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Lincoln Electric 119-A User's Manual

1. Return to Master TOC LINE SENSING Return to Section TOC JITRY GATE DRIVE CIRCL 1 84 55444 15 Ojo o c 5 Oja gt 99 ele 5 5 im 223 OMPLETE BOARD THE EXAC F CONTROLS HAVING HANGE WITHOUT AFFECTING OINT NUMB R E 15 ne CONNECTION JIAGRAM MAY NOT SHOW OMMON CODE THE INTERCH
2. o 2 Return to Section Return to Master TOC o 7 5 2 INSTALLATION BT 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 STRAIN RELIEF HOLE FIGURE A 7 Installing The Work Clamp OUTPUT POLARITY CONNECTION WARNING Turn the welder Power Switch OFF before chang ing output connection The welder is shipped from the factory connected for electrode positive polarity This is the normal polar ity for GMA welding If negative polarity is required interchange the con nection 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 GUN LINER AND CONTACT TIP INSTALLATION The Magnum 250L gun and cable provided with the WIRE MATIC 255 is factory installed wit
3. o 8 5 E Return to Section Return to Master TOC O O o 9 e diis TROUBLESHOOTING amp REPAIR Er TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The output voltage and wire feed is 1 present continuously or pulsing when gun trigger is NOT activated OUTPUT PROBLEMS Remove the gun If the problem is resolved the gun trigger circuit is faulty Repair or replace If the problem is not resolved then contact your Local Lincoln Electric Authorized Field Service Facility Check the machine s internal trigger leads for grounds or shorts See Wiring Diagram The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 8 5 E Return to Section Return to Master TOC o O 7 9 c tc E TROUBLESHOOTING amp REPAIR d TROUBLESHOOTING
4. im Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 diis TROUBLESHOOTING amp REPAIR iis STATIC SCR RECTIFIER ASSEMBLY TEST CONTINUED NOTE DO NOT DISASSEMBLE THE SCR RECTIFIER HEAT SINK ASSEM BLY 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 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 high or infinite resistance is indicated for both tests 6 and 7 the SCR 1 is not shorted O o 5 5 PEN 918 mlt 5 5 im b If alow 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 prob lem or to further test the SCR go to the Active SCR Test Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 oe TROUBLESHOOTING amp REPAIR FUR ACTIVE SCR RECTIFIER ASSEMBLY TEST Return to Section TOC Return to Master TOC A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repair
5. 6 To mount a 10 to 44 Ib 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 diame ter spindle 2 f 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 WARNING When inching the electrode and drive mechanism are electrically hot to work and ground The elec trode 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 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 If the electrode is not properly straightened it may not feed properly into the outgoing guide tube or welding gun causing a birdnest 3 Cut off the first inch 4 Push the wire through the ingoing guide tube 5 Press the gun trigger and push the electrode into the drive roll
6. safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Feb 95 WIRE MATIC 255 LINCOLN 5 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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 6 Operate engines in open well ventil
7. 7 5 F 12 6 8 9 FROM TO EXPECTED LEAD LEAD VOLTAGE TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER TEST CONTINUED Locate the following leads on Plug LEAD PLUG LOCATION 103 3J3 2J3 Connect main input power to the machine Turn the Wire Matic 255 ON OFF POWER SWITCH to ON Make the following voltage tests at Plug J3 a 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 Turn OFF the machine Locate the following leads on Plug J6 on the G2803 Control PC Board G2803 LEAD PLUG LOCATION 206 4J6 208 16J6 209 7J6 10 Turn ON the machine 11 Make the following voltage tests at Plug J6 on the G2803 Control PC FROM TO EXPECTED LEAD LEAD VOLTAGE C 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 If any of the voltages tested are incorrect check for loose or bro ken leads between the test points and the main transformer d If ALL the voltages tested are incorrect or missing go to Step 12 12 Test for correct nameplate input volt WIRE MATIC 255 LINCOLN 5 age 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
8. Board from the static 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 static shielding bag the Board uses protective shorting jumpers don t remove them until installation is complete f 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 trou bleshooting NOTE Allow the machine to heat up so that all electrical components can reach their oper ating 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 fol
9. NOTES WIRE MATIC 255 LINCOLN E DOL 49159 0 901 49159 0 901 J91Se N 01 uunjeH 901 J91Se N uunjeH DOL uonoes DOL uonoes DOL uonoes uumeg DOL uonoes Return to Master TOC Return to Master TOC o O m o 5 tc Return to Master TOC OPERATION TABLE OF CONTENTS OPERATION SECTION OPERATION SECTION 4 Section B Safety 1 General Description iere terit B 1 Recommended Processes Equipment B 2 Design Features and Advantages B 2 Unit FP CANT OS PL B 2 Power Source B 2 Wire Feeder Features B 3 Machine Capability B 3 UN aor i e E X B 3 Controls and Settings ueteri eet ba Res B 4 Using the Wire Drive ctore teta B 5 Procedure for Changing Drive Roll B 5 Loading the Wire B 5 Feeding Electrode Renta B 6 Proper Wire ioa B 6 Setting Idle Roll B 7 Operating SISDS is B 7 Starting the Welder
10. C 3 E Making Spot and Stitch Welds with Timer Kit Installed C 4 Dive Roll C 4 5 3 64 Aluminum Feeding Kit 673 1 C 4 K468 8 5 C 4 K363P Readi Reel C 4 Dual Cylinder Mounting 671 1 C 5 o 7 5 Return to Master TOC WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o PEN 2 im Return to Section TOC Return to Master TOC OPTIONS ACCESSORIES OTHER AVAILABLE MAGNUM 250L GUN AND CABLE ASSEMBLY 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 con nector and includes a liner diffuser and contact tips for the wire sizes specified LENGTH WIRE SIZE PART NO 10 3 0 m 12 3 6 m 15 4 5 m 035 045 0 9 1 2mm 10 3 0 m 12 3 6 m 15 4 5 m 025 030 0 6 0 8mm Included with the K578 1 MAGNUM GUN CONNECTION KIT Optional K466 6 Using the optional K466 6 Magnum Connection kit for the Wire Matic permit
11. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET XCAVITY SHOWN CONNECTED FOR 230 VOLT CAVITY NUMBERING SEQUENCE COMPONENT SIDE OF P C BOARD 2 THERMOSTAT 15 2000000 lo O00 0000 NUMBERING SEQUENCE NON LEAD SIDE OF CONNECTOR 2 J11 J12 1 L9691 is pasted inside the machine on one of the enclosure panels WIRE MATIC 255 G 4 ELECTRICAL DIAGRAMS G 4 Control PC Board G2803 Schematic ITRY 27564 OR ACTUAL CIRCUIT CONTROL CIRC 50 M Return to Section TOC Return to Master TOC 54 1 2 cus 50 758 50 TR 50V pn 74HC373
12. 7 5 ACCESSORIES 23 DUAL CYLINDER MOUNTING 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 WIRE MATIC 255 LINCOLN 5 MAINTENANCE 9 TABLE OF CONTENTS n MAINTENANCE SECTION o MAINTENANCE SECTION Section D 2 Safety Precautions D 1 oc Routine and Periodic Maintenance D 1 Component Locations nu hoes D 2 Drive Rolls and Guide D 3 64 2261 24 D 3 Gun Tubes and NOozzl88 0 3 Contact Tip and Gas Nozzle Installation D 3 Liner Removal and D 4 Liner Removal Installation and Trimming Instructions for Magnum ZOOL cio pott S 0 4 Gun Handle Disassembly 0 5 Accessories and Expendable Replacement Parts for Magnum 250L Gun and Cable Assemblies D 6 Return to Master TOC o 7 5 Return to Master TO
13. Ci THRU C4 30 000 MFD 50V Ki 2 H3 206 4 207 5 GND 6 209 7 lt 9 205 1 aH 12 2065 413 325A 14 320 15 lt 208 416 1111717177 THERMOSTAT S3 250V 470A sca HEATSINK ASBLY OUTPUT CHOKE 202 K 1 204 2 203 lt Hc e 5 lt 204 6 62 K7 lt lt K lt H 104 Kite 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 LINCOLN amp J20 SPOOL GUN ADAPTER AS BLY pie 325 H 2 233 1 324 TO SINGLE PHASE J13 xx SUPPLY LINE GND TO GROUND PER NATIONAL ELECTRICAL CODE GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 COLOR CODE BLACK W WHITE R RED U BLUE NDICATES CONNECTOR CAVITY NO GAS SOLENOID i i I SPOOL GUN OPTION NL JUMPER USED WITHOUT SPOOL GUN OPTION NOTES 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 THERMOSTATS MOUNTED ON CHOKE COIL S2 MOUNTED CLOSEST FAN 53 MOUNTED CLOSEST TO POWER TRANSFORMER THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET
