation.

a. Fasten Case Side with the six screws

removed.

NOTE: Model codes below 9900 require the addition of
three holes to the front of the machine's base as shown
in Figure C.3.

FIGURE C.3 - Spool Gun Connection Box
Installation Mounting Holes.

1. Remove the plug button, if present, from the cen­ter hole in the front of the machine's base.

2. Insert the two #10 thread forming screws (provid­ed with the kit) and partially thread them into the
two small holes on both sides of the center hole.

3. Route a user provided gas supply hose from the
flow regulator of the spool gun gas cylinder, over
the rear axle of the machine, and out to the front
through the center hole in the front of the base.

4. Connect the gas hose to the 5/8-18 female inert
gas fitting on the back of the connection box.

5. Slip the connection box mounting keyholes over
the screw heads installed in Step 2 above. Pivot
the box clockwise to engage and level the box and
then tighten the screws.

6. Route the control cable of the connection box up
through the opening provided for the work lead in
the front louver and then up behind the wire drive.

a. Connect the plug to the kit receptacle when

installing the Spool Gun Module Board. See
Figure C.4.

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WIRE-MATIC 250

C-4

ACCESSORIES

2. Strip .50" (12.7 mm) of insulation jacket off the lead
end and slip the supplied copper tube ferrule over
the stripped end.

3. Insert the lead end with ferrule completely into the
brass T wist-Mate plug and tighten the set screw for
a positive electrical connection.

4. Pull the rubber boot over the plug to insulate the
connection.

SPOOL GUN CONNECTION

C-4

CAUTION

FIGURE C.4 - Spool Gun Connection Box
Installation.

7. Route the electrode lead of the connection box up
through the same opening in the front louver.

8. Remove the positive electrode lead from its con­nection on the wire drive with the machine con­nected for electrode positive (refer to Output
Polarity Connection in

9. Reconnect with the connection box electrode lead
on the bolt under the positive electrode lead so the
connection box electrode lead is sandwiched
between the positive electrode lead terminal and
the wire drive contact surface.

a. Tighten snugly being careful not to strip the

threads.

Installation Chapter

).

SPOOL GUN PREPARATION

1. Cut the terminal lug off the end of the spool gun
electrode lead and slip the rubber boot, included in
the kit, over the lead jacket. See Figure C.5.

The spool gun module is intended for use with
Lincoln Electric Magnum Spool Guns only. Use
with other units may cause damage to the equip­ment. For Spool Gun operation, refer to the
instruction manual provided with the Magnum
Spool Gun.

____________________________________

1. Connect the spool gun control cable 6-pin plug to
the mating receptacle on the front of the spool gun
adapter connection box installed during Spool Gun
Box Connection

NOTE: If using a K469 spool gun with 4 pin plug, use
the K518 adapter.

2. Insert the T wist-Mate plug installed when preparing
the spool gun into the mating receptacle on the
front of the connection box and twist to lock the
connection.

3. Attach the spool gun gas line to the gas outlet fit­ting on the front of the connection box.

NOTE: Refer to the Instruction Manual included with
the K487 or K469 Spool Gun for more details about
Spool Gun set-up and operation.

FIGURE C.5 - Spool Gun Preparation.

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WIRE-MATIC 250

C-5

ACCESSORIES

C-5

MAKING A WELD WITH THE SPOOL
GUN ADAPTER (K607-1) INSTALLED

The toggle switch on the front of the spool gun adapter
box permits quick transfer when you want to switch
between using the WIRE-MATIC 250 Feeder Gun and
the connected Spool Gun when the electrodes are at
the same polarity.

CAUTION

In either transfer switch position, closing the gun
trigger will cause the electrode of both guns to be
electrically energized, or "HOT." Be sure the
unused gun is positioned so the electrode or the
tip will not contact metal case or other metal com­mon to the work.

____________________________________

When the transfer switch is in the Feeder Gun position:

4. Adjusting the Wire Speed Control will increase or
decrease the Spool Gun Wire Feed Speed. This
represents the set speed for the K469 Spool Gun
and the maximum set speed for the K487 Spool
Gun with the remote control in gun handle at max­imum.

The remote control turned to minimum will give
approximately 50% of the maximum set WFS.

NOTE: The WIRE-MATIC 250 speed calibrated dial
markings are not accurate when used for setting the
Spool Gun speed.

The following procedure settings can be used as initial
settings for making test welds to determine final set­tings:

Wire Diameter

.030” (.8mm)
.035” (.9mm)

3/64” (1.2mm)

Wire Feed

Speed Setting

270
250
210

Arc Voltage

Setting

15 V
16 V
21 V

a. The Spool Gun trigger, wire feed, and gas out-

put are disabled.

b. Closing the Feeder Gun trigger Starts Feeder

Gun welding and makes the Feeder Gun and
the Spool Gun electrodes electrically "HOT."

When the transfer switch is in the Spool Gun position:

a. The Feeder Gun, wire feed, and gas output

are disabled.

b. Closing the Spool Gun trigger makes both the

Feeder Gun and Spool Gun electrodes electri­cally "HOT" and activates Spool Gun gas out­put.

MAKING THE WELD:

1. Set the transfer switch in the SPOOL GUN posi­tion.

2. Turn input power ON by setting the POWER
SWITCH in the ON position.

5. To return to normal WIRE-MATIC 250 welding, set
the transfer switch to FEEDER GUN position and
reset feeder gun weld procedure settings.

3. Adjust the VOLTAGE CONTROL KNOB to
increase or decrease your welding Voltage.

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WIRE-MATIC 250

C-6

ACCESSORIES

C-6

TIMER KIT (K585-1)

The Timer Kit provides selectable 4-step trigger inter­lock, spot and stitch functions, and manual adjustment
of burnback time. This kit installs easily using only a
screwdriver. It replaces the blank upper panel on Case
Front. It offers the following mode selections:

• The Normal Welding mode provides welding
power only while gun trigger is pressed.

• The 4-Step Trigger mode eliminates the need to
hold gun trigger while welding. It operates in 4
steps:

1. Close trigger and establish welding arc.

2. Release trigger and continue welding.

3. Re-close trigger near end of weld.

4. Release trigger again to stop welding.

• The Spot Weld mode allows a single timed weld
cycle each time the gun trigger is held closed.
Duration is set with SPOT/STITCH ON TIME knob.

• The Stitch Weld mode allows repeated timed weld
cycles while gun trigger is held closed. Weld on­time is set with SPOT/STITCH ON TIME knob, and
weld off time is set with STITCH OFF TIME knob.

The BURNBACK TIME knob is used to manually set
arc power delay at the end of any above selected weld
mode to prevent wire sticking in the weld. With the
Timer Kit not installed, a preselected delay is automat­ically set by the machine.

TIMER KIT INSTALLATION
(OPTIONAL K585-1)

WARNING

Remove all input power to the WIRE-MATIC 250
before proceeding.

____________________________________

1. Verify that the following items have been included
in the kit:

a. Timer Board and Panel Assembly.
b. Two sheet metal screws.
c. Wiring harness.

2. Turn the POWER SWITCH to OFF.

3. Disconnect AC input power to the machine.

4. Remove the Cover Plate Assembly from the front
of the machine by removing the two screws which
fasten it using a screwdriver, a 5/16" (8mm) nut dri­ver, or other suitable tool.

5. Reach through the exposed panel opening and
attach the rectangular 8-pin plug connector on the
Timer Kit wiring harness to the available mating
receptacle connector on the upper left corner of
the Control Board inside the machine.

a. Be sure that the latch on the connector is

aligned with that on the Control Board and
insert it until the latch engages.

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b. Check that the remaining connector on the

opposite end of the wiring harness is firmly
attached to the mating connector on the PC
Board on the Timer Kit panel, and that the
latch is engaged.

6. Align the Timer Kit panel so you can carefully insert
the printed circuit board and wiring harness
through the opening in the front panel.

a. Make sure the wiring harness is not pinched

between panels or between printed circuit
board and front panel.

7. Fasten the Timer Kit assembly with either the two
supplied screws or with the original screws to com­plete the installation.

WIRE-MATIC 250

C-7

ACCESSORIES

C-7

MAKING SPOT AND STITCH WELDS
WITH TIMER KIT INSTALLED

TO MAKE SPOT PLUG WELDS:

The SPOT WELD MODE is used to make spot plug
welds when continuous welds are not needed or to
hold thin sheet metal together prior to stitch welding or
continuous welding.

Plug welds are made by using a punch to make a 3/16"
(5mm) diameter hole in the top sheet and arc welding
through the hole into the back sheet.

1. Punch 3/16" (5mm) holes in the top sheet.

2. Set the SPOT/STITCH ON-TIME control to
approximately 1.2 seconds.

3. Set the procedure for the metal thickness to be
welded.

4. Install spot weld nozzle (if available) on gun and
press it against the top sheet so the top and bot­tom sheets are tight together.

5. Close trigger and hold it closed until the arc goes
out.

a. If a spot weld nozzle is not used, smoother

welds will result by moving the welding wire in
a small circle during the weld.

3. Set the procedure for the metal thickness to be
welded.

4. Close trigger and hold it closed for length of seam.
a. Hold gun in one place during ON time and

move gun just beyond edge of molten metal
during OFF time.

NOTE: For smoothest welds on thinner metal, point
gun slightly toward the direction of travel.

ADJUSTABLE GAS REGULATOR
AND HOSE KIT (K586-1)

The kit can be used with CO2 or Argon blend gas. It
includes a cylinder pressure gauge, a dual scale flow
gauge, and a gas hose to connect the regulator to the
WIRE-MATIC 250 gas inlet.

DRIVE ROLL KITS

The following drive rolls and Magnum 250L gun and
cable parts are available to feed different sizes and
types of electrodes.

Steel Wire Sizes:

.025 - .035" (0.6-0.9mm)
.030 - .045" (0.8-1.2mm)

.045" Cored (1.2mm)

Part Number

M14932
M15809

S14541-052 (2 Req’d)

TO MAKE A STITCH WELD:

The STITCH WELD MODE is used to weld thin mater­ial when warpage and burn through are a problem.
Proper adjustment of the Spot/Stitch On-Time, Stitch
Off-Time, and arc travel speed permits welding thin
sheet metal with small welds, minimum distortion, and
no burnthrough.

1. The SPOT/STITCH ON-TIME KNOB sets welding
time.

a. Start with a dial setting of 0.5 seconds. Raise

2. The STITCH OFF-TIME KNOB sets off time
between welds.

a. Start with a dial setting of 0.5 seconds. Raise

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setting to increase penetration and weld size.
Lower setting to reduce burnthrough and dis­tortion.

setting to reduce burnthrough. Lower setting
to make weld flatter and smoother.

