RETURN TO MAIN INDEX
WIRE-MATIC 255
SVM 119-A
January 1996
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.
10166,
10167.
VOLTS
WIRE SPEED
20
18
22
16
14
WIRE-MATIC 255
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. (216) 481-8100
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 255
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 255
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 255
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 255
NOTES
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WIRE-MATIC 255
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
Other Available Magnum 250L Gun and Cable Assembly . . . . . . . . . . . .C-1
Magnum Gun Connection Kit (Optional K466-6) . . . . . . . . . . . . . . . . . . .C-1
K672-1 Spool Gun Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Making a Weld with the Spool Gun Adapter and Spool Gun
(K672-1) Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Making a Weld with the Spool Gun Adapter (K672-1) Installed . . . . . . . .C-2
Timer Kit (K585-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3
Timer Kit Installation (Optional K585-1) . . . . . . . . . . . . . . . . . . . . . . . . . .C-3
Making Spot and Stitch Welds with Timer Kit Installed . . . . . . . . . . . . . . .C-4
Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
3/64” Aluminum Feeding Kit (K673-1) . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
K468 8” Spool Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
K363P Readi-Reel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
Dual Cylinder Mounting (K671-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Drive Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
WIRE-MATIC 255
vi
RETURN TO MAIN INDEX
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-258
vi
WIRE-MATIC 255
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 255
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - Wire-Matic-255
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 255
A-2
INSTALLATION
A-2
Read entire Installation Section before installing
the WIRE-MATIC 255
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 255 grounding terminal to a good electrical earth ground
through the cable plug per the National
Electrical Code.
• Set the Wire-Matic 255 ON/OFF Power switch to
the OFF position when connecting power cord
to input power.
____________________________________
SELECT PROPER LOCATION
Place the WIRE-MATIC 255 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 255 cannot be stacked.
TILTING
The Wire-Matic 255 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 255
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 255
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 255
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. Strip 1/2" (13mm) of insulation from the input
power supply leads.
2. Connect the input power leads to terminals L1 and
L2 on the Reconnect Panel Assembly.
3. Torque the terminal screws to 16 in.-lbs. (1.8nm).
Technical Specifications
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 255.
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.
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.
a. Remove dust and dirt with a clean cloth.
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 255
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 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 255 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.
13. The 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 Gas 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 255
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. 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 255
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 255 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
WARNING
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.
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.
If negative (-) polarity is required, interchange the connection of the electrode and work cables at the output
terminals located in the wire drive compartment near
the front panel. The electrode cable, which is attached
to the wire drive, is to be connected to the negative (-)
labeled output terminal. The work cable which is
attached to the work clamp is to be connected to the
positive (+) labeled output terminal.
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FIGURE A.8 - Contact Tip and Electrode
Connections.
WIRE-MATIC 255
A-8
INSTALLATION
WIRE SIZE CONVERSION PARTS
The Wire-Matic 255 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 knurled thumb 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 thumb 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 255 might result if this switch is common to
an electrical circuit other than the WIRE-MA TIC 255
trigger circuit.
____________________________________
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WIRE-MATIC 255
NOTES
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WIRE-MATIC 255
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 Slow Run-In Mode.........................................B-7
Enter Fast Run-In Mode .........................................B-7
Making a Weld.............................................................B-8
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WIRE-MATIC 255
B-1
OPERATION
B-1
Read and understand this entire section before operating your WIRE-MATIC 255.
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 255 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 255 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 255
B-2
OPERATION
B-2
RECOMMENDED PROCESSES AND
EQUIPMENT
The WIRE-MA TIC 255 is recommended for GMAwelding processes using 10 to 44 lb. (4.5 to 20 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 255 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.
Adjustable Flow Regulator - Accomodates CO2 or
argon blend gas. Includes a cylinder pressure gauge
and a dual seal flow gauge.
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.
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.
Easy Accessibility - The door on the wire feeder
enclosure protects wire and wire drive from dirt, dust,
and damage.
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WIRE-MATIC 255
B-3
OPERATION
B-3
WIRE FEEDER FEATURES:
Wire Loading - Adjustable brake spindle mounts
Readi-Reel®Adapter , included with WIRE-MATIC 255,
or most any 2" (51mm) I.D. wire spool.
Accommodating standard 12" (305mm) and 8"
(203mm) diameter coils, the spindle’s adjustable brake
provides appropriate dereeling drag to prevent wire
reel overrun and loop-offs.
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.
Selectable Run-In Start-Up - A user selectable feature allows the wire feeder to feed wire directly at the
selected speed, (factory selected), or when the trigger
is pulled the wire feeder feeds wire at slow 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 stick out a snap
The 2 second limit permits high speed loading of the
gun and cable.
