Lincoln Electric SVM 119-A User Manual

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. [phone]

i

SAFETY

i

WARNING

ARC WELDING can be hazardous.

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

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

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

ELECTRIC SHOCK can kill.

1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

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

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

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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

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

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

1.f.

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

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

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

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

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

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

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

fumes and gases away from the breathing zone. When

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

3.b.

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

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

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

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

ARC RAYS can burn.

2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

FUMES AND GASES
can be dangerous.

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

vapors

to

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3.e. Also see item 7b.

WIRE-MATIC 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