WIRE-MATIC 250

Aluminum Wire Sizes:

3/64" (1.2mm)

S17092-3/64A

MAINTENANCE

TABLE OF CONTENTS

- MAINTENANCE SECTION -

MAINTENANCE SECTION ...................................... Section D

Safety Precautions...........................................................D-1

Routine and Periodic Maintenance..................................D-1

Component Locations......................................................D-2

Drive Rolls and Guide Tubes...........................................D-3

Drop-In Reel Spindle and Clips .......................................D-3

Cable Cleaning.................................................................D-3

Gun Tubes and Nozzles...................................................D-3

Contact Tip and Gas Nozzle Installation..........................D-3

Liner Removal and Replacement.....................................D-4

Liner Removal, Installation, and Trimming Instructions

for Magnum 250L........................................................D-4

Gun Handle Disassembly ................................................D-5

Accessories and Expendable Replacement Parts for

Magnum 250L Gun and Cable Assemblies .....................D-6

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WIRE-MATIC 250

D-1

MAINTENANCE

SAFETY PRECAUTIONS

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.

• Unplug the power cable if it is connected to a
receptacle.

____________________________________

Read the Safety Precautions in the front of this manu­al before working on this machine.

ROUTINE AND PERIODIC
MAINTENANCE

D-1

1. Disconnect input AC power supply lines to the
machine before performing periodic maintenance,
tightening, cleaning, or replacing parts. See
Figure D.1.

Perform the following daily:

1. Check that no combustible materials are in the
welding or cutting area or around the machine.

2. Remove any debris, dust, dirt, or materials that
could block the air flow to the machine.

3. Inspect the electrode cables for any slits, punc­tures in the cable jacket, or any condition that
would affect the proper operation of the machine.

Perform Periodically:

Clean the inside of the machine with low pressure air
stream. Clean the following parts. Refer to Figure D.1.

Main transformer and choke.
Electrode and work cable connections.
SCR rectifier bridge and heat sink fins.
Fan Motor Assembly.
Control Printed Circuit Board.

NOTE: The fan motor has sealed bearings which
require no maintenance.

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WIRE-MATIC 250

D-2

MAINTENANCE

D-2

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Figure D.1 - Component Locations.

WIRE-MATIC 250

D-3

MAINTENANCE

D-3

DRIVE ROLLS AND GUIDE TUBES

After every coil of wire, inspect the wire drive mecha­nism. Clean it as necessary by blowing with low pres­sure compressed air. Do not use solvents for cleaning
the idle roll because it may wash the lubricant out of
the bearing. All drive rolls are stamped with the wire
sizes they will feed. If a wire size other than that
stamped on the roll is used, the drive roll must be
changed.

DROP-IN REEL SPINDLE AND
CLIPS

Before loading a coil of wire onto the WIRE-MA TIC 250
drop-in spindle, inspect the mating surfaces of the
spindle hubs and the spindle mounting clips (V-brack­ets) and, if necessary, wipe or blow out any dirt and
debris which may have accumulated on these sur­faces.

CABLE CLEANING

Clean the cable liner after using approximately 300
pounds (136 kg) of electrode.

GUN TUBES AND NOZZLES

1. Replace worn contact tips as required.

2. Remove spatter from the inside of the gas nozzle
and tip every 10 minutes of arc time or as required.

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.

2. Slip or screw the appropriate gas nozzle onto the
nozzle insulator.

Note: Either a standard .50" (12.7mm) or optional .62"
(15.9mm) I.D. slip-on gas nozzle may be used and
should be selected based on the welding application.

1. Remove the cable from the wire feeder and lay it
out straight on the floor.

2. Remove the contact tip from the gun.

3. With an air hose at the gas diffuser end, use low
pressure to gently blow out the cable liner.

CAUTION

Excessive pressure at the start may cause the dirt
to form a plug.

____________________________________

4. Flex the cable over its entire length and again blow
out the cable.

5. Repeat this procedure until no more dirt comes
out.

3. Adjust the gas nozzle as appropriate for the
GMAW process to be used.

a. Typically, the contact tip end should be flush to

extended .12" (3.2mm) for the short-circuiting
transfer process and recessed .12" (3.2mm)
for spray transfer.

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WIRE-MATIC 250

D-4

MAINTENANCE

LINER REMOVAL AND
REPLACEMENT

NOTE: When you change wire size, a replacement
gas diffuser is required. Use the table below to select
the proper diffuser so the liner is held securely in place.

D-4

Electrode Diameter

.025-.030" Steel
(0.6-0.8mm)

.035-.045" Steel
(0.9-1.2mm)

3/64" Aluminum
(1.2mm)

Replacement Liner

Part Number

M16087-2

M16087-1

M16107-1

LINER REMOVAL, INSTALLATION,
AND TRIMMING INSTRUCTIONS
FOR MAGNUM 250L

NOTE: The variation in cable lengths prevents the
interchange ability of liners between guns. Once a liner
has been cut for a particular gun, it should not be
installed in another gun unless it can meet the liner cut
off length requirement. Liners are shipped with the
jacket of the liner extended the proper amount.

Size Stenciled on the End

of the Liner Bushing

.030 (0.8mm)

.045 (1.2mm)

(Plastic Liner)

9. Tighten the setscrew on the brass cable connector .

NOTE: Do not install the gas diffuser onto the end of
the gun tube at this time.

10. Straighten the cable with the gas nozzle and noz­zle insulator removed from the gun tube.

11. Trim the liner to the length shown in FIGURE D.2.

Gas Diffuser Part Number

(and Stencil)

S19418-2

S19418-1

S19418-1

1. Remove the gas nozzle and nozzle insulator.

2. Locate the set screw in the gas diffuser which is
used to hold the old liner in place.

3. Loosen the set screw with a 5/64" (2.0mm) Allen
wrench.

4. Remove the gas diffuser from the gun tube.

5. Lay the gun and cable out straight on a flat sur­face.

6. Loosen the set screw located in the brass connec­tor at the feeder end of the cable and pull the liner
out of the cable.

7. Insert a new untrimmed liner into the connector
end of the cable.

a. Check the liner bushing stencil to make sure it

8. Fully seat the liner bushing into the connector.

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is the appropriate one for the wire size being
used.

FIGURE D.2 - Liner maintenance.

WIRE-MATIC 250

D-5

12 Remove any burrs from the end of the liner.

13. Screw the gas diffuser onto the end of the gun tube
and tighten.

NOTE: Be sure the gas diffuser is correct for the liner
being used. (See table and diffuser stencil.)

14. Slightly tighten the set screw in the side of the gas
diffuser against the cable liner using 5/64" (2.0mm)
Allen wrench.

MAINTENANCE

CAUTION

This screw should only be gently tightened. Over
tightening will split or collapse the liner and cause
poor wire feeding.

____________________________________

GUN HANDLE DISASSEMBLY

D-5

FIGURE D.3 - Gun Handle disassembly.

The internal parts of the gun handle may be inspected
or serviced if necessary.

The gun handle consists of two halves that are held
together with a collar on each end.

To open up the handle:

1. Turn the collars approximately 60 degrees coun­terclockwise (the same direction as removing a
right hand thread) until the collar reaches a stop.

2. Pull the collar off the gun handle.

NOTE: If the collars are difficult to turn, position the
gun handle against a corner, place a screwdriver
against the tab on the collar and give the screwdriver a
sharp blow to turn the collar past an internal locking rib.
See Figure D.3.

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WIRE-MATIC 250

D-6

MAINTENANCE

ACCESSORIES AND EXPENDABLE
REPLACEMENT PARTS FOR
MAGNUM 250L GUN AND CABLE
ASSEMBLIES

D-6

DESCRIPTION

Cable Liner
For 15' (4.5m) or Shorter Cable

Contact Tips

Standard Duty

Heavy Duty

Tapered

Gas Diffuser Assembly

Gas Nozzles

Adjustable Slip-On

(Requires Nozzle Insulator Assembly.)

PART NO.

M16087-2
M16087-1*
M17701-1**

S19391-6
S19391-7
S19391-1*
S19391-2*

S19392-1
S19292-2

S19393-5
S19393-6
S19393-1
S19393-2

S19418-2
S19418-1

M16093-2*
M16093-1

ENGLISH SIZE

.025- .030"
.035- .045"

3/64" (Alum. Wire)

.025"
.030"
.035"
.045"

.035"
.045"

.025"
.030"
.035"
.045"

0.25 - .030"

0.35 - .045"

1/2"
5/8"

METRIC SIZE

0.6 - 0.8 mm

0.9 - 1.2 mm

1.2 mm (Alum. Wire)

0.6 mm

0.8 mm

0.9 mm

1.2 mm

0.9 mm

1.2 mm

0.6 mm

0.8 mm

0.9 mm

1.2 mm

0.6 - 0.8 mm

0.9 - 1.2 mm

12.7 mm

15.9 mm
Nozzle Insulator Assembly
Gasless Nozzle (for Innershield®)
Gun Tube Assembly

Standard (60 Degrees)
45 Degrees

* Included with WIRE-MATIC 250
** 5356 alloy aluminum wire and 450gun tube are

recommended to alleviate potential soft wire feed­ing problems with push-type wire feeding.

S19417-1*
M16938

S18920*
S19890**

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WIRE-MATIC 250

NOTES

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WIRE-MATIC 250

THEORY OF OPERATION

TABLE OF CONTENTS

- THEORY OF OPERATION SECTION -

THEORY OF OPERATION SECTION ...................... Section E

Power Supply Operation .................................................E-1

Input Line Voltage and Main Transformer...................E-1

Output Rectification and Feedback Control ................E-2

Constant Voltage Output.............................................E-3

Wire Drive Motor and Feedback .................................E-4

Thermal Protection...........................................................E-5

SCR Operation.................................................................E-6

LINE

SWITCH

RECONNECT

FAN

MOTORS

VOLTAGE

MAIN

TRANSFORMER

ARC

WIRE

SPEED

SOLENOID

CONTROL BOARD

G
A
T
E

S

I
G
N
A
L

SCR

RECTIFIER

GAS

WIRE

DRIVE

MOTOR

TACH

GUN TRIGGER AND THUMB SWITCH

FEEDBACK

POSITIVE

TERMINAL

C
A
P
A
C

I
T
O
R
S

SHUNT

F
E
E
D
B
A
C
K

CHOKE

NEGATIVE

TERMINAL

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Figure E.1 -Block Logic Diagram

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

WIRE-MATIC 250

E-1

THEORY OF OPERATION

INPUT LINE VOLTAGE AND MAIN TRANSFORMER

E-1

LINE

SWITCH

RECONNECT

FAN

MOTORS

SCR

G
A
T
E

S

I
G
N
A
L

GAS

SOLENOID

WIRE

DRIVE

MOTOR

TACH

GUN TRIGGER AND THUMB SWITCH

FEEDBACK

C
A
P
A
C

I
T
O
R
S

SHUNT

F
E
E
D
B
A
C
K

CHOKE

VOLTAGE

MAIN

TRANSFORMER

ARC

WIRE

SPEED

CONTROL BOARD

RECTIFIER

Figure E.2 - Input Line Voltage and Main Transformer.