14. Make sure electrode polarity is correct or welding process being used Check for rusty or dirty wire Make sure machine settings and gas are correct for process being used Make sure the weld procedure and electrode polarity is correct for the process being used Make sure shielding gas is cor rect and flow is proper Make sure the weld joint is not contaminated The tip being over heated due to excessive current and or high duty cycle welding A light application of high tem perature antisieze lubricant such Lincoln E2607 Graphite Grease may be applied to the contact tip threads Check for loose connections at the output terminals the choke the capacitor bank and all heavy current carrying leads Make sure that the transformer secondary leads are securely connected to the SCR Rectifier Assembly The output capacitor bank may be faulty Check for loose con nections at the capacitors Also check for leaky capacitors Replace if necessary WARNING The liquid elec trolyte in these capacitors is toxic Avoid contact with any portion of your body The control board may be faulty Replace The output capacitor bank may be faulty Check for loose con nections at the capacitors Also check for leaky capacitors Replace if necessary WARNING The liquid elec trolyte in these capacitors is toxic Avoid contact with any portion of your body The control board may be faulty Replace
15. o O o 9 c 5 tc Return to Master TOC G 5 Control PC Board G2803 Layout ELECTRICAL DIAGRAMS 2082 5 55 gt Ro 15 S 4 55 THIS SHEET CONTAINS PROPRIETARY INFORMATId OWNED BY THE LINCOLN ELECTRIC CO AND 15 NOT TO BE REPRODUCED DISCLOSED OR USED WITHOUT THE EXPRESS PERMISSION OF THE LINCOLN ELECTRIC CO CAPACITORS MFD VOLTS RESISTORS OHMS ITEM REQ D PART NO IDENTIFICATION C4 C5 C33 C40 C4 1 C52 C53 23 516668 5 022750 C57 C60 C62 C 100 C 101 C 103 C104 C 105 C 106 C107 C118 C119 C120 C 122 C123 C 124 C21 C34 2 s13490 25 4 7 35 C30 C31 2 516668 1 22pF 100 C32 C35 C111 112 C113 10 516668 11 1 50 C114 C116 C117 C121 C125 C36 1 16668 4 2700 750 C42 1 711577 28 22 100 C50 1 _ 513490 102 0477100 C51
16. NOTE Unshaded areas of Block Logic Diagram are the subject of discussion WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O o 515 0 PEN 22 5 2 im Return to Section TOC Return to Master TOC Return to Master TOC ET THEORY OF OPERATION ES WIRE DRIVE MOTOR AND FEEDBACK WIRE GAS SPEED SOLENOID ARC VOLTAGE GUN TRIGGER AND THUMB SWITCH LINE FEEDBACK POSITIVE TERMINAL SCR RECTIFIER ODOA OYFVSO gt NEGATIVE MOTORS TERMINAL Figure E 5 Wire Drive Motor and Feedback 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 com mands set forth by the Wire Speed Control poten tiometer 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 NOTE Unshaded areas of Block Logic Diagram are the subject of discussion WIRE MATIC 255 LINCOLN 5 E 5 THEORY OF OPERATION THERMAL PROTECTION THERMAL PROTECTION A thermostat protects the machine from excessive operating temperatures Excessive operating temper atures may be caused by a lack of cooling air or oper
17. 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 bot tom sheets are tight together 5 Close trigger and hold it closed until the arc goes out a spot weld nozzle is not used smoother welds will result by moving the welding wire in a small circle during the weld TO MAKE A STITCH WELD The STITCH WELD MODE is used to weld thin mater ial 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 setting to increase penetration and weld size Lower setting to reduce burnthrough and dis tortion 2 The STITCH OFF TIME KNOB sets off time between welds a Start with a dial setting of 0 5 seconds Raise setting to reduce burnthrough Lower setting to make weld flatter and smoother T ACCESSORIES ii 3 Set the procedure for the metal thickness to be welded 4 Close trigger and hol
18. Recessed M16080 1 3 e M16080 2 5 8 M16080 3 5 8 Requires Gas Diffuser Assembly 19418 3 025 045 Adjustable Slip On M16093 2 M16093 1 Requires Nozzle Insulator Assembly 19417 1 O o Fie 8 nl 2 Requires Gas Diffuser Assembly 19416 2 0 25 030 19416 2 Gasless Nozzle for Innershield M16938 Gun Tube Assembly Standard 60 Degrees S18920 45 Degrees S19890 Included with K673 1 3 64 1 2 mm Aluminum Feeding Kit 5356 alloy aluminum wire recom mended to alleviate potential soft wire feeding problems with push type wire feeding __Included with Wire Matic 255 Requires S19428 1 Gas Diffuser Assembly Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 NOTES WIRE MATIC 255 LINCOLN E DOL 49159 0 901 49159 0 901 J91Se N 01 uunjeH 901 J91Se N uunjeH DOL uonoes DOL uonoes DOL uonoes uumeg DOL uonoes Return to Master TOC Return to Master TOC o 7 5 Return to Master TOC 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
19. tee B 7 Changing Run In Mode eaten B 7 Enter Slow Run In B 7 Enter Fast Run In Mode B 7 Making a Weld C B 8 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC 9 5 212 Return to Section TOC Return to Master TOC Return to Master TOC Read and understand this entire section before operat ing your WIRE MATIC 255 SAFETY INSTRUCTIONS A 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 gloves insulating FUMES AND GASES a can be dangerous TUM Use ventilation or exhaust to remove fumes from breathing zone Keep your head out of fumes WELDING CUTTING and Tx GOUGING SPARKS can cause fire or explosion Keep flammable material away Do not weld cut gouge containers that have held combustibles 4 ARC RAYS can burn 2 Wear eye ear and body protection Only qualified personnel should operate this equip ment Observe all safety information throughout this manual e OPERATION EH CAUTION When using a Wire Matic 255 power source there will be a small spark if the electrode contacts the work or ground within sev
20. 320 15 208 616 5158 5158 7 555 gt 2 555 26 325 8 206 4 206 5 461 324 m LE eee MOTOR Br 1 wk T THERMOSTAT THERMOSTAT SUPPLY LINE 54 H4 P2 i aL LI 2 GND RECONNECT PANEL B 320 RI 328 325A Nin dni TO SINGLE PHASE S3 GND TO GROUND PER NATIONAL ELECTRICAL CODE SCR HEATSINK ASBLY CAVITY NUMBERING SEQUENCE FAN 2 MOTORS THERMOSTAT 18 OHMS C1 THRU C4 iow 30 000 MFD 50V OUTPUT CHOKE SPOOL GUN ADAPTER HARNESS GENERAL INFORMATION ELECTRICAL SYMBOLS PER E1537 COLOR CODE B BLACK W WHITE R RED U BLUE INDICATES CONNECTOR CAVITY NO GAS SOLENOID TO SPOOL GUN OPTION NL JUMPER USED WITHOUT SPOOL GUN OPTION NOTES 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 THERMOSTATS MOUNTED ON CHOKE COIL 52 MOUNTED CLOSEST 3 MOUNTED CLOSEST POWER TRANSFORMER THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET COMPONENT SIDE OF P C BOARD 255500 000000 XCAVITY NUMBERING SEQUENCE NON LEAD SIDE OF C
21. 6mm 8 10mm 460 60 14 2 5mm 12 Amm 575 60 14 2 5mm 12 Amm PHYSICAL DIMENSIONS HEIGHT Width DEPTH WEIGHT W GUN O o Fie ci 8 nl ele 2 im 40 1 220 lbs 1019mm 100 Kg OPERATING TEMPERATURE STORAGE OPERATING 40 C 20 C to 40 C Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O o PEN 2 2 i im Return to Section TOC Return to Master TOC Return to Master TOC a INSTALLATION ne Read entire Installation Section before installing the WIRE MATIC 255 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should install this machine Turn the input power OFF at the dis connect switch or fuse box before working on the equipment touch electrically hot parts Always connect the WIRE MATIC 255 ground ing 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 machi
22. ating the machine beyond the duty cycle and output rating There are three thermostats within the WIRE MATIC 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 Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC O10 Fle 515 5 2 im NOTE Unshaded areas of Block Logic Diagram are the subject of discussion WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC O o 515 0 PEN mlt 5 5 im Return to Section TOC Return to Master TOC Return to Master TOC THEORY OF OPERATION Em SCR OPERATIO
23. please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 O o E S8 0 PEN 9 gt 4 5 2 aja Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 ds TROUBLESHOOTING amp REPAIR re 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 The easiest access to these leads is from the right side of the machine 9 SCR OUTPUT RECTIFIER REMOVAL amp REPLACEMENT CONTINUED Fle 5 5 PROCEDURE 4 Cut the SCR gate leads G1 and G2 2 see wire markers and wiring dia 1 Disconnect lead 208 and gram using wire cutters b Cut any necessary cable ties a Thin lead is always on the out board side of the connection 5 Remove the four screws holding the SCR Assembly to the floor of the machine using a 5 16 nut drive