MACHINE CAPABILITY
The WIRE-MATIC 255 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 255 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 255 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 255. A liner,
diffuser and contact tips for .035" (0.9mm) and .045"
(1.2mm) electrodes are included.
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WIRE-MATIC 255
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
3
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 255 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
VOLTS
WIRE-MATIC 255
WARNING
WIRE-MATIC 255
WIRE SPEED
2
ON
1
0
OFF
POWER
1
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.
B-5
USING THE WIRE DRIVE ROLL
OPERATION
B-5
The drive roll provided with the WIRE-MATIC 255 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.
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.
MOULDED ADAPTER
RETAINING SPRING
WIRE DEREELING
DIRECTION
2" (51 mm)
O.D. SPINDLE
LOCKING COLLAR
BRAKE TENSION
ADJUSTING SCREW
READI-REEL
INSIDE CAGE WIRES
FIGURE B.2 - Wire Reel Loading.
4. Set one of the Readi-Reel inside cage wires on the
slot in the retaining spring tab.
5. Lower the Readi-Reel to depress the retaining
spring and align the other inside cage wires with
the grooves in the molded adapter.
6. Slide the cage all the way onto the adapter until the
retaining spring "pops" up fully.
4. Remove the thumb screw from the drive roll.
5. Turn the drive roll over or change to another roll as
required.
6. Replace the thumb 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 Readi-Reel adapter provided:
1. Remove the locking collar from the 2” (51mm) O.D.
spindle and mount the K363PAdapter so the spindle pin engages the hole provided in the Adapter.
Replace and tighten the locking collar.
2. Rotate the spindle and adapter so the retaining
spring is at the 12 o'clock position.
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.
____________________________________
NOTE: The retaining spring side of the Adapter should
be facing the center (inner) panel of the WIRE-MATIC
255.
7. To remove the Readi-Reel from Adapter, depress
retaining spring tab with thumb while pulling the
Readi-Reel cage from the molded adapter with
both hands. Do not remove Adapter from spindle.
3. Position the Readi-Reel so that it will rotate in a
clockwise direction when wire is dereeled from the
top of the coil. See Figure B.2.
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WIRE-MATIC 255
B-6
OPERATION
B-6
To mount a 10 to 44 lb. (4.5 to 20 kg) spools: 8”
(200mm) [Use K468 Adapter] and 12” (300mm)
diameter:
1. Remove the locking collar and the Readi-Reel
Adapter (if installed) on the 2 inch (51mm) diameter spindle.
2. If using an 8” (200mm) spool, place the K468
Adapter on the spindle first. The hole in the
Adapter arm is to engage the pin on the spindle.
3. Place the spool on the spindle, making certain the
brake driving pin enters one of the holes in the
back side of the spool. Be certain the wire comes
off the reel in a clockwise direction when dereeled
from the top of the coil.
4. Replace and tighten the locking collar for several
seconds.
FEEDING ELECTRODE
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: If using the low speed starting feature, 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
Changing the Run In Mode Section
.
PROPER WIRE FEEDING
Wire feeding problems can be avoided by observing
the following gun handling procedures:
WARNING
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.
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.
• 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.
4. Push the wire through the ingoing guide tube.
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WIRE-MATIC 255
B-7
OPERATION
B-7
SETTING IDLE ROLL PRESSURE
The idle roll pressure thumb 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 thumb screw out 1/2 turn, run new
wire through gun, and repeat steps 1 and 2.
b. If the drive roll slips, loosen the thumb 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 thumb 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
FAST OR SLOW RUN-IN MODE
SELECTION
The WIRE-MATIC 255 is factory set for fast run-in
mode where the wire feed will accelerate directly to the
preset wire feed speed when the gun trigger is closed.
Slow run-in mode may also be selected, where it 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.
INSTRUCTIONS TO ENTER SLOW RUN-IN
MODE
1. Turn power OFF on front panel of Wire-Matic 255.
OPERATING STEPS
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.
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WARNING
2. Turn the wire feed speed dial to minimum, fully
counterclockwise.
3. With the gun trigger closed, turn the power ON at
the front panel of the Wire-Matic 255.
4. The gas solenoid will actuate two times to signal
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).
INSTRUCTIONS TO ENTER FAST RUN-IN
MODE
1. Turn power OFF on front panel of Wire-Matic 255.
2. Turn the wire feed speed dial to maximum, fully
clockwise.
3. With the gun trigger closed, turn the power ON at
the front panel of the Wire-Matic 255.
4. The gas solenoid will actuate four times to signal
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).
WIRE-MATIC 255
B-8
OPERATION
B-8
NOTE: Arc starting characteristics may be affected
when using the fast run-in mode since optimum starting processes are being overriden.
When the trigger is closed at power up, no output
power or wire feed will be available until the trigger is
opened and reclosed, regardless of wire feed speed
dial setting.