POSITIVE

TERMINAL

NEGATIVE

TERMINAL

INPUT LINE VOLTAGE AND MAIN
TRANSFORMER

The desired single phase input power is connected to
the WIRE-MATIC 250 through a line switch located on
the front panel.

A reconnect panel allows the user to configure the
machine for the desired input voltage. This AC input
voltage is applied to the primary of the main trans­former and to the thermostatically controlled fan
motors. The transformer changes the high voltage, low
current input power to a low voltage, high current out­put. In addition, the main transformer also has an iso­lated center tapped 30 VAC auxiliary winding that sup­plies power to the Control Board for SCR gate drive
and gas solenoid operation. The weld power windings
connect to the Control Board as well as to the main
SCR Rectifier.

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

WIRE-MATIC 250

E-2

THEORY OF OPERATION

OUTPUT RECTIFICATION AND FEEDBACK

E-2

LINE

SWITCH

RECONNECT

FAN

MOTORS

VOLTAGE

MAIN

TRANSFORMER

SCR

G
A
T
E

S

I
G
N
A
L

GAS

SOLENOID

WIRE

DRIVE

MOTOR

TACH

GUN TRIGGER AND THUMB SWITCH

FEEDBACK

POSITIVE

TERMINAL

C
A
P
A
C

I
T
O
R
S

SHUNT

F
E
E
D
B
A
C
K

CHOKE

NEGATIVE

TERMINAL

ARC

WIRE

SPEED

CONTROL BOARD

RECTIFIER

Figure E.3 - Output Rectification and Feedback.

OUTPUT RECTIFICATION AND
FEEDBACK CONTROL

The AC output from the main transformer secondary
weld winding is rectified and controlled through the
SCR rectifier assembly. Output voltage and current
are sensed at the shunt and output terminals and are
fed back to the control board. The control board com­pares the commands of the ARC Voltage Control
potentiometer with the feedback signals. The appro­priate gate firing pulses are generated by the control
board and applied to the SCR rectifier assembly. The
control board controls the firing of the SCRs, thus con­trolling the output of the machine. See

Operation

mands the gas solenoid and the wire drive motor.

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SCR

. The control board also powers and com-

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

WIRE-MATIC 250

E-3

THEORY OF OPERATION

CONSTANT VOLTAGE OUTPUT

E-3

LINE

SWITCH

RECONNECT

FAN

MOTORS

VOLTAGE

MAIN

TRANSFORMER

SCR

G
A
T
E

S

I
G
N
A

L

GAS

SOLENOID

GUN TRIGGER AND THUMB SWITCH

C
A
P
A
C

I
T
O
R
S

SHUNT

F
E
E
D
B
A
C
K

ARC

WIRE

SPEED

CONTROL BOARD

RECTIFIER

Figure E.4 - Constant Voltage Output.

WIRE

DRIVE

MOTOR

TACH

FEEDBACK

CHOKE

POSITIVE

TERMINAL

NEGATIVE

TERMINAL

CONSTANT VOLTAGE OUTPUT

The controlled DC output from the SCR rectifier
assembly is filtered by the capacitor bank resulting is a
constant voltage DC output. Since the output choke is
in series with the positive leg of the rectifier and also in
series with the gun and welding load, a filtered con­stant voltage output is applied to the output terminals
of the machine.

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

WIRE-MATIC 250

E-4

THEORY OF OPERATION

WIRE DRIVE MOTOR AND FEEDBACK

E-4

LINE

SWITCH

RECONNECT

FAN

MOTORS

VOLTAGE

MAIN

TRANSFORMER

G
A
T
E

S
G

N
A

L

I

GAS

SOLENOID

C
A
P
A
C

T
O
R
S

WIRE

DRIVE

MOTOR

TACH

GUN TRIGGER AND THUMB SWITCH

FEEDBACK

TERMINAL

F
E
E

SHUNT

D
B
A
C
K

I

CHOKE

NEGATIVE

TERMINAL

ARC

WIRE

SPEED

CONTROL BOARD

SCR

RECTIFIER

Figure E.5 - Wire Drive Motor and Feedback.

POSITIVE

WIRE DRIVE MOTOR AND
FEEDBACK

The wire drive motor is controlled by the control board.
A motor speed feedback signal is generated at the
motor tach and sent to the control board. The control
board compares this feedback signal with the com­mands set forth by the Wire Speed Control poten­tiometer and sends the appropriate armature voltage
to the wire drive motor. The drive motor speed is thus
controlled which in turn regulates the electrode wire
feed speed through the gun.

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

WIRE-MATIC 250

E-5

THEORY OF OPERATION

THERMAL PROTECTION

THERMAL PROTECTION

A thermostat protects the machine from excessive
operating temperatures. Excessive operating temper­atures may be caused by a lack of cooling air or oper­ating the machine beyond the duty cycle and output
rating. There are three thermostats within the WIRE­MATIC 250 machine. One of the thermostats, located
on the output choke, energizes the cooling fan motors
when required. The other choke thermostat "opens"
the trigger circuit, preventing machine weld output and
wire feed, if excessive operating temperatures are
detected. The third thermostat insures that the fan
motors are operating when required.

The thermostats are self-resetting once the machine
cools sufficiently. If the thermostat shutdown is caused
by excessive output or duty cycle and the fans are
operating normally, the power switch may be left on
and the reset should occur within a 15 minute period.
If the fans are not turning or the air intake louvers are
obstructed, then the input power must be removed and
the fan problem or air obstruction be corrected.

E-5

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

WIRE-MATIC 250

E-6

THEORY OF OPERATION

SCR OPERATION

E-6

Figure E.6 - SCR Operation

A silicon controlled rectifier (SCR) is a three terminal
device used to control rather large currents to a load.
An SCR acts very much like a switch. When a gate sig­nal is applied to the SCR it is turned ON and there is
current flow from anode to cathode. In the ON state the
SCR acts like a closed switch. When the SCR is turned
OFF there is no current flow from anode to cathode
thus the device acts like an open switch. As the name
suggests, the SCR is a rectifier, so it passes current
only during positive half cycles of the AC supply. The
positive half cycle is the portion of the sine wave in
which the anode of the SCR is more positive than the
cathode.

When an AC supply voltage is applied to the SCR, the
device spends a certain portion of the AC cycle time in
the off state and the remainder of the time in the on
state. The amount of time spent in the ON state is con­trolled by the gate.

An SCR is fired by a short burst of current into the gate.
This gate pulse must be more positive than the cath­ode voltage. Since there is a standard PN junction
between gate and cathode, the voltage between these
terminals must be slightly greater than 0.6V. Once the
SCR has fired it is not necessary to continue the flow
of gate current. As long as current continues to flow
from anode to cathode the SCR will remain on. When
the anode to cathode current drops below a minimum
value, called holding current, the SCR will shut off. This
normally occurs as the AC supply voltage passes
through zero into the negative portion of the sine wave.
If the SCR is turned on early in the positive half cycle,
the conduction time is longer resulting in greater SCR
output. If the gate firing occurs later in the cycle the
conduction time is less resulting in lower SCR output.

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WIRE-MATIC 250

NOTES

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WIRE-MATIC 250

TROUBLESHOOTING & REPAIR

TABLE OF CONTENTS

- TROUBLESHOOTING & REPAIR SECTION -

TROUBLESHOOTING & REPAIR SECTION ........................................................................ Section F

How to use Troubleshooting Guide ....................................................................................................F-1

PC Board Troubleshooting Procedures..............................................................................................F-2

Troubleshooting Guide.......................................................................................................................F-3

Test Procedures

Main Transformer Test................................................................................................................F-10

Static Output Rectifier Bridge Test .............................................................................................F-13

Active SCR Rectifier Assembly Test...........................................................................................F-16

Wire Drive Motor and Tachometer Feedback Test.....................................................................F-19

Oscilloscope Waveforms..................................................................................................................F-22

Normal Open Circuit Voltage Waveform ....................................................................................F-22

Typical Output Voltage Waveform - Machine Loaded................................................................F-23

Abnormal Output Voltage Waveform - Machine Loaded One Output SCR Not Functioning.....F-24

Abnormal Open Circuit Voltage Output Capacitor Bank Not Functioning..................................F-25

Typical SCR Gate Voltage Waveform ........................................................................................F-26

Replacement Procedures

Control PC Board Removal and Replacement...........................................................................F-27

Wire Drive Assembly Removal and Replacement......................................................................F-29

SCR Output Rectifier Removal and Replacement.....................................................................F-31

Capacitor Bank Removal and Replacement ..............................................................................F-33

Main Transformer Removal and Replacement...........................................................................F-35

Fan Motor and Fan Removal and Replacement........................................................................F-37

Retest After Repair .....................................................................................................................F-40

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WIRE-MATIC 250

F-1

TROUBLESHOOTING & REPAIR

F-1

HOW TO USE TROUBLESHOOTING GUIDE

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 and
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.

__________________________________________________________________________

This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos­sible symptoms that the machine may exhib­it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob­lems, wire feeding problems, and welding
problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con­tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with­out removing the case wrap-around cover.

Step 3. RECOMMENDED COURSE OF
ACTION

The last column labeled “Recommended
Course of Action” lists the most likely com­ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com­ponent is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.

All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical trou­bleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.

_____________________________________________________________

WIRE-MATIC 250

F-2

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TROUBLESHOOTING & REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

- Remove the P.C. Board from the static-

WARNING

ELECTRIC SHOCK can kill.
Have an electrician install

and service this equipment.
T urn the input power OFF at
the fuse box before work­ing on equipment. Do not
touch electrically hot parts.

_______________________________

CAUTION: Sometimes machine failures

appear to be due to PC board failures. These
problems can sometimes be traced to poor
electrical connections. To avoid problems
when troubleshooting and replacing PC
boards, please use the following procedure:

1. Determine to the best of your technical abil­ity that the PC board is the most likely com­ponent causing the failure symptom.

2. Check for loose connections at the PC
board to assure that the PC board is proper­ly connected.

3. If the problem persists, replace the suspect
PC board using standard practices to avoid
static electrical damage and electrical
shock. Read the warning inside the static
resistant bag and perform the following pro-

cedures:

P.C. Board can be dam­aged by static electricity.

- Remove your body’s stat­ic charge before opening

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

Reusable
Container
Do Not Destroy

ment frame. Keep touching the frame to pre­vent static build-up. Be sure not to touch any
electrically live parts at the same time.