24. 1 513490 73 20 50 C54 1 S 13490 76 001 400 C55 1 S13430 39 18 15 C56 1 813490 30 35 10 C61 1 51340 85 27 50 C70 C75 2 T11577 35 68 400 C7 1 C72 C80 C90 5 T11577 52 0047 or 00571400 C73 1 S13490 92 3300 50 C74 1 313490 104 39uF 20V C78 1 513490 118 2200763 1 513490 8 50 25 C91 C92 2 513490 42 1 0735 D1 02 03 04 05 06 07 08 60 12199 1 14004 023 024 033 034 040 041 050 051 052 053 054 060 061 062 070 071 072 073 074 075 080 082 083 085 086 090 091 092 093 096 097 098 099 0100 0101 0102 0103 0104 0105 0106 0107 0108 0109 0110 0111 0112 D113 D114 0115 0116 0117 0118 013 014 2 T12199 2 1N4007 001 1 518214 2 DUAL DIODE ON HEATSIN 021 1 112702 29 1847444 072 1 112702 1 IN4745A 073 074 075 3 T12702 45 IN4746A 076 1 T12702 40 1N4735 077 1 T12702 33 1453478 11 24 2 518248 8 CONNECTOR J2 1 S18248 10 HEADER J3 1 518248 12 HEADER 15 1 18248 14 HEADER J6 1 18248 16 HEADER 17 28 2 518248 4 HEADER J9 J10 2 18248 6 HEADER L6 L7 L8 LIO 211 L IZ L 13 11 T12218 7 330uH L 14 LIS L17 L19 OCIT 1 515000 10 ISOLATOR 0 12 0613 2 515000 8 ISOLATOR 010 012 022 023 040 041 amp T12704 68 2N4401 011 1 T12704 54 S9 013 025 2 T12704 69 2N4403 020 1 618395 5 H S ASBLY SS 021 031 2 112704 35 024 1 518395 4 H S ASBLY 55 030 1 518105 4 HEAT SINK ASBLY R6 R7 R8 R9 R60
25. 313 Qu 20 volts 5ms MACHINE LOADED TO 220 AMPS AT 22 VDC SCOPE SETTINGS This is NOT a typical DC output voltage waveform One output SCR is not function volts Div ing Note the increased ripple content One SCR gate was disconnected to simulate an Horizontal Sweep open or non functioning output SCR Each vertical division represents 20 volts and Coupling each horizontal division represents 5 mil O o 515 0 PEN 9 gt g 8 mlt 5 2 im liseconds in time The machine was loaded Trigger with a resistance grid bank Note Scope probes connected at machine output terminals probe to electrode probe to work Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 8 5 5 Return to Section Return to Master TOC o 7 5 ree TROUBLESHOOTING amp REPAIR 7757 ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING CH1 volts 20 volts 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 divi sio
26. 37 FAN MOTOR AND FAN REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel 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 pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC MATERIALS NEEDED 3 4 Open end wrench 1 2 Socket wrench with extension Phillips head screwdriver O o 5 5 PEN 9 gt 4 mlt 5 2 im Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o 5 5 PEN 2 mlt 5 2 im Return to Section TOC Return to Master TOC F 38 FAN MOTOR AND FAN REMOVAL AND REPLACEMENT CONTINUED TROUBLESHOOTING amp REPAIR PROCEDURE See Figure F 16 for fan motor and fan removal components
27. 6810 681 174W R165 R170 2 319400 2687 26 7 1 4W R167 R168 8173 8174 4 S19400 5620 562 1 44 R188 R190 R194 8197 8198 5 319400 4422 44 2 1 44 R207 R208 2 519400 1822 18 2K 1 4W R211 1 S19400 2431 2 43K 1 4W 1 2 2 113640 9 20 JOULES 4 1 13640 16 80 JOULES TPS 1 T13640 12 38 JOULES 6 7 2 13640 15 15 JOULES wi 1 6000001 E2387 20 2 00 xi 1 S15128 4 1 517900 24 55 X4 1 S20311 6 56 x5 1 517900 5 ssi 6 1_ 15101 6 55 8 1 __ 517900 10 ss 1 _ 15102 3 55 X10 1 515018 4 55 X19 2 515128 11 1 515018 6 55 X14 X17 X18 3 S15128 10 x15 1 518395 3 X22 1 S15128 13 Yi 1 516665 2 4 0 Maz EQUIP THE LINCOLN ELECTRIC CO WM 255 CLEVELAND OHIO U S A sussecr_ CONTROL P C BOARD ASSEMBLY SCALE FuLL DR DATE 9399 AV REF SUP S D G 2803 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
28. G 3 Control PC Board G2803 Schematic G 4 Control PC Board G2803 Layout G 5 Return to Master TOC o 7 5 Return to Master TOC WIRE MATIC 255 LINCOLN NOTES WIRE MATIC 255 LINCOLN 8 DOL 49159 NOL 49159 0 901 J91Se N 901 J91Se N 01 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo Oja gt ele 2 Return to Section TOC Return to Master TOC G 2 ELECTRICAL DIAGRAMS G 2 Wiring Diagram 208 230 Code 10166 EN OPTIONAL TIMER 251 WIRE SPEED 252 256 ARC VOLTAGE 253 POWER ON INDICATOR GUN 5l 325 TRIGGER o p it 324 N A 260 262 261 263 265 264 266 K7 267 254 252 K 253 t 3 255 251 14 WIRE MATIC 255 208 2304 un CONTROL BOARD un x 4 390 nm 515 lt lt 325A lt 4 3244 lt 4 206A 495 o 542 543 o i K 1 5 5 125 1 7 ES J2 SPITEST PLUG TTTTTTTTT d T 1 PPM pis RS 325A 14 lt
29. 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 f 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 Changing Run In Mode Section 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 8 OPERATION B 8 NOTE When using Innershield electrode the gas nozzle may be removed from the insulation on the end of the gun This will give improved visibility and elimi nate the possibility of the gas nozzle overheating 7 Connect the work cable to metal to be welded Work clamp if used must make good electrical contact to the work The work must be grounded A WARNING When using an open arc process it is necessary to use corre
30. GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION No control of arc voltage Wire feed 1 ing is normal There is no gas flow when gun trig 1 ger is pulled Wire feeds and weld voltage is present The machine stops feeding wire 1 while welding FUNCTION PROBLEMS The Arc Voltage Control poten tiometer may be dirty Rotate several times and check if prob lem is resolved Check gas source and hoses for leaks or kinks If Spool Gun adaptor is not installed make certain jumper plug is installed in plug J20 See Wiring Diagram Check for mechanical restric tions in the wire feeding path The gun may be clogged Assembly Test The Arc Voltage Control poten tiometer may be faulty Check or replace See Wiring Diagram SCR Rectifier Perform the The control board may be faulty Replace Check the gas solenoid by dis connecting 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 The control broad may be faulty Replace Check the motor armature cur rent Normal armature current is 1 75 amps maximum If the motor armature current is normal the control board may be faulty Replace If the motor armature current is high 2 to 2 5 amps and there are NO restrictions in the wire feedin
31. J3 and J6 from the G2803 Control Board See Figure F 5 o ES z o re FIGURE F 5 Control Board Molex Plug Locations for G2803 PC Control Board 3 Verify that the capacitors have com pletely discharged with an Analog Volt Ohm meter Disconnect leads X2 and X3 from the negative capacitor bank using a 1 2 open end wrench See Figure F 6 X2 AND X3 NEGATIVE CAPACITOR BANK BUSS BAR FIGURE F 6 Location of Leads X2 and 5 Separate leads X2 and X3 from the negative capacitor bank buss bar Be sure there is no electrical con tact See Figure F 6 NOTE DO NOT DISASSEMBLE THE SCR RECTIFIER HEAT SINK ASSEM BLY 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 bat tery WIRE MATIC 255 LINCOLN 5 F 18 TROUBLESHOOTING amp REPAIR 9 ACTIVE SCR RECTIFIER ASSEMBLY TEST CONTINUED Fle 8 7 Connect the Tester to the SCR 1 as 10 Close or keep closed switch SW 1 amp shown in Figure F 7 11 Close switch SW 2 for 2 seconds a Connect Tester lead A to the and release and read meter 5 5 anode 2 2 a If the voltag
32. SCREWS HOLDING RECONNECT PANEL FAN BLADE FAN MOTOR MOUNTING BRACKET FIGURE F 16 Fan Motor and Fan Removal Components 1 2 Remove the Case Back screws Remove the gas solenoid using a 3 4 open end wrench Using a 5 16 wrench remove the 5 screws holding the fan motor mount ing bracket to the case back 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 LINCOLN 5 25 GAS I FITTING SCREWS MOUNTING CASE BACK TO FLOOR Loosen the two screws holding the reconnect panel in place and a slide the reconnect panel from the frame Remove the fan blade Note fan blade position on motor shaft for ref erence for replacing fan a Pry the fan blade off the motor b Slide the fan blade off the motor shaft TROUBLESHOOTING amp REPAIR pun 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 Return to Section TOC Return to Master TOC b When the motor is free from the mounting bracket place it care fuly 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 9 Install t
33. Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o 7 5 F 11 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER TEST TEST PROCEDURE A 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 NOTE The location of Plugs may vary depending on the machine code 202 1J3 J3 HE le 204A 2J3 D 4203 343 BE 206 49 4J6 WM 255 CONTROL 209 7J6 J6 0 208 16 6 5 FIGURE F 1 G2803 Control Board Main Transformer Test Points WIRE MATIC 255 LINCOLN 5 F 11 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o
34. 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 con trol 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 fea ture 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 cur rent 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 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 sim ply 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 k
35. arc peut tre plus s v re qu un coup de soliel donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les TRANSFORMATEUR ET Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place WIRE MATIC 255 LINCOLN 5 NOTES WIRE M
36. electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 4 c and 6 2 3 e Also see item 7b 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 787 standards 2 6 Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 me
37. 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 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 trou bleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O o E lt gt 2 2 aja Return to Section TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING amp REPAIR F 2 PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power OFF at the fuse box before work ing on equipment Do not touch electrically hot parts CAUTION Sometimes machine failur
38. poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POU R enrouler le c ble lectrode autour de n importe quelle partie du corps LES MACHINES SOUDER Un coup d
39. 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 Stitch Weld mode allows repeated timed weld cycles while gun trigger is held closed Weld on time 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 automat ically set by the machine ACCESSORIES is 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 dri ver or other suitable tool 5 Reach through the exposed pane
40. rotate in a clockwise direction when wire is dereeled from the top of the coil See Figure B 2 E OPERATION zii MOULDED ADAPTER RETAINING SPRING WIRE DEREELING DIRECTION 2 51 mm O D SPINDLE LOCKING COLLAR BRAKE TENSION ADJUSTING A 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 A 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 elec trode 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 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q S o 2 5 tc Return to Section TOC Return to Master TOC O 2 8 E 2 6
41. 1 5 3 5 VDC between lead 555 positive 145 and lead 206B negative 2J5 Seq Figure 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 RUN NING THE FEEDBACK VOLTAGE MAY BE FROM 0 TO 5 VDC b If the 1 5 3 5 VDC is not pre sent or not correct the Control Board is not receiving the prop er feedback voltage from the tach circuit Check the leads from the tach circuit to the Control Board for loose or bro ken connections Ifthe leads are okay the Control Board may be faulty Replace WIRE MATIC 255 LINCOLN 5 F 21 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o 7 5 F 22 TROUBLESHOOTING amp REPAIR F 22 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM H1 C 0 volts 20 volts 2ms SCOPE SETTINGS This is a typical DC output voltage wave form generated from a properly operating Volts Div machine Note that each vertical division represents 20 volts and that each horizontal Horizontal Sweep division represents 2 milliseconds in ti
42. 2 Input Connections 2 Fuse and Wire A 3 Input Power Connections and Ground Connections A 3 Connect Shielding 4 gt Reconnect Procedure A 5 E Connect Output A 7 Install the Work Clap 7 Output Polarity Connection A 7 Gun Liner and Contact Tip Installation A 7 Wire Size Conversion Parts A 8 Gun and Cable Installation 8 o 7 5 Return to Master TOC WIRE MATIC 255 LINCOLN 5 A INSTALLATION AA TECHNICAL SPECIFICATIONS Wire Matic 255 INPUT SINGLE PHASE 60 HERTZ ONLY Standard Voltage Input Current at Rated Output Return to Section TOC Return to Master TOC 208 230 1 60 53 49 Amps 230 460 575 50 25 20 Amps RATED OUTPUT OUTPUT CurentRange _ CurentRange _ Maximum Open Circuit Voltage Wire Speed Range 250A 50 600 IPM 1 27 15 2 m minute RECOMMENDED INPUT WIRE amp FUSE SIZE Input Voltage Fuse Superlag Type 75 C wire in Type 75 C Copper Frequency or Breaker Size Copper conduit AWG Ground Wire in Conduit IEC Sizes Runs to Runs over 100ft 30m 100ft 30m Return to Section TOC Return to Master TOC 208 60 8 10mm 6 16mm 230 60 10
43. 24 to 325 should have conti nuity zero ohms when the gun trigger is pulled If not then the gun may be faulty replace Contact The Lincoln Electric Service Dept 216 383 2531 or 1 800 833 9353 WELD Check input power switch S1 It may be faulty Check for lose or broken wires at the reconnect panel Perform Main Transformer Check the thermostats and associated leads for loose or broken connections See wiring diagram The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 WIRE MATIC 255 LINCOLN 5 TROUBLESHOOTING amp REPAIR ET TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION OUTPUT PROBLEMS No Open Circuit Voltage output but 1 Check the input voltage at the 1 Check for loose or broken con wire feeds normally when gun trig machine Input voltage must nections at the output terminals ger is pulled match the rating plate and the the choke the capacitor bank reconnect panel and all heavy current carrying leads Return to Section TOC Return to Master TOC The gun may be faulty Check or replace Make sure t
44. 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 Seg Figure A 4 for the location of the com ponents used to connect the air supply cylinder INSTALLATION ii WARNING Gas under pressure is explosive Always keep gas cylinders in an upright position and always keep chained to undercarriage or sta tionary 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 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 pres ence 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 O
45. A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 8 5 E Return to Section Return to Master TOC o O 7 9 c tc ES TROUBLESHOOTING amp REPAIR ED TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The welding arc is variable and slug gish The arc striking is poor WELDING PROBLEMS Check the welding cable con nections for loose or faulty con nections Make sure the wire feed speed voltage and shielding gas are correct for the process being used Check the welding cable con nections for loose or faulty con nections Make sure the wire feed speed voltage and shielding gas are correct for the process being used Perf the Output Rectifier i orm Bridge Test The control board may be faulty Replace The control board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perfo
46. ANGEABILITY OF A THIS OMPONENTS OR CIRCUITRY NE CIRCUIT BOARD MAY LEAD A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED EARTH GROUND BLACK CTRICAL 7 COMMON CONNECTION SUPPLY VOLTAG 1 B GENERAL INFORMATION L SYMBOLS PI POWER SUPPLY SOURCE 7 7 FRAME CONNECTION 3 24 498 THE LINCOLN ELECTRIC CO one WIREMATIC 255 CONTROL CLEVELAND OHIO U S A SUBJECT SCHEMATIC SCALE NONE m Date _9 2 92 CHK SUP S D G 62802 THERM LD CONN JWL SWIL N HOVENENE 710 duvog NOLLdO OL Return to Section Return to Master TOC 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 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 5 2 5 tc Return to Section TOC
47. ATIC 255 LINCOLN E DOL 49159 901 49159 0 901 J91Se N 01 901 J91Se N 01 RETURN TO MAIN INDEX TABLE OF CONTENTS Page i v installation Ra Section A Technical Specifications A 1 Safety Pr cautions A 2 Select Proper Location A 2 Input Connections A 2 Reconnect Procedure A 5 Connect Output Components A 7 Operation EE 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 3 Controls and Settings B 4 Using the Wire Drive Roll B 5 Operating Steps B 7 DUertcap Dr 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 K
48. C WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O o Fr 8 nl 2 2 2 Return to Section TOC Return to Master TOC Return to Master TOC ails MAINTENANCE SAFETY PRECAUTIONS A WARNING Have a qualified electrician do the maintenance and troubleshooting work Disconnect the input power off using the dis connect 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 manu al before working on this machine ROUTINE AND PERIODIC MAINTENANCE 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 punc tures 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 tq Figure D 1 Main transformer and choke Electrode and work cable connections SCR rectifier bridge and heat sink fins
49. D CABLE INSTALLATION WARNING Turn the welder Power Switch OFF before chang ing 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 Return to Master TOC 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 insert ed and tighten thumb screw Return to Section TOC 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 specifica tions and the gun trigger switch must be capable of switching 5 milliamps at 15 volts DC resistive A CAUTION The gun trigger switch connected to the gun trig ger 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 WIRE MATIC 255 might result if this switch is common to an electrical circuit other than the WIRE MATIC 255 trigger circuit O o lt gt 2 2 im Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5