It is not necessary to repeat either of the above procedures each time the unit is powered up. The unit will
remember the run-in mode from the previous power
down and return you to that same state upon your next
power up. Thus, you need only perform one of the
above procedures when you want to change the run-in
mode.
MAKING A WELD
1. Check that the electrode polarity is correct for the
process being used.
2. Turn the POWER SWITCH to ON.
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 eliminate 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.
3. Set desired arc voltage and wire speed for the
electrode wire, material type and thickness, and
gas (for GMAW) being used.
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: If set to slow run-in, 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
Mode Section
.
Changing Run In
10. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.
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.
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).
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WIRE-MATIC 255
NOTES
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WIRE-MATIC 255
ACCESSORIES
TABLE OF CONTENTS
- ACCESSORIES SECTION -
ACCESSORIES SECTION ....................................... Section C
Other Available Magnum 250L Gun and
Cable Assembly ..........................................................C-1
Magnum Gun Connection Kit (Optional K466-6).............C-1
K672-1 Spool Gun Adapter Kit.........................................C-1
Making a Weld with the Spool Gun Adapter and
Spool Gun (K672-1) Installed......................................C-1
Making a Weld with the Spool Gun Adapter (K672-1)
Installed.......................................................................C-2
Timer Kit (K585-1)............................................................C-3
Timer Kit Installation (Optional K585-1)...........................C-3
Making Spot and Stitch Welds with Timer Kit Installed ...C-4
Drive Roll Kits ..................................................................C-4
3/64” Aluminum Feeding Kit (K673-1)..............................C-4
K468 8” Spool Adapter.....................................................C-4
K363P Readi-Reel Adapter..............................................C-4
Dual Cylinder Mounting (K671-1).....................................C-5
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WIRE-MATIC 255
C-1
ACCESSORIES
C-1
OPTIONS/ACCESSORIES
OTHER AVAILABLE MAGNUM 250L
GUN AND CABLE ASSEMBL Y
The following GMAW gun and cable assemblies are
available for use with the WIRE-MATIC 255. 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)
The kit includes a spool gun adapter module assembly
with a single connecting plug, a rear gas inlet setting
with hose, a gun and cable holders and mounting
hardware with installation and operating instructions.
(L9696)
CAUTION
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.
____________________________________
MAKING A WELD WITH THE SPOOL
GUN ADAPTER AND SPOOL GUN
(K672-1) INSTALLED
* Included with the K578-1.
MAGNUM GUN CONNECTION KIT
(Optional K466-6)
Using the optional K466-6 Magnum Connection kit for
the Wire-Matic permits use of standard Magnum 200,
300 or 400 gun and cable assemblies.
K672-1 SPOOL GUN ADAPTER KIT
WARNING
Remove all input power to the Wire-Matic 255
before proceeding.
____________________________________
The K672-1 Spool Gun Adapter Kit provides recessed
panel “up front" direct connection of the K487 Spool
Gun (with remote speed control), or the K469 Spool
Gun (requiring K518 Connection Adapter) with the SP255, SP255-I and Wire-Matic 255 wire feed welder
machines.
The toggle switch on the front of the spool gun adapter
box permits quick transfer between the use of the
Wire-Matic 255 with its feeder gun and the connected
spool gun for same polarity electrodes.
It also provides single switch transfer between the
machine's use with its feeder gun or the spool gun for
same polarity welding with different wire and gas
processes.
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WIRE-MATIC 255
C-2
ACCESSORIES
C-2
MAKING A WELD WITH THE SPOOL
GUN ADAPTER (K672-1) INSTALLED
CAUTION
In either transfer switch position, closing the gun
trigger will cause the electrode of both guns to be
electrically "HOT." Be sure unused gun is positioned so the electrode or the tip will not contact
metal case or other metal common to the work. A
gun holder is provided with the K672-1 kit for this
purpose.
____________________________________
1. The transfer switch in FEEDER position:
a. Disables spool gun trigger, wire feed, and gas
output.
b. Closing the feeder gun trigger starts feeder
gun welding and makes both electrodes electrically "HOT."
NOTE: The WIRE-MATIC 255 speed calibrated dial
markings are not accurate when used for setting the
Spool Gun speed.
4. The following procedure settings can be used as
initial settings for making test welds to determine
final settings:
Wire Diameter
In. (mm)
.030” (.8mm)
.035” (.9mm)
3/64” (1.2mm)
5. To return to normal WIRE-MATIC 255 welding, set
the transfer switch to FEEDER position and reset
feeder gun weld procedure settings.
WFS Setting
Wire-Matic 255
270
250
210
Arc Voltage
Setting
15 V
16 V
21 V
2. Transfer switch in SPOOL position:
a. Disables feeder gun wire feed and gas output.