- Tools which come in contact with the P.C.

Board must be either conductive, anti-static or
static-dissipative.

the static-shielding bag.
Wear an anti-static wrist
strap. For safety, use a 1
Meg ohm resistive cord
connected to a grounded
part of the equipment
frame.

- If you don’t have a wrist
strap, touch an unpainted,
grounded, part of the equip-

WIRE-MATIC 250

shielding bag and place it directly into the
equipment. Don’t set the P.C. Board on or
near paper, plastic or cloth which could have a
static charge. If the P.C. Board can’t be
installed immediately, put it back in the static­shielding bag.

- If the P.C. Board uses protective shorting
jumpers, don’t remove them until installation is
complete.

- If you return a P.C. Board to The Lincoln
Electric Company for credit, it must be in the
static-shielding bag. This will prevent further
damage and allow proper failure analysis.

4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.

NOTE: It is desirable to have a spare (known
good) PC board available for PC board trou­bleshooting.

NOTE: Allow the machine to heat up so that
all electrical components can reach their oper­ating temperature.

5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.

a. If the original problem does not reappear

by substituting the original board, then
the PC board was not the problem.
Continue to look for bad connections in
the control wiring harness, junction
blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then
the PC board was the problem. Reinstall
the replacement PC board and test the
machine.

6. Always indicate that this procedure was fol­lowed when warranty reports are to be sub­mitted.

NOTE: Following this procedure and writing
on the warranty report, “INSTALLED AND
SWITCHED PC BOARDS TO VERIFY PROB­LEM,” will help avoid denial of legitimate PC
board warranty claims.

F-2

F-3

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-3

PROBLEMS

(SYMPTOMS)

Major Physical or Electrical Damage is Evident

Machine is dead- No Open Circuit Voltage output and No Wire Feed when gun trigger is pulled.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

OUTPUT PROBLEMS

1. Contact your local Lincoln
Electric Authorized Field
Service Facility.

1. Make certain that the input
power switch is in the "ON" posi­tion.

2. Check the input voltage at the
machine. Input voltage must
match the rating plate and the
reconnect panel.

3. Blown or missing fuses in the
input line.

4. The thermostats may be open
due to machine overheating. If
machine operates normally after
a cooling off period then check
for proper fan operation and
ventilation. Make certain that
the machine's duty cycle is not
being exceeded.

RECOMMENDED

COURSE OF ACTION

1. Contact The Lincoln Electric
Service Dept. [phone] or
1-800-833-9353 (WELD)

1. Check input power switch (S1).
It may be faulty.

2. Check for lose or broken wires
at the reconnect panel.

3. Perform

Test

4. Check the thermostats and
associated leads for loose or
broken connections. See wiring
diagram.

5. The control board may be faulty .
Replace.

Main Transformer

.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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5. Check the trigger circuit. Leads
#324 to #325 should have conti­nuity (zero ohms) when the gun
trigger is pulled. If not then the
gun may be faulty - replace.

CAUTION

WIRE-MATIC 250

F-4

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-4

PROBLEMS

(SYMPTOMS)

No Open Circuit Voltage output but
wire feeds normally when gun trig­ger is pulled.

Wire feeds but welding output is low
causing wire to "stub". Welds are
"cold". Machine cannot obtain full
rated output of 200 amps at 28 volts.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

OUTPUT PROBLEMS

1. Check the input voltage at the
machine. Input voltage must
match the rating plate and the
reconnect panel.

2. The gun may be faulty. Check
or replace.

1. Make sure that the proper wire
and procedures are being used.

2. Check gun and work cable for
loose or faulty connections.

RECOMMENDED

COURSE OF ACTION

1. Check for loose or broken con­nections at the output terminals,
the choke, the capacitor bank
and all heavy current carrying
leads.

2. Make sure that the transformer
secondary leads are securely
connected to the SCR Rectifier
Assembly.

3. Perform the

Assembly Test

4. The control board may be faulty

- Replace.

1. Check for loose or faulty con­nections of the heavy current
carrying leads.

2. The output capacitor bank may
be faulty. Check for loose con­nections at the capacitors. Also
check for leaky capacitors.
Replace if necessary.

WARNING: The liquid elec­trolyte in these capacitors is
toxic. Avoid contact with any
portion of your body.

SCR Rectifier

.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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CAUTION

WIRE-MATIC 250

3. Perform the

Assembly Test

4. Perform the

Test

.

5. The control board may be faulty .
Replace.

SCR Rectifier

.

Main Transformer

F-5

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-5

PROBLEMS

(SYMPTOMS)

The output voltage and wire feed is present continuously or pulsing when gun trigger is NOT activated.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

OUTPUT PROBLEMS

1. Remove the gun. If the problem
is resolved the gun trigger circuit
is faulty. Repair or replace.

2. If the problem is not resolved
then contact your Local Lincoln
Electric Authorized Field
Service Facility.

RECOMMENDED

COURSE OF ACTION

1. Check the machine's internal
trigger leads for grounds or
shorts. See Wiring Diagram.

2. The control board may be faulty .
Replace.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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CAUTION

WIRE-MATIC 250

F-6

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-6

PROBLEMS

(SYMPTOMS)

No control of arc voltage. Wire feed­ing is normal.

There is no gas flow when gun trig­ger is pulled. Wire feeds and weld
voltage is present.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

FUNCTION PROBLEMS

1. The Arc Voltage Control poten­tiometer may be dirty. Rotate
several times and check if prob­lem is resolved.

1. Check gas source and hoses for
leaks or kinks.

RECOMMENDED

COURSE OF ACTION

1. The Arc Voltage Control poten­tiometer may be faulty . Check or
replace. See Wiring Diagram.

2. Perform the

Assembly Test

3. The control board may be faulty.
Replace.

1. Check the gas solenoid by dis­connecting it from the control
board (Plug J8) and applying a
12 VDC external supply to the
gas solenoid. If the solenoid
does NOT activate then it may
be faulty. Replace.

2. The control broad may be faulty.
Replace.

SCR Rectifier

.

The machine stops feeding wire while welding.

1. Check for mechanical restric­tions in the wire feeding path.
The gun may be clogged.

1. Check the motor armature cur­rent. Normal armature current is

1.75 amps maximum. If the
motor armature current is normal
the control board may be faulty.
Replace.

2. If the motor armature current is
high (2 to 2.5 amps) and there
are NO restrictions in the wire
feeding path then the motor or
gear box may be defective.
Replace.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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CAUTION

WIRE-MATIC 250

F-7

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-7

PROBLEMS

(SYMPTOMS)

No control of wire feed speed.
Other machine functions are nor­mal.

There is no wire feed when gun trig­ger is pulled. Normal open circuit
voltage is present.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

WIRE FEEDING PROBLEMS

1. The wire feed speed control
may be dirty. Rotate several
times and check if problem is
resolved.

1. If the drive rolls are turning then
check for a mechanical restric­tion in the wire feed path.

2. The gun liner may be clogged.
Check or Replace.

3. If the drive rolls are NOT turning
when the gun trigger is pulled
then contact your local Lincoln
Electric Authorized Field
Service Facility.

RECOMMENDED

COURSE OF ACTION

1. The Wire Speed Control poten­tiometer may be faulty. Check
or replace. See Wiring
Diagram.

2. Perform the

and Tach Feedback test

3. The control board may be faulty .
Replace.

1. Perform the

and Tach Feedback Test

2. The Wire Feed Control poten­tiometer may be faulty. Check
or replace. See Wiring
Diagram.

3. The control board may be faulty .
Replace.

Wire Drive Motor

.

Wire Drive Motor

.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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CAUTION

WIRE-MATIC 250

F-8

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-8

PROBLEMS

(SYMPTOMS)

The arc is unstable and or "hunting".

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

WELDING PROBLEMS

1. Check for worn or melted con­tact tip.

2. Check for loose or faulty con­nections on the work and elec­trode cables.

3. Make sure electrode polarity is
correct or welding process
being used.

4. Check for rusty or dirty wire.

5. Make sure machine settings
and gas are correct for process
being used.

RECOMMENDED

COURSE OF ACTION

1. Check for loose connections at
the output terminals, the choke,
the capacitor bank and all heavy
current carrying leads.

2. Make sure that the transformer
secondary leads are securely
connected to the SCR Rectifier
Assembly.

3. The output capacitor bank may
be faulty. Check for loose con­nections at the capacitors. Also
check for leaky capacitors.
Replace if necessary.

WARNING: The liquid elec­trolyte in these capacitors is
toxic. Avoid contact with any
portion of your body.

Weld bead is narrow or ropy. May
have porosity with electrode stub­bing into plate.

The contact tip seizes in the gas dif­fuser.

1. Make sure the weld procedure
and electrode polarity is correct
for the process being used.

2. Make sure shielding gas is cor­rect and flow is proper.

3. Make sure the weld joint is not
"contaminated".

1. The tip being over heated due to
excessive current and/or high
duty cycle welding.

2. A light application of high tem­perature antisieze lubricant
(such as Lincoln E2607
Graphite Grease) may be
applied to the contact tip
threads.

4. The control board may be faulty .
Replace

1. The output capacitor bank may
be faulty. Check for loose con­nections at the capacitors. Also
check for leaky capacitors.
Replace if necessary.

WARNING: The liquid elec­trolyte in these capacitors is
toxic. Avoid contact with any
portion of your body.

2. The control board may be faulty .
Replace.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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CAUTION

WIRE-MATIC 250

F-9

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-9

PROBLEMS

(SYMPTOMS)

The welding arc is variable and slug­gish.

The arc striking is poor.

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

WELDING PROBLEMS

1. Check the welding cable con­nections for loose or faulty con­nections.

2. Make sure the wire feed speed,
voltage, and shielding gas are
correct for the process being
used.

1. Check the welding cable con­nections for loose or faulty con­nections.

2. Make sure the wire feed speed,
voltage, and shielding gas are
correct for the process being
used.

RECOMMENDED

COURSE OF ACTION

1. Perform the

Bridge Test.

2. The control board may be faulty .
Replace.

1. The control board may be faulty .
Replace.

Output Rectifier

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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CAUTION

WIRE-MATIC 250

F-10

TROUBLESHOOTING & REPAIR

F-10

MAIN TRANSFORMER TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

TEST DESCRIPTION

This test will determine if the correct voltages are being:
a. Applied to the primary windings of the Main Transformer.
b. Induced on the secondary and auxiliary windings of the main transformer.

MATERIALS NEEDED

5/16" Nut Driver.
Volt-Ohm Meter.

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WIRE-MATIC 250

F-11

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER TEST (CONTINUED)

TEST PROCEDURE

WARNING

The ON/OFF POWER SWITCH will be
"hot" during these tests.

__________________________

NOTE: Secondary voltages will vary
proportionably with the primary input
voltage.