50. Fan Motor Assembly Control Printed Circuit Board NOTE The fan motor has sealed bearings which require no maintenance WIRE MATIC 255 LINCOLN 5 D 1 D 2 o tc lt LL e 8 2 8 lt 5 5 2 5 5 EB LLI ano 2 lt oa lt 9 E EO 9 E lt gm z a o 3 LL oc tc LL D Z lt oc lt a DOL uunjeu 901 49159 901 J91Se N 01 UuunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes uumeg DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 9 o 2 3 Return to Section Return to Master TOC o 7 5 DRIVE ROLLS AND GUIDE TUBES After every coil of wire inspect the wire drive mecha nism Clean it as necessary by blowing with low pres sure 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 floo
51. LIGHT The red LED pilot light located next to the POWER SWITCH is lit when the power is ON VOLTAGE 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 WIRE SPEED CONTROL POTENTIOMETER KNOB Controls the wire speed from 50 to 600 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 com partment 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 start ing and makes it easier to set the stickout The 2 sec ond limit permits high speed loading of the gun and cable WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q S o 2 5 tc Return to Section TOC Return to Master TOC O 2 D 9 gt o E 2 tc USING THE WIRE DRIVE ROLL 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 i
52. N INPUT LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED 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 sig nal 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 con trolled by the gate An SCR fired by a short burst of current into the gate This gate pulse must be more positive than the cath ode 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 b
53. ONNECTOR z 12 J13 5 J21 1 34 0000000 2 120 14 6 19690 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 one of the enclosure panels LINCOLN amp WIRE MATIC 255 Return to Section TOC Return to Master TOC Return to Section TOC Ojo o gt ele 2 Return to Section Return to Master TOC Return to Master TOC G 3 Wiring Diagram 230 460 575 Code 10167 om OPTIONAL TIMER BOARD qu 45 WIRE SPEED 252 256 ARC VOLTAGE 253 POWER ON INDICATOR 325 GUN roc TRIGGER o pops N A d FILTER ELECTRICAL DIAGRAMS WIRE MATIC 255 230 460 575V 1 gt a Li 260 1 262 2601 64 3 263 4 265 5 264 Ix 6 266 267 4 a 1 3 nee 1 5 T 7 l qe 324 SHUNT LINE SWITCH 1 77777777 SCI TEST PLUG x 1 ee 555 SPI TEST 2 4 2068 PLUG gt 3 5158 4 gt 325 6 324 8 gt 104 12 gt 4 B 137 W 51589 1 5158 655 692 555 8 2068 9422 2068 5 MOTOR GEARBOX
54. PLATE 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 OUTER STEEL HEX NUT OUTER STEEL INPUT POWER HEX NUT INPUT POWER RECONNECT TRANSFORMER TRANSFORMER INPUT LEAD INPUT LEAD LOWER VOLTAGE CONNECTION HIGHER VOLTAGE CONNECTION FIGURE A 5 Reconnect Diagram For 208 230 1 60 Machines 1 ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHEST NAME PLATED SINGLE PHASE INPUT VOLTAGE TO CHANGE CONNECTIONS FOR A DIFFERENT 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 INPUT TERMINAL BLOCK L1 AND L2 AT THE UPPER COR NER OF THE PANEL TORQUE TO 16 IN LBS 3 CONNECT A GROUNDING LEAD TO THE GROUND STUD ON THE MACHINE NEAR THE TER MINAL BLOCK 230 V 60 HZ 460 V 60 HZ 575 V 60 HZ JUMPER CONNECTION DIAGRAMS JUMPERS GROUND PER NATIONAL ELECTRICAL CODE SINGLE PHASE INPUT POWER SUPPLY LINES FIGURE A 6 Reconnect Diagram For 230 460 575 1 60 Machine WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o
55. R DAMAGE IS PRESENT Have an authorized repair station clean the regulator or repair any damage WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o 7 5 7 Attach the flow regulator to the cylinder valve and tighten the union nut s securely with a wrench a NOTE f connecting the flow regulator to 10096 CO 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 con nect to the CO 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 regula tor adjusting knob counter clockwise until the pres sure is released from the adjusting spring 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
56. R62 R63 10 519400 1001 IK 174W R64 R72 R200 R10 R7 1 R81 R90 R91 R132 10 519400 4751 4 75K R 136 R192 R209 R210 R18 R19 R24 R25 R78 R80 13 519400 1002 10 1 4W R93 R96 R124 R163 R176 R193 R206 R20 R65 R94 R103 1108 8121 13 519400 1000 100 1 4W R 129 148 R20 t R202 R203 R204 R205 R23 R115 R147 3 519400 1502 15K_174W R61 1 S18380 4 THERMI STOR R66 8146 2 519400 3921 3 92K 1 4W 67 1 519400 4753 475K 1 44 R68 R104 R106 3 19400 5621 5 62 1 4W R70 1 T14231 2 10M 1 2W R74 R153 2 T14648 19 1 R77 R103 R113 R122 8149 5 19400 6811 6 BIK 1 4W RB2 1 _ 519400 3320 332 174 R89 1 319400 4750 475 1 4W R35 1 519400 1652 16 5K 1 4W R97 R110 2 519400 1501 1 5 1 4W R100 R101 8164 8169 4 S19400 33R2 33 2 1 4W R102 R111 2 519400 2212 22 IK 1 44 R105 1 319400 2672 26 7 1 4W R107 8117 2 619400 7500 750 1 4W R112 1 519400 3321 3 32K 1 4W 114 1 S19400 2671 2 67 1 4W R116 R212 2 519400 4752 47 5 1 4W R118 1 S19400 2670 257 174W R119 1 112300 75 25 7W R120 1 519400 5232 52 3K 1 4W R123 R166 R177 8191 4 51920022211 2 21K 1 4W R125 R127 R187 R183 8195 7 19400 5110 511 174W R196 R199 R126 R131 2 S19400 5112 1 4W R140 8141 2 T14764 2 25 7W R143 1 T14648 5 3 3K 5 R144 R152 2 T14648 25 10 54 R145 R162 R175 3 T14648 22 50 5W R150 1 _ 519400 3011 3 01 174W R160 R161 8171 8172 4 519400
57. ROUBLESHOOTING amp REPAIR ree WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST CONTINUED TEST PROCEDURE NOTE POLARITY MUST BE OBSERVED FOR THESE TESTS Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC WM 255 CONTROL 541 W 1345 539 555 145 2068 5158 _ 2 5 3 5 O10 515 gt 2 im FIGURE F 8 Plug J5 Location on G2803 PC Control Board Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 o 2 3 Return to Section Return to Master TOC o 0 5 F 21 TROUBLESHOOTING amp REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST CONTINUED 4 Test for 2 25 VDC between lead plug location 12J5 539 B posi tive 12J5 and lead 541 W 1345 negati
58. 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 is ACCESSORIES iis 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 WFS Setting Wire Matic 255 Arc Voltage Setting 030 8mm 270 035 9mm 250 3 64 1 2mm 210 15V 16V 21V 5 return to normal WIRE MATIC 255 welding set the transfer switch to FEEDER position and reset feeder gun weld procedure settings WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 5 o 2 3 Return to Section Return to Master TOC o 7 5 TIMER KIT 585 1 The Timer Kit provides selectable 4 step trigger inter lock 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
59. WIRE MATIC 255
60. WIRE MATIL 255 bn For use with machines having Code Numbers 10166 10167 Return to Master TOC View Safety Info 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 WIRE MATIC 255 EQUIPMENT WITHOUT READ ae ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT most importantly think before you act and be careful Return to Master View Safety Info gt as 5 5 jo z 2 als SERVICE MANUAL LINCOLN E World s Leader in Welding and Cutting Products ELECTRIC Sales and Service through Subsidiaries and Distributors Worldwide 22801 St Clair Ave Cleveland Ohio 44117 1199 U S A Tel 216 481 8100 View Safety Info Return to Master TOC Premier Manufacturer of Industrial Motors SAFETY WARNING 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 amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Flori
61. a Ifthe electrode fails to thread itself into the out going guide tube of the wire drive open the quick release idle roll arm e 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 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 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 o 2 5 tc Return to Section TOC Return to Master TOC o O 2 8 E 2 tc 87 OPERATION 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 T
62. and Feedback Control E 2 Constant Voltage E 3 Wire Drive Motor and Feedback E 4 Thermal Protection 5 SCR Operation 6 WIRE SOLENOID VOLTAGE MAIN GUN TRIGGER AND THUMB SWITCH LINE TRANSFORMER SWITOH FEEDBACK POSITIVE TERMINAL SCR RECTIFIER ODOA OFVSO gt NEGATIVE TERMINAL Figure E 1 Block Logic Diagram NOTE Unshaded areas of Block Logic Diagram are the subject of discussion WIRE MATIC 255 LINCOLN 5 THEORY OF OPERATION E INPUT LINE VOLTAGE AND MAIN TRANSFORMER WIRE GAS SPEED SOLENOID Return to Section TOC Return to Master TOC ARC VOLTAGE CONTROL BOARD GUN TRIGGER AND THUMB SWITCH LINE TRANSFORMER SWITCH ir FEEDBACK POSITIVE TERMINAL SCR RECTIFIER ODOA OFVSO gt FAN NEGATIVE MOTORS TERMINAL Return to Section TOC Return to Master TOC Figure E 2 Input Line Voltage and Main Transformer 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 trans former and to the thermostatically controlled fan motors The transformer cha