However, closing feeder gun trigger will make
both electrodes electrically “HOT” and activate
spool gun gas output.
b. Closing spool gun trigger starts spool gun
welding and makes both electrodes electrically "HOT".
3. Operation with Wire-Matic 255:
a. Turn the Wire-Matic input power ON, and the
transfer switch is to be in the SPOOL position.
b. Adjusting the voltage control will increase or
decrease your welding Voltage.
c. 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.
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WIRE-MATIC 255
C-3
ACCESSORIES
C-3
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 255
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 255
C-4
ACCESSORIES
C-4
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.
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.
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)
Aluminum Wire Sizes:
3/64" (1.2mm)
Part Number
KP674-035S
KP674-045S
KP674-045C
KP674-3/64A
5. Close trigger and hold it closed until the arc goes
out.
a. If a spot weld nozzle is not used, smoother
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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welds will result by moving the welding wire in
a small circle during the weld.
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 255
3/64” (1.2mm) ALUMINUM FEEDING
KIT (K673-1)
Provides gun and wire drive conversion parts to weld
with 3/64” (1.2mm) aluminum wire. 5356 alloy aluminum wire is recommended for best push feeding
performance.
Kit includes drive roll and incoming guide tube for the
wire drive, and 450gun tube, liner and two contact tips
for the gun, along with S21529 installation instructions.
K468 8” SPOOL ADAPTER
The K468 Spool Adapter permits the use of 8” Spools
on the Wire-Matic 255 spindle.
K363P READI-REEL ADAPTER
The K363P Readi-Reel Adapter mounts to the 2” spindle. It is needed to mount the 22-20 lb. Readi-Reels.
C-5
ACCESSORIES
DUAL CYLINDER MOUNTING KIT
(K671-1)
Permits stable side-by-side mounting of two full size
(9” dia. x 5’ high) gas cylinders with “no lift” loading.
Simple installation with installation kick stand and easy
instructions provided (L9687). Includes upper and
lower cylinder supports, wheel axles and mounting
hardware.
C-5
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WIRE-MATIC 255
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
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 255
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 255
D-2
MAINTENANCE
CONTROL PC
BOARD
SCR RECTIFIER
BRIDGE
D-2
FAN MOTORS
MAIN TRANSFORMER
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CHOKE
Figure D.1 - Component Locations.
WIRE-MATIC 255
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.
CABLE CLEANING
Clean the cable liner after using approximately 300
pounds (136 kg) of electrode.
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.
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.
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.
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.
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.
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WIRE-MATIC 255
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
Diameter of
Electrodes Used
Replacement Liner
Part Number
Size Stenciled on
End of Liner
Bushing
.025-.030" Steel
M16087-2
.030 (0.8mm)
(0.6-0.8mm)
.035-.045" Steel
M16087-1
.045 (1.2mm)
(0.9-1.2mm)
3/64" Aluminum
M17714-1
3/64” (1.2mm)
(1.2mm)
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.
Fixed Nozzle Gas
Diffuser Part No.
(and Stencil)
S19418-3
S19418-3
S19418-3
Adjustable Nozzle
Gas Diffuser Part
No. (and Stencil)
S19418-2
S19418-1
S19418-1
8. Fully seat the liner bushing into the connector.
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.
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
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is the appropriate one for the wire size being
used.
WIRE-MATIC 255
SET SCREW
BRASS CABLE CONNECTOR
GAS DIFFUSER
NOZZLE INSULATOR
GAS NOZZLE
FIGURE D.2 - Liner maintenance.
1-1/4" (1.25)
(31.8MM)
LINER TRIM
LENGTH
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
COUNTER-
CLOCKWISE
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 255
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
Tab (For Aluminum)
Gas Nozzles
Fixed (Flush)
(Recessed)
PART NO.
M16087-2
M16087-1
M17714-1*
S19391-6
S19391-7
S19391-1**
S19391-2**
S19392-1
S19292-2
S19393-5
S19393-6
S19393-1
S19393-2
S18697-46*
M16081-1
M16081-2**
M16081-3
M16080-1
M16080-2
M16080-3
ENGLISH SIZE
.025- .030"
.035- .045"
3/64" (Alum. Wire)
.025"
.030"
.035"
.045"
.035"
.045"
.025"
.030"
.035"
.045"
3/64” (Alum. wire)
3/8”
1/2”
5/8”
3/8”
5/8”
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
1.2 mm
9.5 mm
12.1 mm
15.9 mm
9.5 mm
15.9 mm
15.9 mm
(Requires: Gas Diffuser Assembly.)
Adjustable Slip-On
(Requires: Nozzle Insulator Assembly.)
(Requires: Gas Diffuser Assembly)
Gasless Nozzle (for Innershield®)
Gun Tube Assembly
* Included with K673-1 3/64” (1.2 mm) Aluminum
Feeding Kit. 5356 alloy aluminum wire recommended to alleviate potential soft wire feeding
problems with push-type wire feeding.