1. Disconnect the main input power
supply to the machine.

2. Remove the Case Top and Side
Panels with a 5/16" nut driver.

3. Locate Plug J3 and Plug J6 on the
G2332 Control PC Board.

F-11

NOTE: The location of Plugs may vary
depending on the machine code.

WM-250 CONTROL

G2332

J1

J7

J10

J2

J4

J3

J9

#202

(1J3)

#204A (2J3)

#203

(3J3)

#206
(4J6)

#209

(7J6)

J6

#208

(16J6)

J5

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FIGURE F.1 - G2332 Control PC
Board Main Transformer Test Points.

WIRE-MATIC 250

F-12

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER TEST (CONTINUED)

F-12

4. Locate the following leads on Plug
J3:
G2332:

LOCATION

TO

PLUG

1J3
3J3
2J3

EXPECTED

VOL TAGE

LEAD

#202
#203

#204 A

5. Connect main input power to the
machine.

6. Turn the Wire-Matic 250 ON/OFF
POWER SWITCH to ON.

7. Make the following voltage tests at
Plug J3.

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.

G2332:

FROM

LEAD

LEAD

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.
G2332:

FROM

LEAD

#208

(16J6)

#208

(16J6)

#209
(7J6)

c. If any of the voltages tested are

incorrect, check for loose or bro­ken leads between the test
points and the main transformer.

d. If ALL the voltages tested are

incorrect or missing, go to Step

12.

TO

LEAD

#209
(7J6)

#206
(4J6)

#206
(4J6)

EXPECTED

VOLTAGE

60 VAC

30 VAC

30 VAC

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#202

(1J3)
#202

(1J3)
#203

(3J3)

8. Turn OFF the machine

9. Locate the following leads on Plug
J6 on the G2332 Control PC Board.
G2332:

LEAD

#206
#208
#209

10. Turn ON the machine.

11. Make the following voltage tests at
Plug J6 on the G2332 Control PC
Board.

#203
(3J3)

#204 A

(2J3)

#204 A

(2J3)

LOCATION

30 VAC

15 VAC

15 VAC

PLUG

4J6

16J6

7J6

WIRE-MATIC 250

12. Test for correct nameplate input volt­age between the H1 lead at the
ON/OFF POWER SWITCH to H2 or
H3 (H5 if connected for 575 VAC) at
the reconnect panel. Voltage tested
will vary depending on Input Voltage
Connection. See wiring diagram for
test point locations.

a. If the voltage test is incorrect,

- check for loose or broken
leads between the reconnect
panel and the ON/OFF POWER
SWITCH.

- test the ON/OFF POWER
SWITCH for proper operation.

b. If the correct nameplate voltage

is being applied to the main
transformer and one or more of
the secondary voltages are
missing or are incorrect, the
main transformer may be faulty.
Replace.

F-13

TROUBLESHOOTING & REPAIR

F-13

STATIC SCR RECTIFIER ASSEMBLY TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

TEST DESCRIPTION

This test is used to quickly determine if an SCR or diode is shorted or "leaky." See the
Machine Waveform Section in this manual for normal and abnormal output waveforms.

MATERIALS NEEDED

Analog Ohmmeter (Multimeter).
Wire-Matic 250 wiring diagrams (See Electrical Diagrams Section of this Manual).
5/16" Nut Driver.
1/2" Open end or socket wrench.

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WIRE-MATIC 250

F-14

TROUBLESHOOTING & REPAIR

STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED)

TEST PROCEDURE

1. Disconnect main AC input power to
the machine.

2. Disconnect Plugs J3 and J6 from
the G2332 Control Board. This
electrically isolates the SCR bridge
assembly. See Figure F.2.

F-14

WM-250 CONTROL

J1

J7

J3

G2332

J9

J4

J10

J2

FIGURE F.2 - Remove Plugs J3 and J6
to Perform Static SCR Rectifier
Assembly Test.

3. Verify that the capacitors have com­pletely discharged with an Analog
Volt-Ohm meter.

REMOVE
PLUGS J3 & J6

J6

J5

LEADS
X2 AND X3

NEGATIVE
CAPACITOR
BANK
BUSS BAR

FIGURE F.3 - Location of Leads X2
and X3.

5. Separate leads X2 and X3 from the
negative capacitor bank buss bar.
Be sure there is no electrical con­tact. See Figure F.3.

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4. Disconnect leads X2 and X3 from
the negative capacitor bank using a
1/2" open end wrench. See Figure
F.3.

WIRE-MATIC 250

F-15

TROUBLESHOOTING & REPAIR

STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED)

NOTE: DO NOT DISASSEMBLE THE
SCR RECTIFIER HEAT SINK ASSEM­BLY.

6. Test for high or infinite resistance
from the anode to the cathode of
SCR 1. See Figure F.4. Use an
analog ohmmeter (Multimeter).

F-15

FIGURE F.4 - SCR 1 Test Points.

7. Test for high or infinite resistance
from the cathode to the anode of
SCR 1 by reversing the meter leads.
See Figure F.4.

a. If a high or infinite resistance is

indicated for both tests 6 and 7,
the SCR 1 is not “shorted”.

b. If a low resistance is indicated in

either tests 6 or 7, the SCR is
faulty. Replace SCR Assembly.

8. Repeat Steps #7 to test SCR 2.

9. Reconnect leads X2 and X3.

10. Reconnect Plugs J3 and J6.

11. If this test did not identify the prob­lem or to further test the SCR, go to
the Active SCR Test.

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WIRE-MATIC 250

F-16

TROUBLESHOOTING & REPAIR

F-16

ACTIVE SCR RECTIFIER ASSEMBLY TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

TEST DESCRIPTION

The Active SCR Test will determine if the device is able to be gated ON and conduct current
from anode to cathode.

MATERIALS NEEDED

An SCR Tester as specified in this procedure.
Wire-Matic 250 wiring diagrams (See Electrical Diagrams Section of this Manual).
SCR Heat Sink Assembly Drawings.

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WIRE-MATIC 250

F-17

TROUBLESHOOTING & REPAIR

ACTIVE SCR RECTIFIER ASSEMBLY TEST (CONTINUED)

TEST PROCEDURE

1. Disconnect main AC input power to
the machine.

2. Disconnect Molex Plugs J3 and J6
from the G2332 Control Board.
See Figure F.5.

WM-250 CONTROL

G2332

J1

J10

J7

FIGURE F.5 - Control Board Molex
Plug Locations for G2332 PC Control
Board.

3. Verify that the capacitors have com­pletely discharged with an Analog
Volt-Ohm meter.

4. Disconnect leads X2 and X3 from
the negative capacitor bank using a
1/2" open end wrench.
See Figure F. 6.

J3

J9

J4

J5

J2

F-17

LEADS
X2 AND X3

NEGATIVE
CAPACITOR
BANK

J6

FIGURE F.6 - Location of Leads X2
and X3.

5. Separate leads X2 and X3 from the
negative capacitor bank buss bar.
Be sure there is no electrical con­tact. See Figure F.6.

NOTE: DO NOT DISASSEMBLE THE
SCR RECTIFIER HEAT SINK ASSEM­BLY.

6. Construct the circuit shown in Figure
F.7. One 6-volt lantern battery can
be used. R1 and R2 resistor values
are ±10%. Set voltmeter scale low,
at approximately 0-5 volts or 5-10
volts.

a. Test the voltage level of the bat-

tery. Short leads (A) and (C).
Close switch SW-1. Battery
voltage should be 4.5 volts or
higher. If lower, replace the bat­tery.

BUSS BAR

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WIRE-MATIC 250

F-18

TROUBLESHOOTING & REPAIR

ACTIVE SCR RECTIFIER ASSEMBLY TEST (CONTINUED)

F-18

7. Connect the Tester to the SCR 1 as
shown in Figure F.7.

a. Connect Tester lead (A) to the

anode.

b. Connect Tester lead (C) to the

cathode.

c. Connect Tester lead (G) to the

gate.

10. Close or keep closed switch SW-1.

11. Close switch SW-2 for 2 seconds
and release and read meter.

a. If the voltage is 3 - 6 volts while

the switch is closed and after
the switch is open, the SCR is
functioning.

b. If the voltages is 3-6 volts only

when the switch is closed or
there is no voltage when the
switch is closed, the SCR is
defective.

NOTE: Be sure battery is functioning
properly. A low battery can affect the
results of the test. Repeat Battery Test
Procedure in Step 6 if needed.

12. Open switch SW-1.

13. Reconnect the Tester leads. See
Figure F.7.

FIGURE F.7 - SCR Tester Circuit and
SCR connections.

8. Close switch SW-1.
NOTE: Switch SW-2 should be open.

9. Read meter for zero voltage.

a. Connect Tester lead (A) to the

cathode.

b. Connect Tester lead (C) to the

anode.

c. Disconnect Test lead (G) from

the gate.

14. Close switch SW-1.

15. Read meter for zero voltage.
a. If the voltage is zero, the SCR is

functioning.

b. If the voltage is higher than

zero, the SCR is shorted.

16. Perform the Active Test Procedure
outlined in Steps 5-13 for SCR 2.

17. Replace all SCR assemblies that do
not pass the above tests.

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a. If the voltage reading is higher

than zero, the SCR is shorted.

WIRE-MATIC 250

18. Replace all Molex Plugs onto the
Control Board and connect leads X2
and X3.

F-19

TROUBLESHOOTING & REPAIR

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

F-19

TEST DESCRIPTION

This test will determine if the wire drive motor and voltage feedback circuit are functioning
properly.

MATERIALS NEEDED

5/16" Nut Driver.
Volt-Ohmmeter.

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WIRE-MATIC 250

F-20

TROUBLESHOOTING & REPAIR

F-20

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (CONTINUED)

TEST PROCEDURE

NOTE: POLARITY MUST BE
OBSERVED FOR THESE TESTS.

Test for Correct Wire Drive Motor
Armature Voltage

1. Disconnect main input power to the
machine.

2. Remove the Case Top and Side
Panels using a 5/16" nut driver.

3. Locate Plug J5 on the G2332
Control Board. See Figure F.8.

WM-250 CONTROL

G2332

J1

J7

J10

FIGURE F.8 - Plug J5 Location on
G2332 PC Control Board.

J2

J4

J3

J9

#539
(8J5)

#541 (NEGATIVE)

J5

#515B

(3J5)

J6

(9J5)

#555
(1J5)

#206B

(2J5)

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WIRE-MATIC 250

F-21

TROUBLESHOOTING & REPAIR

F-21

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (CONTINUED)

4. Test for 2 - 25 VDC between lead
#539 (positive) (8J5) and lead #541
(9J5) (negative) to determine if the
correct armature voltage is being
supplied. See Figure F.8.

a. Insert probes in to the Molex pin

cavities.