63. and Side Panels Perform the Capacitor Bank Removal Procedure Remove lead X1 from the left side SCR heat sink assembly using a 1 2 socket wrench extender and universal adapter Remove lead X4 from the right side heat sink assembly using a 1 2 socket wrench extender and univer sal adapter Disconnect all leads from the recon nect panel using a 3 8 open end wrench Disconnect all leads from the POWER SWITCH Remove the POWER SWITCH Label and cut leads 202 203 204 a 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 Remove all cable ties wire mounts and any harness tape that could get in the way during transformer removal using wire cutters and screwdriver Remove the four screws mounting the transformer to the floor of the machine using a 5 16 nut driver 12 13 14 15 WIRE MATIC 255 LINCOLN 5 Disconnect the positive output lead at the wire drive motor Remove the strain relief grommet through which the positive output lead passes through the horizontal baffle of the machine Pull down on the positive output lead until it slides out the hole in the baffle Carefully remove the main trans former a sure all leads are clear F 36 PE TROUBLESHOOTING amp REPAIR
64. ated areas or vent the engine exhaust fumes 2 1 AR outdoors Do not add the fuel near an open flame welding arc or when the engine is run ning 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 AN from V belts gears fans and all other moving parts when starting operating or repairing equipment 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 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 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 To avoid scalding do not remove the radiator pressure cap when the engine is hot SAFETY ELECTRIC AND MAG _ NETIC FIELDS may be danger
65. connect all wiring harness plugs and Molex Plugs connected to the Control Board See Figure F 9 OOO OOHH WM 255 CONTROL Return to Section TOC Return to Master TOC FIGURE F 10 Control Board Mounting Locations may vary with different Code Machines 5 Lift the Control Board straight up FIGURE F 9 Wiring Harness and and out from the machine Molex Plug Locations 6 When re installing the Control Board carefully secure Board to mounting standoffs O o 5 5 0 PEN 2 mlt 5 2 im Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 ES TROUBLESHOOTING amp REPAIR pen WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel 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 pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact the Lincoln Electric se
66. ct eye head and body protection 8 Position electrode over joint End of electrode may be lightly touching the work 9 Lower welding helmet close gun trigger and begin welding Hold the gun so the contact tip to work distance is about 3 8 inch 10mm or 3 4 20mm for Outershield 10 To stop welding release the gun trigger and then pull the gun away from the work after the arc goes out 11 When no more welding is to be done close the valve on gas cylinder if used momentarily oper ate gun trigger to release gas pressure 12 Turn POWER SWITCH to OFF WIRE MATIC 255 LINCOLN 5 NOTES WIRE MATIC 255 LINCOLN E DOL 49159 0 901 49159 0 901 J91Se N 01 uunjeH 901 J91Se N uunjeH DOL uonoes DOL uonoes DOL uonoes uumeg DOL uonoes ACCESSORIES 9 TABLE OF CONTENTS ACCESSORIES SECTION ACCESSORIES SECTION sue Section C 2 Other Available Magnum 2501 Gun and oc 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 iscia eer RH C 2 Timer Kit K585 1 3 gt Timer Kit Installation Optional 585 1
67. d 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 O o E 515 0 PEN 9 gt 4 5 2 aja Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 dads TROUBLESHOOTING amp REPAIR p STATIC SCR RECTIFIER ASSEMBLY TEST CONTINUED TEST PROCEDURE 1 Disconnect main AC input power to the machine Return to Section TOC Return to Master TOC 2 Disconnect Plugs J3 and J6 from the G2803 Control Board This electrically isolates the SCR bridge assembly See Figure F 2 a z o o 10 re si NEGATIVE CAPACITOR BANK BUSS BAR Return to Section TOC Return to Master TOC FIGURE F 3 Location of Leads X2 and 5 Separate leads X2 and X3 from the negative capacitor bank buss bar FIGURE F 2 Remove Plugs J3 and J6 Be sure there is no electrical con to Perform Static SCR Rectifier tact See Figure F 3 Assembly Test 3 Verify that the capacitors have com pletely 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 O o 5 5 PEN 2 mlt 5 2
68. d be performed only by Lincoln Electric factory trained per sonnel 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 pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 O o 5 5 PEN 9 gt 4 mlt 5 2 im Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o 7 5 F 36 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT CONTINUED PROCEDURE Disconnect main input power to the machine Remove the Case Top
69. d for the welding process required 3 Operate the gun trigger for welder output and to energize the wire feeder motor 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 power OFF on front panel of Wire Matic 255 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 t
70. d 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 Part Number KP674 035S KP674 045S KP674 045C KP674 3 64A 3 64 1 2mm ALUMINUM FEEDING KIT K673 1 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 Provides gun and wire drive conversion parts to weld with 3 64 1 2mm aluminum wire 5356 alloy alu minum wire is recommended for best push feeding performance Kit includes drive roll and incoming guide tube for the wire drive and 45 gun 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 spin dle It is needed to mount the 22 20 Ib Readi Reels WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 2 3 Return to Section Return to Master TOC o
71. d only be gently tightened Over tightening will split or collapse the liner and cause poor wire feeding 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 coun terclockwise the same direction as removing a right hand thread until the collar reaches a stop 2 Pull the collar off the gun handle NOTE 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 ET MAINTENANCE 38 COUNTER CLOCKWISE FIGURE D 3 Gun Handle disassembly WIRE MATIC 255 LINCOLN 5 ais MAINTENANCE aii ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES Return to Section TOC Return to Master TOC Cable Liner M16087 2 025 030 0 6 0 8 mm For 15 4 5m or Shorter Cable M16087 1 035 045 0 9 1 2 mm M17714 1 3 64 Alum Wire 1 2 mm Alum Wire Contact Tips 19391 6 Standard Duty 19391 7 S19391 1 S19391 2 Heavy Duty S19393 5 Tapered 519393 6 19393 1 19393 2 Return to Section TOC Return to Master TOC Tab For Aluminum Gas Nozzles Fixed Flush M16081 1 M16081 2 M16081 3
72. da 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 Return to Master TOC BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PER FORMED ONLY BY QUALIFIED INDIVIDUALS Return to Master TOC o 7 5 Return to Master TOC 1 b e ELECTRIC SHOCK can kill 1 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 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 In semiautomatic or automatic wire welding the electrode
73. e 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 PANEL E ACCESS DOOR REAR NAMEPLATE RECONNECT PANEL ASSEMBLY FIGURE A 1 Case Back Assembly Input Power Cable Entry Connections WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O o 515 0 PEN 9 4 mlt 5 5 im Return to Section TOC Return to Master TOC Return to Master TOC INSTALLATION s FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the Technical specifications page of this manual for the machine 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 ther mal magnetic circuit breakers DO NOT use fuses or circuit breakers with a lower amp rating than recommended This can result in nui sance tripping caused by inrush current even when machine is not being used for welding at high output currents Use input and grounding wire sizes tha electrical codes or see the Technical Specifications page in this manual INPUT POWER CONNECTIONS AND GROUND CONNECTIONS Have a qualified electrician conn
74. e control board com pares the commands of the ARC Voltage Control potentiometer with the feedback signals The appro priate 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 con trolling the output of the machine See SCR The control board also powers and com mands the gas solenoid and the wire drive motor NOTE Unshaded areas of Block Logic Diagram are the subject of discussion WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O o 5 5 0 PEN 2 mlt 5 2 cc im Return to Section TOC Return to Master TOC Return to Master TOC a THEORY OF OPERATION aii CONSTANT VOLTAGE OUTPUT WIRE GAS SPEED SOLENOID CONTROL BOARD BAIN GUN TRIGGER AND THUMB SWITCH TRANSFORMER FEEDBACK POSITIVE TERMINAL e ARC VOLTAGE SCR RECTIFIER AOoP uommr FAN NEGATIVE MOTORS TERMINAL Figure E 4 Constant Voltage Output 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 con stant voltage output is applied to the output terminals of the machine