** Included with Wire-Matic 255.
*** Requires S19428-1 Gas Diffuser Assembly.
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Standard (60 Degrees)
45 Degrees
S19418-3
M16093-2
M16093-1
S19417-1
S19416-2
S19416-2
M16938***
S18920**
S19890*
WIRE-MATIC 255
.025-.045”
1/2”
5/8”
0.25 - .030"
0.35 - .045"
0.6-1.2 mm
12.7 mm
15.9 mm
0.6-0.8 mm
0.9-1.2mm
NOTES
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WIRE-MATIC 255
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 255
E-1
THEORY OF OPERATION
INPUT LINE VOLTAGE AND MAIN TRANSFORMER
E-1
LINE
SWITCH
RECONNECT
FAN
MOTORS
SCR
SOLENOID
G
A
T
E
S
I
G
N
A
L
GAS
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 255 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.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
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WIRE-MATIC 255
E-2
THEORY OF OPERATION
OUTPUT RECTIFICATION AND FEEDBACK
E-2
LINE
SWITCH
RECONNECT
FAN
MOTORS
VOLTAGE
MAIN
TRANSFORMER
SCR
SOLENOID
G
A
T
E
S
I
G
N
A
L
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
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 255
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 255
E-4
THEORY OF OPERATION
WIRE DRIVE MOTOR AND FEEDBACK
E-4
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
C
A
P
A
C
I
T
O
R
S
SHUNT
F
E
E
D
B
A
C
K
CHOKE
ARC
WIRE
SPEED
CONTROL BOARD
RECTIFIER
Figure E.5 - Wire Drive Motor and Feedback.
POSITIVE
TERMINAL
NEGATIVE
TERMINAL
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 255
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 255 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 255
E-6
INPUT
CATHODE
THEORY OF OPERATION
SCR OPERATION
E-6
OUTPUT
ANODE
GATE
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.
NOTE: AS THE GATE
PULSE IS APPLIED
LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.
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 255
NOTES
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WIRE-MATIC 255
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 SCR 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 255
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 255
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
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.
charge before opening 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 255
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. (216) 383-2531 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 255
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 255
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 255
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.
2. If Spool Gun adaptor is not
installed make certain jumper
plug is installed in plug J20. See
Wiring Diagram.
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 255
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 255
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 255
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 255
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 (216) 383-2531 or (800) 833-9353 (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 255
F-11
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER TEST
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
G2803 Control PC Board.
F-11
NOTE: The location of Plugs may vary
depending on the machine code.
G2803
WM-255 CONTROL
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 - G2803 Control PC
Board Main Transformer Test Points.
WIRE-MATIC 255
F-12
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER TEST (CONTINUED)
F-12
4. Locate the following leads on Plug
J3:
G2803:
LEAD
#202
#203
#204 A
5. Connect main input power to the
machine.
6. Turn the Wire-Matic 255 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.
G2803:
FROM
LEAD
LEAD
PLUG
LOCATION
TO
1J3
3J3
2J3
EXPECTED
VOL TAGE
Board.
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.
G2803:
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
#202
(1J3)
#202
(1J3)
#203
(3J3)
8. Turn OFF the machine
9. Locate the following leads on Plug
J6 on the G2803 Control PC Board.
G2803:
LEAD
#206
#208
#209
10. Turn ON the machine.
11. Make the following voltage tests at
Plug J6 on the G2803 Control PC
#203
(3J3)
#204 A
(2J3)
#204 A
(2J3)
LOCATION
30 VAC
15 VAC
15 VAC
PLUG
4J6
16J6
7J6
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.
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WIRE-MATIC 255
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 (216) 383-2531 or (800) 833-9353 (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 255 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 255
F-14
G2803
WM-255 CONTROL
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 G2803 Control Board. This
electrically isolates the SCR bridge
assembly. See Figure F.2.
J3
LEADS
X2 AND X3
J9
J6
J4
NEGATIVE
CAPACITOR
BANK
BUSS BAR
F-14
J1
J10
J7
J2
J5
FIGURE F.3 - Location of Leads X2
and X3.
5. Separate leads X2 and X3 from the
negative capacitor bank buss bar.
FIGURE F.2 - Remove Plugs J3 and J6
to Perform Static SCR Rectifier
Be sure there is no electrical contact. See Figure F.3.
Assembly Test.
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.3.
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WIRE-MATIC 255
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 255
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 (216) 383-2531 or (800) 833-9353 (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 255 wiring diagrams (See Electrical Diagrams Section of this Manual).
SCR Heat Sink Assembly Drawings.
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WIRE-MATIC 255
F-17
G2803
WM-255 CONTROL
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 G2803 Control Board.