5. Pull the gun trigger.

6. Read meter. Normal DC volts is
from 2 - 25 VDC. VDC varies
depending on wire feed speed.

b. If the leads are okay and 15

VDC is present, the correct volt­age is being received from the
Control Board. Go to Feedback
Test.

c. If the 15 VDC is not present and

the leads are okay, the Control
Board may be faulty. Replace.

Test for Feedback Voltage to the
Control Board

a. If voltage to the wire drive motor

armature is zero, check the
wires between Plug J5 and the
wire drive motor.

b. If the wires are okay and voltage

to the drive motor armature is
zero, the Control Board may be
faulty. Replace.

c. If the correct DC armature volt-

age is present at the wire drive
motor, the motor or motor brush­es may be faulty. Test and/or
replace.

d. If the motor is running at high

speed and the armature voltage
is high and uncontrollable, pro­ceed with the tachometer test.

Test for Supply Voltage to
Tachometer

1. Test for 15 VDC between lead
#515B (positive) (3J5) and lead
#206B (negative) (2J5) . See Figure
F.8 for pin locations.

1. Test for 1.5 - 3.5 VDC between lead
#555 (positive) (1J5) and lead
#206B (negative) (2J5) . See Figure
F.8 for pin locations.

a. Insert probes into Molex pin

cavities.

2. Pull gun trigger.

3. Read meter for 1.5 - 3.5 VDC.
a. If the 1.5 - 3.5 VDC is present,

the tach circuit is sending the
correct feedback signal to the
Control Board.

NOTE: IF THE MOTOR IS NOT RUN­NING, THE FEEDBACK VOL TAGE MAY
BE FROM 0 TO 5 VDC.

b. If the 1.5 - 3.5 VDC is not pre-

sent or not correct, the Control
Board is not receiving the prop­er feedback voltage from the
tach circuit. Check the leads
from the tach circuit to the
Control Board for loose or bro­ken connections.

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a. Insert probes into Molex pin

cavities.

2. Pull gun trigger.

3. Read meter for 15 VDC.
a. If the 15 VDC is present, check

the leads to the tach circuit.

c. If the leads are okay, the Control

Board may be faulty. Replace.

WIRE-MATIC 250

F-22

TROUBLESHOOTING & REPAIR

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

F-22

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This is a typical DC output voltage wave­form generated from a properly operating
machine. Note that each vertical division
represents 20 volts and that each horizontal
division represents 2 milliseconds in time.

Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-)
probe to work.

WIRE-MATIC 250

SCOPE SETTINGS

Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.

Horizontal Sweep . . . . . . . . . .2 ms/Div.

Coupling . . . . . . . . . . . . . . . . . . . . .DC.

Trigger . . . . . . . . . . . . . . . . . . .Internal.

F-23

TROUBLESHOOTING & REPAIR

TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

F-23

MACHINE LOADED TO 250 AMPS AT 26 VDC

This is a typical DC output voltage wave­form generated from a properly operating
machine. Note that each vertical division
represents 20 volts and that each horizontal
division represents 5 milliseconds in time.
The machine was loaded with a resistance
grid bank.

Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-)
probe to work.

SCOPE SETTINGS

Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.

Horizontal Sweep . . . . . . . . . .5 ms/Div.

Coupling . . . . . . . . . . . . . . . . . . . . .DC.

Trigger . . . . . . . . . . . . . . . . . . .Internal.

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WIRE-MATIC 250

F-24

TROUBLESHOOTING & REPAIR

ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

ONE OUTPUT SCR NOT FUNCTIONING

F-24

MACHINE LOADED TO 220 AMPS AT 22 VDC

This is NOT a typical DC output voltage
waveform. One output SCR is not function­ing. Note the increased ripple content. One
SCR gate was disconnected to simulate an
open or non-functioning output SCR. Each
vertical division represents 20 volts and
each horizontal division represents 5 mil­liseconds in time. The machine was loaded
with a resistance grid bank.

Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-)
probe to work.

SCOPE SETTINGS

Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.

Horizontal Sweep . . . . . . . . . .5 ms/Div.

Coupling . . . . . . . . . . . . . . . . . . . . .DC.

Trigger . . . . . . . . . . . . . . . . . . .Internal.

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WIRE-MATIC 250

F-25

TROUBLESHOOTING & REPAIR

ABNORMAL OPEN CIRCUIT VOLTAGE

OUTPUT CAPACITOR BANK NOT FUNCTIONING

F-25

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This is NOT the typical DC output voltage
waveform. The output capacitors are not
functioning. Note the lack of “filtering” in the
output waveform. The output capacitor
bank was disconnected. Each vertical divi­sion represents 20 volts and each horizontal
division represents 5 milliseconds in time.

Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-)
probe to work.

WIRE-MATIC 250

SCOPE SETTINGS

Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.

Horizontal Sweep . . . . . . . . . .5 ms/Div.

Coupling . . . . . . . . . . . . . . . . . . . . .DC.

Trigger . . . . . . . . . . . . . . . . . . .Internal.

F-26

TROUBLESHOOTING & REPAIR

TYPICAL SCR GATE VOLTAGE WAVEFORM

F-26

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This is a typical SCR gate pulse voltage
waveform. The machine was in an open cir­cuit condition (no load) and operating prop­erly. Note that each vertical division repre­sents 2 volts and each horizontal division
represents 5 milliseconds in time.

Note: Scope probes connected at Plug J3
on the control board. The (+) probe to lead
G2, and the (-) probe to lead 204.

WIRE-MATIC 250

SCOPE SETTINGS

Volts/Div . . . . . . . . . . . . . . . . . .2 V/Div.

Horizontal Sweep . . . . . . . . . .5 ms/Div.

Coupling . . . . . . . . . . . . . . . . . . . . .DC.

Trigger . . . . . . . . . . . . . . . . . . .Internal.

F-27

TROUBLESHOOTING & REPAIR

CONTROL PC BOARD REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

F-27

CAUTION

Printed Circuit Boards can be damaged by static electricity. Follow static handling
guidelines detailed in “PC Board Troubleshooting Procedures” at the beginning of
this chapter.

_____________________________________________________________

REMOVAL AND REPLACEMENT PROCEDURE

MATERIALS NEEDED

5/16" Nutdriver.
Phillips head screwdriver.
Static electricity grounding strap.

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WIRE-MATIC 250

F-28

TROUBLESHOOTING & REPAIR

CONTROL PC BOARD REMOVAL AND REPLACEMENT (CONTINUED)

F-28

REMOVAL AND REPLACE­MENT PROCEDURE

1. Disconnect main input power the

2. Remove the Case Top and Side

3. Disconnect all wiring harness plugs

WM-250 CONTROL

G2332

4. Remove the eight Phillips Head
mounting screws using a Phillips
Head screwdriver. See Figure F.10.

machine.

Panels using 5/16" nut driver.

and Molex Plugs connected to the
Control Board. See Figure F.9.

J3

J9

J6

J4

J5

FIGURE F.10 - Control Board

J1

J7

J10

J2

Mounting Screw Locations may
vary with different Code
Machines.

FIGURE F.9 - Wiring Harness and
Molex Plug Locations.

5. Lift the Control Board straight up
and out from the machine.

6. Replace all mounting screws and
wiring connections when
installing the Control Board.

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WIRE-MATIC 250

F-29

TROUBLESHOOTING & REPAIR

WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

F-29

MATERIALS NEEDED

Large slot head screwdriver.
5/16" Nut Driver.
Small slot head screwdriver.

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WIRE-MATIC 250

F-30

TROUBLESHOOTING & REPAIR

WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT (CONTINUED)

PROCEDURE

1. Disconnect main input power to the
machine.

2. Remove the Case Top and Side
Panels.

3. Remove the large mounting screw
with a large slot head screwdriver
located in front of the drive roll. See
Figure F.11.

a. Note the placement of the insu-

lators and washers for replace­ment.

F-30

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FIGURE F.11 - Wire Drive Assembly
Removal

4. Using a small slot head screw driver,
loosen the set screw holding the out
going guide tube into the drive roll
assembly. Carefully slide out the
wire drive assembly.

5. Disconnect the six pin plug from the
vertical baffle connector.

WIRE-MATIC 250

a. The six pin plug contains the

wire feed drive motor wires.

6. Remove carefully the drive motor
and drive roll assembly.

F-31

TROUBLESHOOTING & REPAIR

SCR OUTPUT RECTIFIER REMOVAL & REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

F-31

MATERIALS NEEDED

5/16" Nut driver.
1/2" Open end wrench.
1/2" Socket wrench, universal tool, and extension.
3/8" Open end wrench.
Slot head screwdriver.
Wire cutters.

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WIRE-MATIC 250

F-32

TROUBLESHOOTING & REPAIR

SCR OUTPUT RECTIFIER REMOVAL & REPLACEMENT (CONTINUED)

F-32

PROCEDURE

1. Disconnect lead #208 and
Transformer Lead X1 from the heat
sink on the left side of the machine
(facing the front) using a 1/2" socket
wrench. See Figure F.12.

a. Thin lead is always on the out-

board side of the connection.

4. Cut the SCR gate leads G1 and G2
(see wire markers and wiring dia­gram) using wire cutters.

a. The easiest access to these

leads is from the right side of the
machine.

b. Cut any necessary cable ties.

5. Remove the four screws holding the
SCR Assembly to the floor of the
machine using a 5/16" nut driver.

6. Pivot the SCR Assembly counter­clockwise to provide access to the
right side heat sink.
See Figure F.14.

FIGURE F.12 - Heat Sink lead discon­nection.

2. Disconnect lead #204 and heavy
lead from the middle heat sink with a
1/2" socket wrench and 1/2" open
end wrench. See Figure F.13.

3. Remove the diode lead from the
negative capacitor band buss bar on
the right side of the machine using a
slot head screwdriver and 3/8" open
end wrench.

FIGURE F.14 - Heat Sink Lead
Disconnection

7. Remove lead #209 and Transformer
Lead X4 from the right side heat sink
using a 1/2" socket wrench and 1/2"
open end wrench.

8. Clear the leads and carefully
remove the SCR Rectifier Assembly.

NOTE: When installing the SCR
Rectifier Assembly, apply a thin coating
of Dow Corning #340 Compound to the
electrical connections.

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FIGURE F.13 - Heat Sink lead discon­nection.

WIRE-MATIC 250

F-33

TROUBLESHOOTING & REPAIR

CAPACITOR BANK REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

F-33

WARNING

THE LIQUID ELECTRODE IN THE CAPACITORS IS T OXIC. DO NOTTOUCH THE CAPAC­ITORS WITH ANY PART OF YOUR BODY.