75. e is 3 6 volts while b Connect Tester lead C to the the switch is closed and after cathode the switch is open the SCR is functioning c Connect Tester lead G to the gate b 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 5 defective 5 5 NOTE Be sure battery is functioning O12 properly A low battery can affect the 2 results of the test Repeat Battery Test 212 Procedure in Step 6 if needed 5 5 12 Open switch SW 1 tc 13 Reconnect the Tester leads See Figure F 7 a Connect Tester lead A to the cathode b Connect Tester lead C to the anode mt 6 VOLT c Disconnect Test lead G from LANTERN 5 BATTERY the gaie R1 4 ohms 10watts 14 Close switch SW 1 R2 3 ohms 10watts 5 To test SCR s construct the circuit outlined above 15 Read meter for zero voltage Resistor values plus or minus ten percent voltmeter scale should be low approximately 0 5 or a lf the voltage is zero the SCR is 0 10 volts DC functioning b If the voltage is higher than FIGURE 7 SCR Tester Circuit and zero the SCR is shorted SCR connections 8 Close switch SW 1 16 Perform the Active Test Procedure outlined in Steps 5 13 for SCR 2 O e NOTE Switch SW 2 should be open 55 17 Replace all SCR assemblies that d
76. ect 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 three phase 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 a The center terminal in the receptacle is for the grounding connection 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 ter minal to the frame of the welder This ensures proper grounding of the welder frame when the welder plug is inserted into the receptacle 4 e proper wire sizes See the Technical for proper wire sizes cable lengths over 100 feet larger copper wires should be used CAUTION Connect to a system grounding wire See the United States National Electrical Code and local codes for other details and means for proper groundin
77. elow 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 WIRE MATIC 255 LINCOLN 5 NOTES WIRE MATIC 255 LINCOLN E DOL 491 59 0 901 49159 901 J91Se N 01 uunjeH 901 J91Se N 01 uunjeH DOL uonoes DOL uonoes uumeg DOL uonoes uumeg DOL uonoes Return to Master TOC Return to Master TOC o 7 5 Return to Master TOC TROUBLESHOOTING amp REPAIR TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION TROUBLESHOOTING amp REPAIR SECTION sise Section F How to use Troubleshooting Guide sis F 1 PC Board Troubleshooting ProCedures ettet et et ERU me eee F 2 Mi geld siete RET Mee EET on ES F 3 Test Procedures Main 6 e ta F 10 Static SCR Rectifier Bridge F 13 Active SCR Rectifier Assembly TS nets annee F 16 Wire Drive Motor and Tachometer Feedback Test F 19 Oscilloscope WAV GIONS te sien ele raie
78. eral 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 high performance welding system Simple controls consisting of continuous full range cal ibrated voltage control and wire feed speed control provide versatility with ease of use WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o B 5 2 tc Return to Section TOC Return to Master TOC O 2 8 E 2 tc RECOMMENDED PROCESSES AND EQUIPMENT The WIRE MATIC 255 is recommended for GMA weld ing processes using 10 to 44 Ib 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 self shielding electrodes The WIRE MATIC 255 is factory equipped to feed 035 0 9mm and 045 1 2mm electrodes It includes 12 ft 8 6m GMAW gun and cable assem bly equipped for these wire sizes with a duty cycle rat ing of 200A 60 or 250A 35 Using GMAW processes requi
79. es 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 abil ity that the PC board is the most likely com ponent causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is proper ly 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 dam aged by static electricity Remove your body s static charge before opening the ATTENTION 2919 Static Sensitive Static shielding bag Wear Devices an anti static wrist strap For Handle only at Safety use a 1 Meg ohm Static Safe resistive cord connected to Workstations a grounded part of the equipment frame Reusable Container If you don t have a wrist Do Not Destroy strap touch an unpainted grounded part of the equip ment frame Keep touching the frame to pre vent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the Board must be either conductive anti static or static dissipative WIRE MATIC 255 LINCOLN 5 Remove the
80. ez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine a souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger 6 zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas
81. g Connect to hot wires of a three wire single phase system or to one phase of a two or three phase system CONNECT TO A SYSTEM GROUNDING WIRE SEE THE UNITED STATES 5 NATIONAL ELECTRICAL CODE AND OR LOCAL CODES FOR OTHER DETAILS AND MEANS FOR PROPER GROUNDING GREEN WIRE CONNECT TO HOT WIRES OF A THREE WIRE SINGLE PHASE SYSTEM OR TO ONE PHASE OF THREE PHASE SYSTEM c FIGURE A 2 Ground Connections WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 Return to Section Return to Master TOC Q 7 5 For the 230 460 575V 60 HZ model which is equipped with a plug an input cord or a receptacle the input power supply leads must be connected directly to the_Reconnect Panel shown in Figure A 3 Refer to Technical Specifications lat the begin 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 INPUT LINES TORQUE TERMINAL SCREWS TO 16 IN LBS 1 8 Nm FIGURE A 3 Input Power Connection For 230 460
82. g path then the motor or gear box may be defective Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 8 5 E Return to Section Return to Master TOC o O 9 c tc dad TROUBLESHOOTING amp REPAIR E TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION No control of wire feed speed Other machine functions are nor mal There is no wire feed when gun trig ger is pulled Normal open circuit voltage is present WIRE FEEDING PROBLEMS The wire feed speed control may be dirty Rotate several times and check if problem is resolved If the drive rolls are turning then check for a mechanical restric tion in the wire feed path The gun liner may be clogged Check or Replace If the drive rolls are NOT turning when the gun trigger is pulled then contact your local Lincoln Electric Authorized Field Service Facility The Wire Speed Control poten
83. h a liner for a 035 045 0 9 1 2mm diameter electrode and an 035 0 9mm contact tip 1 Ifa 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 c Slip the appropriate gas nozzle onto the noz zle insulator Either a standard 50 12 7mm or optional 62 15 9mm 1 0 slip on gas noz zle may be used and should be selected based on the welding application d Adjust the gas nozzle for the GMAW process to be used For the short circuiting transfer process the contact tip end should be flush to extended to 12 3 2mm See Figure A 8 For the spray transfer process the contact tip should be flush to recessed 12 3 2mm See Figure A 8 FIGURE 8 Connections Contact Tip and Electrode WIRE MATIC 255 LINCOLN 5 mE 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 vari ous drive roll kits refer to Acessories Section Return to Section TOC Return to Master TOC GUN AN
84. hat the transformer secondary leads are securely connected to the SCR Rectifier Assembly Perform the SCR Rectifier Assembly Test The control board may be faulty Replace Wire feeds but welding output is low 1 Make sure that the proper wire 1 Check for loose or faulty con causing wire to stub Welds are and procedures are being used nections of the heavy current cold Machine cannot obtain full carrying leads rated output of 200 amps at 28 volts 2 Check gun and work cable for loose or faulty connections The output capacitor bank may be faulty Check for loose con nections at the capacitors Also check for leaky capacitors Replace if necessary WARNING The liquid elec trolyte in these capacitors is toxic Avoid contact with any portion of your body Perform the SCR Rectifier Assembly Test Return to Section TOC Return to Master TOC O o 91 5 nl 2 2 im The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC
85. he fan blade When installing the fan blade the blade is flush with the end of the motor shaft Return to Section TOC Return to Master TOC a Spin the fan to be sure it is free to rotate 10 Reassemble the remaining compo nents in reverse order of removal O10 Fle 515 5 2 im Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS Input Volts Hertz Maximum Idle Amps Maximum Idle Watts Return to Section TOC Return to Master TOC OPEN CIRCUIT VOLTAGE 10 to 40 VDC 35 40 VDC Strike Voltage Return to Section TOC Return to Master TOC WIRE SPEED RANGE 50 600 IPM 1 27 15 2 m minute O o Fie 5 5 9 nl mlt 5 2 im Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 NOTES WIRE MATIC 255 LINCOLN E DOL 49159 0 901 49159 0 901 J91Se N 01 uunjeH 901 J91Se N uunjeH DOL uonoes DOL uonoes DOL uonoes uumeg DOL uonoes TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION o 5 o 5 Electrical Diagram Section Section G 3 c Wiring Diagram 208 230 Code 10166 G 2 Wiring Diagram 230 460 575 Code 10167