See Figure F.5.
J3
J9
J4
J1
J10
J7
J2
FIGURE F.5 - Control Board Molex
Plug Locations for G2803 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.
J5
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 255
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 255
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 (216) 383-2531 or (800) 833-9353 (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 255
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 G2803
Control Board. See Figure F.8.
J3
G2803
WM-255 CONTROL
J1
J7
J10
J2
FIGURE F.8 - Plug J5 Location on
G2803 PC Control Board.
J9
#541 (W)
(13J5)
J4
J5
#515B
(3J5)
J6
#539 (B)
(12J5)
#555
(1J5)
#206B
(2J5)
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WIRE-MATIC 255
F-21
TROUBLESHOOTING & REPAIR
F-21
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (CONTINUED)
4. Test for 2 - 25 VDC between lead
plug location 12J5 #539(B) (positive) (12J5) and lead #541(W)
(13J5) (negative) to determine if the
correct armature voltage is being
supplied. See Figure F.8.
a. Insert probes in to the Molex pin
cavities.
a. If the 15 VDC is present, check
the leads to the tach circuit.
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.
5. Pull the gun trigger.
6. Read meter. Normal DC volts is
from 2 - 25 VDC. VDC varies
depending on wire feed speed.
a. If voltage to the wire drive motor
armature is zero, check the
wires between Plug J5 and the
wire drive motor. (Check J11,
J12, and J15). See Wiring
Diagram.
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.
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
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.
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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.
a. Insert probes into Molex pin
cavities.
2. Pull gun trigger.
3. Read meter for 15 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.
c. If the leads are okay, the Control
Board may be faulty. Replace.
WIRE-MATIC 255
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 255
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 255
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 255
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 255
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 255
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 (216) 383-2531 or (800) 833-9353 (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 255
F-28
TROUBLESHOOTING & REPAIR
CONTROL PC BOARD REMOVAL AND REPLACEMENT (CONTINUED)
F-28
G2803
WM-255 CONTROL
REMOVAL AND REPLACEMENT PROCEDURE
1. Disconnect main input power the
machine.
2. Remove the Case Top and Side
Panels using 5/16" nut driver.
3. Disconnect all wiring harness plugs
and Molex Plugs connected to the
Control Board. See Figure F.9.
J3
J9
J6
4. Carefully remove the P.C. Board
from the mounting standoffs. See
Figure F.10.
J4
J5
FIGURE F.10 - Control Board
J1
J7
J10
J2
Mounting Locations may vary
with different Code Machines.
5. Lift the Control Board straight up
FIGURE F.9 - Wiring Harness and
Molex Plug Locations.
and out from the machine.
6. When re-installing the Control
Board carefully secure Board to
mounting standoffs.
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WIRE-MATIC 255
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 (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
F-29
MATERIALS NEEDED
Large slot head screwdriver.
5/16" Nut Driver.
Small slot head screwdriver.
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WIRE-MATIC 255
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. Using the 5/16” Nutdriver remove
the gear box top cover.
4. Remove the two sheet metal screws
located on the left rear side of the
gear box housing using a 5/16” nutdriver.
5. Remove the drive roll. See Figure
F.11.
a. Remove the thumb screw, drive
hub, and the spacer.
F-30
6. Remove the screw holding the gun
connector assembly to the Case
Front Panel. See Figure F.11.
7. Slide the entire wire drive assembly
carefully toward the Case Back and
approximately 2” (51 mm) away
from the center baffle to gain access
to the drive motor and wiring.
a. The gas hose and gun connec-
tor leads will limit the travel distance.
8. Disconnect the drive motor from the
drive roll assembly.
a. Remove the three large phillips
head screws on the outboard
side of the drive roll assembly
face plate using a phillips head
screw driver.
9. Separate the drive roll assembly
from the drive motor.
a. Grip the drive motor in one hand
and the drive assembly in the
other hand.
FIGURE F.11 - Wire Drive Assembly
Removal
10. Disconnect molex plugs J15, J12,
and J11. See wiring diagram.
11. Remove the drive roll assembly.
a. Remove the two screws mount-
ing the drive roll assembly to the
insulator board using a 5/16” nut
driver.
b. Loosen the set screw using a
slot head screwdriver that holds
the outgoing guide tube into the
drive roll assembly.
c. Remove the drive assembly by
sliding it off the out going guide
tube and towards the Case
Back at the rear of the machine.
b. Wiggle the drive motor and drive
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assembly gently back and forth
until the two parts separate.
WIRE-MATIC 255
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 (216) 383-2531 or (800) 833-9353 (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 255
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 255
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 (216) 383-2531 or (800) 833-9353 (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 255
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 255
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 (216) 383-2531 or (800) 833-9353 (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 255
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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11. Remove the four screws mounting
the transformer to the floor of the
machine using a 5/16" nut driver.