_____________________________________________________________

MATERIALS NEEDED

5/16" Nut driver.
5/16" Socket wrench, extension, and universal tool.
1/2" Open end wrench.
3/8" Open end wrench.
Slot head screwdriver.
Wiring diagram.

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WIRE-MATIC 250

F-34

TROUBLESHOOTING & REPAIR

CAPACITOR BANK REMOVAL AND REPLACEMENT (CONTINUED)

F-34

PROCEDURE

See Figure F.15 for location of Capacitor
Bank Removal and Replacement com­ponents.

6. Remove the #204 lead from the pos­itive buss bar.

7. Remove the shunt from the negative
capacitor bank buss bar using a 1/2"
socket wrench with a universal tool
adapter.

a. Two people may be required to

remove the shunt. One person
may have to reach through from
the left side of the machine to
keep the bolt in position while
the other person loosens the
nut.

8. Remove the two screws holding the
capacitor bank to the floor of the
machine using a 5/16" nut driver.

9. Clear the leads and carefully
remove the capacitor bank assem­bly from the machine.

FIGURE F.15 - Location of Capacitor
Bank Removal and Replacement
Components.

1. Disconnect main input power to the
machine.

2. Test that the capacitors are dis­charged using a volt ohmmeter.
Polarity must be observed.

3. Remove the two transformer sec­ondary leads (X2 and X3) for the
negative capacitor bank buss bar
using two 1/2" open end wrenches.

4. Remove the output choke lead and
the heavy lead extending from the
SCR Rectifier Assembly to the posi­tive capacitor bank buss bar using a
1/2" open end wrench.

5. Remove lead #206 and the D1
diode lead from the negative capac­itor bank buss bar using a slot head
screwdriver and 3/8" open end
wrench.

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WIRE-MATIC 250

F-35

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

F-35

MATERIALS NEEDED

5/16" Nut Driver.
1/2" Open end wrench.
3/8" Open end wrench.
1/2" Socket wrench, extender, universal adapter.
Wire cutters.

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WIRE-MATIC 250

F-36

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER REMOVAL AND REPLACEMENT (CONTINUED)

F-36

PROCEDURE

1. Disconnect main input power to the
machine.

2. Remove the Case Top and Side
Panels.

3. Perform the Capacitor Bank
Removal Procedure.

4. Remove lead X1 from the left side
SCR heat sink assembly using a
1/2" socket wrench, extender and
universal adapter.

5. Remove lead X4 from the right side
heat sink assembly using a 1/2"
socket wrench, extender and univer­sal adapter.

6. Disconnect all leads from the recon­nect panel using a 3/8" open end
wrench.

12. Disconnect the positive output lead
at the wire drive motor.

13. Remove the strain relief grommet
through which the positive output
lead passes through the horizontal
baffle of the machine.

14. Pull down on the positive output
lead until it slides out the hole in the
baffle.

15. Carefully remove the main trans­former.

a. Be sure all leads are clear.

7. Disconnect all leads from the
POWER SWITCH.

8. Remove the POWER SWITCH.

9. Label and cut leads #202, #203,
#204A.

a. Cut lead #204A at a point just in

front of the transformer.

b. These leads must be re-spliced

during reassembly.

c. An alternative to cutting these

leads is to remove them from
Molex Plug J3 and pull them
free of any wire bundles.

10. Remove all cable ties, wire mounts,

- and any harness tape that could
get in the way during transformer
removal using wire cutters and
screwdriver.

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Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

11. Remove the four screws mounting
the transformer to the floor of the
machine using a 5/16" nut driver.

WIRE-MATIC 250

F-37

TROUBLESHOOTING & REPAIR

FAN MOTOR AND FAN REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

F-37

MATERIALS NEEDED

3/4" Open end wrench.
1/2" Socket wrench with extension.
Phillips head screwdriver.

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WIRE-MATIC 250

F-38

TROUBLESHOOTING & REPAIR

FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED)

PROCEDURE

See Figure F.16 for fan motor and fan
removal components.

F-38

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FIGURE F.16 - Fan Motor and Fan
Removal Components

1. Remove the Case Back screws.

2. Remove the gas solenoid using a
3/4" open end wrench.

3. Using a 5/16” wrench, remove the 5
screws holding the fan motor mount­ing bracket to the case back.

4. Tilt the Case Back away from the
machine and remove the screws
holding the Case Back to the floor of
the machine using a 1/2" socket
wrench with extension.

WIRE-MATIC 250

5. Loosen the two screws holding the
reconnect panel in place and a slide
the reconnect panel from the frame.

6. Remove the fan blade. Note fan
blade position on motor shaft for ref­erence for replacing fan.

a. Pry the fan blade off the motor.
b. Slide the fan blade off the motor

shaft.

F-39

TROUBLESHOOTING & REPAIR

FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED)

7. Remove the fan motor.
a. Loosen and remove the two

screws from the motor mounting
bracket using a slot head screw
driver.

b. When the motor is free from the

mounting bracket, place it care­fully on the bottom of the
machine.

c. Cut any necessary wire wraps

bundling the motor leads.

d. Remove the leads from the fan

motor.

8. Install the replacement motor in the
reverse order of removal.

F-39

9. Install the fan blade. When
installing the fan blade, the blade is
flush with the end of the motor shaft.

a. Spin the fan to be sure it is free

to rotate.

10. Reassemble the remaining compo­nents in reverse order of removal.

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WIRE-MATIC 250

F-40

TROUBLESHOOTING & REPAIR

RETEST AFTER REPAIR

INPUT IDLE AMPS AND WATTS

OPEN CIRCUIT VOLTAGE

F-40

Maximum Idle WattsMaximum Idle AmpsInput Volts/Hertz

3756.4230/60

10 to 40 VDC

35-40 VDC Strike Voltage

WIRE SPEED RANGE

50 - 600 IPM (1.27 - 15.2 m/minute)

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WIRE-MATIC 250

NOTES

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WIRE-MATIC 250

TABLE OF CONTENTS

- ELECTRICAL DIAGRAMS SECTION -

Electrical Diagram Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G

Wiring Diagram (230/460/575) Code 10004 . . . . . . . . . . . . . . . . . . . . . . G-2

Wiring Diagram (230/460/575) Code 10003 . . . . . . . . . . . . . . . . . . . . . . G-3

Wiring Diagram (208/230) Code 9800 . . . . . . . . . . . . . . . . . . . . . . . . . . G-4

Wiring Diagram (208/230) Code 9799 . . . . . . . . . . . . . . . . . . . . . . . . . . G-5

Control PC Board (G2332) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . G-6

Control PC Board (G2332) Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7

G-1G-1

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

WIRE-MATIC 250

NOTES

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

WIRE-MATIC 250

G-2

Wiring Diagram (230/460/575) Code 10004

ELECTRICAL DIAGRAMS

G-2

OPTIONAL
TIMER
BOARD

J14

1

2345678

260

262

261

263

265

WIRE SPEED

R3

ARC VOLTAGE

R4

POWER-ON
INDICATOR

TO
WORK

*

}

264

266

251

252

256

253

*

260
262
261
263
265
264
266

267

254

+

­255

GUN
TRIGGER

2

1

267

254
252
253
255
251
256

325

2

324

4

1
2
3
4

5
6
7
8

1

2

3

4

5

6

7
8

9
10

1
2
3
4
5
6

J1

}

J2

SPI TEST

}

PLUG

J10

}

(J7)

*

1234

SCI TEST
PLUG

*

*

(J5)

*

515B

555
539

206B

541

N.A.

N.B.

207

206

R.F. FILTER

X5

202

X6

204A

X7

203

X1

C1 THRU C4
30,000 MFD
50V

204

X2

X3

X4

C4

L1 L2

H1

H4

LINE

SWITCH

S1

T1

H1
P2
H2
H5

H3

SHUNT

H1

205

206S

H4

POWER TRANSFORMER

+

-

C1 C2

++++

C3

CONTROL BOARD

12345678

515

325A

555

1

206B

2

515B

3
4

325

5
6

324

7

539

8
9

541

10
11
12
13
14

1

515B

2

555
539

3
4

206B

5
6

541

MOTOR/

GEARBOX

D1

300V

85A

P.M.

209

206

204

*

(J4)

495

542

543

541A

324A

206A

GND

W

T
A
C
H

B

320

THERMOSTAT

S3 S4

208

G1

SCR 1
250V
470A

SCR HEATSINK
ASBLY

SCR 2
250V
470A

G2

OUTPUT

CHOKE

R
U
B

207

206
207
GND
209

205

206S

325A

320
208

N.C.

R1

541

515B

555

206B

539

1
2
3
4
5
6

7
8
9

10
11
12
13
14
15
16

328

N.D.

GND.

15 OHMS

100 W

(J8)

(J9)

123456

*

(J6)

THERMOSTAT

L1

RECONNECT PANEL

G

T1

N.E.

*

*

1

202

204A

2

203

3
4

G1

5

204

6

G2

7
8

9
10
11
12

325A

L2

42

13

FAN

MOTORS

R2

2.5K
10W

1
2
3
4

5

H5

H2

H4

H3

H1

N.C.

T2

(J3)

*

H2‰z·^ 63/64 ˆ

(SHOWN CONNECTED

FOR 230 VOLT.)

P2

P1 P2

S2

THERMOSTAT

TO

SPOOL GUN

OPTION

TO SINGLE PHASE

SUPPLY LINE

L1

L2

GND

TO GROUND PER

NATIONAL ELECTRICAL

CODE

GAS

SOLENOID

J1

14

J4

J14

58

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE:

B - BLACK
W - WHITE
R - RED
U - BLUE

INDICATES CONNECTOR CAVITY NO.

*

R.F. CHOKE AS'BLY.

NOTES

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE

CURRENT AND DUTY CYCLE OF IMMEDIATE AND
FUTURE APPLICATIONS.

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.

N.C. THERMOSTATS MOUNTED ON CHOKE COIL

S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO

POWER TRANSFORMER.
N.D. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET
N.E. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.

CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P.C. BOARD)

J2

1

J5

8

J7
J8

1

6

12

34

5

10

7

J6

14

13

J9

J10

46

.

1

J3

712

1

9

6

8

16

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

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2-5-93

L9077

WIRE-MATIC 250

G-3

Wiring Diagram (230/460/575) Code 10003

ELECTRICAL DIAGRAMS

G-3

OPTIONAL
TIMER
BOARD

J14

1

2345678

260

262

261

263

265

WIRE SPEED

R3

ARC VOLTAGE

R4

POWER-ON
INDICATOR

TO
WORK

*

}

264

266

251

252

256

253

H4

*

202

204A

203

G1

204

G2

325A

LOW V.
JUMPER

MOTORS

*

FAN

1
2
3
4

GAS

SOLENOID

TO

SPOOL GUN

1
2
3
4
5
6

(J3)

7

*

8
9

10

11
12

OPTION

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE:

B - BLACK
W - WHITE
R - RED
U - BLUE

INDICATES CONNECTOR CAVITY NO.

*

R.F. CHOKE AS'BLY.

NOTES

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE

CURRENT AND DUTY CYCLE OF IMMEDIATE AND
FUTURE APPLICATIONS.

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.

N.C. THERMOSTATS MOUNTED ON CHOKE COIL

S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO
POWER TRANSFORMER.

N.D. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET

TO SINGLE PHASE

SUPPLY LINE

L1

L2

P2

H2

H3

HIGH V.

N.C.

P1 P2

S2

THERMOSTAT

P2

T2

R2

2.5K
10W

GND

TO GROUND PER

NATIONAL ELECTRICAL

CODE

J1
J4

J14

14

58

N.E. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.

CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P.C. BOARD)

J2

1

J5

8

J7
J8

1

6

12

34

5

10

7

J6

14

13

J9

J10

46

1

9

.

1

J3

712

6

8

16

*

260
262
261
263
265
264
266

267

254

+

­255

GUN

TRIGGER

2

1

267

254
252
253
255
251
256

2

324

4

1
2
3
4

J1

5
6

}

7

8

1
2
3
4

5

J2

6
7

SPI TEST

}

8

PLUG

9

10

1

2

3

J10

4

5

}

6

325

(J7)

*

1234

SCI TEST
PLUG

*

*

(J5)

*

515B

555

539

206B

541

N.A.

MOTOR/
GEARBOX

N.B.

207

X5

202

X6

204A

X7

203

X1

C1 THRU C4
30,000 MFD
50V

204

X2

X3

X4

C4

L1 L2

H1

H4

T1

LINE

SWITCH

S1

R.F. FILTER

H1

SHUNT

205

206S

203

H1

H1

H2

H2

H3

H3

POWER TRANSFORMER

+

-

C1 C2

++++

C3

CONTROL BOARD

12345678

515

324A

325A

555

1

206B

2

515B

3
4

325

5
6

324

7

539

8
9

541

10
11
12
13
14

1

515B

2

555
539

3
4

206B

5
6

541

P.M.

208

D1

300V

85A

209

206

204

*

(J4)

495

542

543

541A

206A

206
207

GND

209

205

206S

325A

320

208

GND

W

R

T
A

U

C

B

H

B

320

THERMOSTAT

OUTPUT

CHOKE

N.C.

S3 S4

G1

SCR 1
250V
470A

SCR HEATSINK
ASBLY

SCR 2
250V
470A

G2

207

R1

541

515B

555

206B

539

1
2
3
4
5
6
7
8
9

10
11
12
13
14
15
16

328

N.D.

GND.

15 OHMS

100 W

(J8)

(J9)

123456

*

(J6)

THERMOSTAT

W

L1

B

L2

RECONNECT PANEL

G

T1

N.E.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

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2-5-93

L9078

WIRE-MATIC 250

G-4

Wiring Diagram (208/230) Code 9800

ELECTRICAL DIAGRAMS

G-4

OPTIONAL
TIMER
BOARD

J14

1

2345678

260

262

261

263

265

WIRE SPEED

R3

ARC VOLTAGE

R4

POWER-ON
INDICATOR

TO
WORK

*

}

264

266

251

252

256

253

267

*

260
262
261
263
265
264
266
267

254
252
253

541B

A

539B

254

+

­255

B
C

(J13)

D
E
F

OPTIONAL SPOOL
OR PULL GUN
RECEPTACLE

GUN
TRIGGER

322
321
325B
324B

GND

2

1

255
251
256

325

2

324

4

1
2
3
4

5
6
7
8

1

2

3

4

5

6

7
8

9
10

1
2
3
4
5
6

J1

}

J2

SPI TEST
PLUG

}

J10

}

*

*

(J7)

1234

SCI TEST
PLUG

*

(J5)

*

515B

555
539

206B

541

N.A.

MOTOR/
GEARBOX

N.B.

207

206

R.F. FILTER

CONTROL BOARD

*

(J4)

12345678

515

541A

324A

325A

206A

555

1

206B

2

515B

3
4

325

5
6

324

7

539

8

9

541

10
11
12
13
14

1

515B

2

555
539

3
4

206B

5
6

541

P.M.

320

THERMOSTAT

541

515B

555

206B

539

N.D.

1
2
3
4

5
6
7
8
9

10
11
12
13
14
15
16

328

123456

THERMOSTAT

495

542

543

206
207
GND
209

205

206S

325A

320

208

GND

W

R

T
A

U

C
H

B

B

N.C.

S3 S4

(J8)

(J9)

204A

*

(J6)

*

202

203

G1

204

G2

325A

*

1
2
3
4

541B

321
324B
539B

322
325B

GAS

SOLENOID

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE:

B - BLACK
W - WHITE
R - RED
U - BLUE

INDICATES CONNECTOR CAVITY NO.

*

SP - 250

SPOOL GUN

MODULE

1
2
3

(J11)

324A

*

206A

*

541A

495

6
7
8

4
5
9

10

542

543

1

2
3
4

5

6

(J3)

7
8
9

10
11
12

*

(J12)

12345678

515

325A

1-31-92

L8828

R.F. CHOKE AS'BLY.

NOTES

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE

CURRENT AND DUTY CYCLE OF IMMEDIATE AND
FUTURE APPLICATIONS.

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.

N.C. THERMOSTATS MOUNTED ON CHOKE COIL

S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO
POWER TRANSFORMER.

TO SINGLE PHASE

SUPPLY LINE

L1

N.D. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET
N.E. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.

.

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

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

L1 L2

H1

H4

LINE

SWITCH

S1

X5

202

X6

204A

204

209

208

OUTPUT

CHOKE

G1

SCR 1
250V
470A

SCR HEATSINK
ASBLY

SCR 2
250V
470A

G2

R1

207

X7

T1

H1
P2
H2
H5

H3

SHUNT

H1

205

206S

H4

POWER TRANSFORMER

+

-

C1 C2

++++

C3

203

X1

C1 THRU C4
30,000 MFD
50V

204

D1
300V
85A

206

X2

X3

X4

C4

GND.

15 OHMS

100 W

L1

RECONNECT PANEL

G

T1

N.E.

L2

13

MOTORS

5

42

T2

FAN

R2

2.5K
10W

H5

H2

H2 21/32 31/32 61/64 1/2 63/64 ð

H4

H3

H1

(SHOWN CONNECTED

FOR 230 VOLT.)

N.C.

P2

P1 P2

S2

THERMOSTAT

L2

GND

TO GROUND PER

NATIONAL ELECTRICAL

CODE

J1

14

J4

J11

J14

58

CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P.C. BOARD)

J2

J12

1

J5

8

J7
J8

1

6

12

34

5

10

7

J6

14

13

J9

J10

46

1

J3

712

1

9

6

8

16

WIRE-MATIC 250

G-5

Wiring Diagram (208/230) Code 9799

ELECTRICAL DIAGRAMS

G-5

OPTIONAL
TIMER
BOARD

J14

1

2345678

260

262

261

263

265

WIRE SPEED

R3

ARC VOLTAGE

R4

POWER-ON
INDICATOR

TO
WORK

*

}

264

266

251

252

256

253

267

*

260
262
261
263
265
264
266
267

254
252
253

541B

A

539B

254

+

­255

B

322

C

(J13)

321

D

325B

E

324B

F

OPTIONAL SPOOL
OR PULL GUN
RECEPTACLE

GUN

TRIGGER

GND

2

1

255
251
256

325

2

324

4

1
2
3
4
5
6
7

8

1
2
3
4
5
6
7
8
9

10

1

2

3

4

5
6

J1

}

J2

SPI TEST
PLUG

}

J10

}

*

*

(J7)

1234

SCI TEST
PLUG

*

(J5)

*

515B

555
539

206B

541

N.A.

MOTOR/
GEARBOX

207

N.B.

203

R.F. FILTER

CONTROL BOARD

*

(J4)

12345678

515

324A

325A

206A

555

1

206B

2

515B

3
4

325

5

6

324

7

539

8
9

541

10
11
12
13
14

1

515B

2

555

539

3
4

206B

5
6

541

P.M.

320

THERMOSTAT

495

542

543

541A

2
3
4

206
207

5

GND

6

209

7
8
9

10

205

11
12

206S

13

325A

14

320

15

208

16

GND

W

T

A

C
H

S3 S4

541

515B

R

555

U

206B

B

B

539

N.C.

N.D.

(J8)

(J9)

123456

1

*

(J6)

328

THERMOSTAT

*

202

204A

203

204

325A

G1

G2

*

1

2
3

4

541B

321
324B
539B

322
325B

GAS

SOLENOID

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537

COLOR CODE:

B - BLACK
W - WHITE
R - RED
U - BLUE

INDICATES CONNECTOR CAVITY NO.

*

SP - 250

SPOOL GUN

MODULE

1
2
3

(J11)

324A

6
7

*

8

4
5
9

10

*

495

542

543

541A

206A

1
2
3

4

5
6

(J3)

7
8

9
10
11
12

*

(J12)

12345678

515

325A

8651

1-31-92

L

R.F. CHOKE AS'BLY.

NOTES

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE

CURRENT AND DUTY CYCLE OF IMMEDIATE AND
FUTURE APPLICATIONS.

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.

N.C. THERMOSTATS MOUNTED ON CHOKE COIL

S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO
POWER TRANSFORMER.

TO SINGLE PHASE

SUPPLY LINE

L1

N.D. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET
N.E. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.

.

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NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

L1 L2

H1

H4

T1

LINE

SWITCH

S1

X5

202

X6

204A

X7

203

X1

H1

H1

C1 THRU C4
30,000 MFD
50V

204

D1

300V

85A

206

X2

H2

H2

X3

X4

H3

SHUNT

H1

205

206S

H3

POWER TRANSFORMER

+

-

C1 C2

++++

C4

C3

204

208

209

G1

SCR 1
250V
470A

SCR HEATSINK
ASBLY

SCR 2
250V
470A

OUTPUT

CHOKE

G2

15 OHMS

100 W

R1

207

W

B

GND.

G

H4

L1

LOW V.
JUMPER

L2

RECONNECT PANEL

T1

MOTORS

N.E.

FAN

P2

H2

H3

HIGH V.

N.C.

P1 P2

S2

THERMOSTAT

P2

T2

R2

2.5K
10W

L2

GND

TO GROUND PER

NATIONAL ELECTRICAL

CODE

J1

J4
J11
J14

CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P.C. BOARD)

14

58

J2

J12

1

J5

8

J7
J8

1

6

12

34

5

10

7

J6

14

13

J9

J10

46

1

J3

712

1

9

8

16

6

WIRE-MATIC 250