WIRE-MATIC 255
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 (216) 383-2531 or (800) 833-9353 (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 255
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 255
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 255
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 255
NOTES
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WIRE-MATIC 255
TABLE OF CONTENTS
- ELECTRICAL DIAGRAMS SECTION -
Electrical Diagram Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Wiring Diagram (208/230) Code 10166 . . . . . . . . . . . . . . . . . . . . . . . . . G-2
Wiring Diagram (230/460/575) Code 10167 . . . . . . . . . . . . . . . . . . . . . . G-3
Control PC Board (G2803) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
Control PC Board (G2803) Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
G-1G-1
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WIRE-MATIC 255
NOTES
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WIRE-MATIC 255
G-2
Wiring Diagram (208/230) Code 10166
ELECTRICAL DIAGRAMS
WIRE - MATIC 255 (208 / 230V)
G-2
OPTIONAL
TIMER
BOARD
J16
2345678
1
260
262
261
263
265
WIRE SPEED
R3
ARC VOLTAGE
R4
POWER-ON
INDICATOR
TO
WORK
1
*
*
CONTROL BOARD
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
J14
260
262
261
263
265
264
266
267
254
252
253
255
251
256
**
1
2
325
3
4
324
*
266
267
264
251
252
256
253
254
+
255
2
GUN
TRIGGER
325
324
1
(J7)
*
1234
SCI TEST
PLUG
*
(J4)
12345678
515
325A
324A
206A
541A
495
542
543
*
555
1
206B
2
515B
3
4
325
5
6
*
(J5)
*
515B
555
B
206B
W
J15
324
7
8
9
10
11
12
B
W
13
14
**
1
515B
2
555
B
3
4
206B
5
6
W
GND
206
207
GND
209
205
206S
325A
320
208
123456
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
(J8)
*
(J6)
2
3
4
*
(J9)
1
202
204A
2
203
3
4
G1
5
204
6
G2
7
8
9
10
11
12
392
390
R.F.
CHOKE
AS'BLY
**
J21
(J3)
*
**
J11
1
B
2
W
J20
SPOOL GUN ADAPTER
HARNESS
515
325A
324A
206A
541A
495
542
543
392
390
392B
390A
392B
390A
1
2
3
4
**
GAS
SOLENOID
1
2
3
4
5
6
7
8
9
9
10
11
12
13
14
TO
SPOOL GUN
OPTION
JUMPER USED WITHOUT
SPOOL GUN OPTION
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
COLOR CODE:
B - BLACK
W - WHITE
R - RED
U - BLUE
INDICATES CONNECTOR CAVITY NO.
*
N.A.
L1 L2
H1
H4
T1
LINE
SWITCH
S1
R.F. FILTER
H1
SHUNT
205
206S
206
H1
H1
H2
H2
H3
H3
POWER TRANSFORMER
+
-
C1 C2
++++
MOTOR/
GEARBOX
207
N.B.
X5
202
X6
204A
X7
203
X1
C1 THRU C4
30,000 MFD
50V
204
D1
300V
85A
206
204
X2
X3
X4
C4
C3
P.M.
208
209
B
320
THERMOSTAT
SCR 1
250V
470A
SCR HEATSINK
ASBLY
SCR 2
250V
470A
OUTPUT
CHOKE
W
S3
G1
515B
T
R
A
555
U
C
206B
B
H
THERMOSTAT
W
B
GND.
325A
S4
H4
H2
L1
LOW V.
JUMPER
L2
RECONNECT PANEL
N.C.
N.D.
328
B
W
P2
H3
HIGH V.
G
G2
T1
MOTORS
15 OHMS
100 W
R1
N.E.
207
N.C.
T2
FAN
R2
2.5K
10W
P1 P2
THERMOSTAT
CHOKE
AS'BLY.
**
J12
1
2
TO SINGLE PHASE
SUPPLY LINE
TO GROUND PER
NATIONAL ELECTRICAL
CODE
P2
S2
R.F.
L1
L2
GND
CAVITY NUMBERING SEQUENCE
14
J1
J4
J16
58
R.F.
CHOKE
AS'BLY.
**
J13
1
2
325
3
324
4
(COMPONENT SIDE OF P.C. BOARD)
15
J2
610
1
J5
8
7
14
12
J7
J8
34
J6
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
NOTES
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
2
J13
J14
J21
1
1
J20
8
1
J3
712
1
9
13
J9
J10
46
6
8
16
NUMBERING SEQUENCE
(NON-LEAD SIDE OF CONNECTOR)
J11
J12
.
12
34
J15
7
14
C-RW
13
46
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.
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L9690
WIRE-MATIC 255
G-3
Wiring Diagram (230/460/575) Code 10167
ELECTRICAL DIAGRAMS
WIRE - MATIC 255 (230 / 460 / 575V)
G-3
OPTIONAL
TIMER
BOARD
J16
2345678
1
260
262
261
263
265
WIRE SPEED
R3
ARC VOLTAGE
R4
POWER-ON
INDICATOR
TO
WORK
*
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
324
J14
260
262
261
263
265
264
266
267
254
252
253
255
251
256
**
1
2
3
4
*
264
266
267
251
252
256
253
254
+
255
2
GUN
TRIGGER
325
324
1
(J7)
*
1234
SCI TEST
PLUG
*
*
(J5)
*
515B
555
B
206B
CONTROL BOARD
*
(J4)
12345678
515
324A
325A
206A
555
1
206B
2
515B
3
4
325
5
6
324
7
8
9
10
11
12
B
13
W
14
**
J15
1
515B
2
555
3
B
4
206B
5
6
WW
541A
495
GND
(J8)
(J9)
542
543
206
207
GND
209
205
206S
325A
320
208
123456
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
*
(J6)
N.A.
W
R
515B
T
A
P.M.
C
H
B
320
THERMOSTAT
S3
208
G1
SCR 1
250V
470A
SCR HEATSINK
ASBLY
SCR 2
250V
470A
G2
209
204
OUTPUT
CHOKE
555
U
206B
B
328
N.C.
N.D.
THERMOSTAT
S4
L1
GND.
G
T1
15 OHMS
100 W
R1
207
N.E.
L1 L2
H1
R.F. FILTER
H4
LINE
SWITCH
S1
MOTOR/
GEARBOX
206
207
N.B.
X5
202
X6
204A
X7
T1
H1
P2
H2
H5
H3
SHUNT
H1
205
206S
H4
POWER TRANSFORMER
+
-
C1 C2
++++
203
X1
C1 THRU C4
30,000 MFD
50V
204
D1
300V
85A
206
X2
X3
X4
C4
C3
1
*
2
3
4
*
1
202
204A
2
203
3
4
G1
5
204
6
G2
7
8
9
10
11
12
325A
L2
42
13
RECONNECT PANEL
FAN
MOTORS
R2
2.5K
10W
(J3)
*
B
W
J12
B
W
5
H5
H2
H4
H3
H1
(SHOWN CONNECTED
FOR 230 VOLT.)
N.C.
T2
P1 P2
S2
THERMOSTAT
392
390
**
J11
1
2
CHOKE
AS'BLY
**
1
2
NATIONAL ELECTRICAL
P2
**
J21
392B
390A
1
2
3
4
**
J20
SPOOL GUN ADAPTER
HARNESS
515
1
325A
2
324A
3
206A
4
541A
5
495
6
542
7
543
8
392
9
9
390
10
392B
11
12
390A
13
14
R.F.
TO SINGLE PHASE
SUPPLY LINE
L1
L2
GND
TO GROUND PER
CODE
CAVITY NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C. BOARD)
14
J1
J4
J16
58
1
J5
8
R.F.
CHOKE
AS'BLY
1
2
325
3
324
4
**
J13
15
J2
610
7
14
12
J7
J8
34
R.F.
CHOKE
AS'BLY
SOLENOID
TO
SPOOL GUN
OPTION
JUMPER USED WITHOUT
SPOOL GUN OPTION
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.
1
J3
712
1
J6
9
J9
J10
8
16
13
46
GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
COLOR CODE:
B - BLACK
W - WHITE
R - RED
U - BLUE
INDICATES CONNECTOR CAVITY NO.
*
GAS
*
*
NUMBERING SEQUENCE
(NON-LEAD SIDE OF CONNECTOR)
2
J11
J12
6
1
J20
.
CAVITY
J13
J14
J21
1
8
12
34
7
14
C-RW
13
J15
46
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.
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L9691
WIRE-MATIC 255
G-4
Control PC Board (G2803) Schematic
ELECTRICAL DIAGRAMS
G-4
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NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
WIRE-MATIC 255
G-5
Control PC Board (G2803) Layout
G
2803
ELECTRICAL DIAGRAMS
G-5
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WIREMATIC 255 CONTROL
G2803
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
THIS SHEET CONTAINS PROPRIETARY INFORMATION
OWNED BY AND IS
THE LINCOLN ELECTRIC CO.
NOT TO BE REPRODUCED, DISCLOSED OR USED
WITHOUT THE EXPRESS PERMISSION OF
THE LINCOLN ELECTRIC CO.
3-24-95A
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
FULL
SCALE
F.V.
DR DATE CHK
EQUIP.
WM-255
TYPE
CONTROL P.C. BOARD ASSEMBLY
SUBJECT
FV 9-19-94
REF.
SUP'S'D'G
SHT.
NO.
G
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
2803
WIRE-MATIC 255
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