86. he 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 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O10 O O Ele 55 9 lt 212 5 c IT Return to Section TOC Return to Master TOC Return to Master TOC NOTE Arc starting characteristics may be affected when using the fast run in mode since optimum start ing 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 proce dures 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 3 Set desired arc voltage and wire speed for the electrode wire material type and thickness and gas for
87. his is an approximate setting The optimum idle roll pressure varies with type of wire wire diameter surface condi tions lubrication and hardness As a general rule hard wires may require greater pressure and soft or aluminum wire may require less pressure than the fac tory setting The optimum idle roll setting can be deter mined 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 OPERATING STEPS WARNING Before operating the machine be sure you have all the materials needed to perform the work Be sure you are familiar with and have taken all possible safety precautions before starting the work It is important that you follow these operating steps each time you use the machine STARTING THE WELDER 1 Turn the POWER switch to ON This illuminates the red LED pilot light 2 Select the correct voltage and wire spee
88. ic 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 pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories output problems function prob lems 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 con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION The last column labeled Recommended Course of Action lists the most likely com ponents that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a
89. ired to LEAD 206 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 CHOKE LEAD 9 Clear the leads and carefully CAPACITOR SEREBAD remove the capacitor bank assem BANK bly from the machine ASSEMBLY Return to Section TOC Return to Master TOC FLOOR MOUNTING SCREWS 2 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 dis charged using a volt ohmmeter Polarity must be observed O o E S8 0 PEN 9 gt g 8 5 2 aja 3 Remove the two transformer sec ondary leads X2 and 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 posi tive capacitor bank buss bar using a 1 2 open end wrench 5 Remove lead 206 and the D1 diode lead from the negative capac itor bank buss bar using a slot head screwdriver and 3 8 open end wrench Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 TROUBLESHOOTING amp REPAIR didi MAIN TRANSFORMER REMOVAL AND REPLACEMENT A WARNING Service and repair shoul
90. it 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 2 02520 eR xh 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 D 3 Cable Cleaning s e ain 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 2501 D 4 Gun Handle Disassembly D 5 Acce
91. it the travel dis tance 11 Remove the drive roll assembly o o 2 3 Return to Section Return to Master TOC o 7 5 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 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 b Wiggle the drive motor and drive assembly gently back and forth until the two parts separate 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 WIRE MATIC 255 LINCOLN 5 did TROUBLESHOOTING amp REPAIR SCR OUTPUT RECTIFIER REMOVAL amp REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel 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
92. its for other sizes and types of wire are also available Quick Connect Welding Gun Gun connector has integrated welding power and gas connection with sep arate front panel twist lock trigger connection mount Gun and Cable A 12 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 B3 OPERATION B3 MACHINE CAPABILITY The WIRE MATIC 255 is rated on the following duty cycles based on a 10 minute time period i e for 6096 duty cycle it is 6 minutes on and 4 minutes off LIMITATIONS The WIRE MATIC 255 may not operate satisfactorily if powered with a portable or in plant generating system WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 2 o 2 5 Return to Section Return to Master TOC o O o 9 c 5 tc B 4 OPERATION sii 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 1 LINCOLNS WIRE MATIC 255 WARNING Figure B 1 Operator Controls 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 PILOT
93. l 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 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 com plete the installation WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o D 7 5 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
94. lowed when warranty reports are to be sub mitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROB LEM will help avoid denial of legitimate PC board warranty claims Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 8 5 E Return to Section Return to Master TOC o O 0 9 c tc dis TROUBLESHOOTING amp REPAIR ES TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION Major Physical or Electrical Damage 1 is Evident Machine is dead No Open Circuit 1 Voltage output and No Wire Feed when gun trigger is pulled OUTPUT PROBLEMS Contact your local Electric Authorized Service Facility Lincoln Field Make certain that the input power switch is in the ON posi tion Check the input voltage at the machine Input voltage must match the rating plate and the reconnect panel Blown or missing fuses in the input line The thermostats may be open due to machine overheating 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 Check the trigger circuit Leads 3
95. me Coupling Note Scope probes connected at machine output terminals probe to electrode Trigger probe to work WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 8 5 5 Return to Section Return to Master TOC o 7 5 dixo TROUBLESHOOTING amp REPAIR diio TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED CH1 HHOHHHHHHHHHHHHHHHHHHHHH THHHHHHHHHEHHHHHEHHTHHHEHUOHH 0 volts 20 volts 5ms MACHINE LOADED TO 250 AMPS AT 26 VDC This is a typical DC output voltage wave form 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 Horizontal Sweep Coupling Trigger WIRE MATIC 255 LINCOLN 5 EET TROUBLESHOOTING amp REPAIR ass ABNORMAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED ONE OUTPUT SCR NOT FUNCTIONING Return to Section TOC Return to Master TOC CH1 ojo slg HH HHHH HHHH tH volts oz 29
96. n 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 5ms SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o 7 5 F 26 TROUBLESHOOTING amp REPAIR F 26 TYPICAL SCR GATE VOLTAGE WAVEFORM CH1 0 volts 2 volts This is a typical SCR gate pulse voltage waveform The machine was in an open cir cuit condition no load and operating prop erly Note that each vertical division repre sents 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 5ms SCOPE SETTINGS Volts Div Horizontal Sweep Coupling Trigger WIRE MATIC 255 LINCOLN 5 dad TROUBLESHOOTING amp REPAIR dic CONTROL PC BOARD REMOVAL AND REPLACEMENT Return to Section TOC Return to Master TOC A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Una
97. n the 030 035 0 8 0 9mm position as indi cated 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 instruc tions 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 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 prop erly sized for wire being used LOADING THE WIRE REEL To mount a 22 30 Ib 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 K363P Adapter so the spin dle 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 3 Position the Readi Reel so that it will
98. ne case back louvers should be kept at a mini mum Not following these precautions can result in the nuisance shutdown of the machine because of exces sive operating temperatures 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 INPUT CONNECTIONS WARNING e 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 ques tion 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 con nected for the highest voltage If the welder is to be operated at a lower voltage it must be recon nected 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 Reconnect Section bf this manual for details on reconnecting the machine to operate at different voltages 3 Be sure the voltage phase and frequency of th
99. ne operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC A WARNING THE LIQUID ELECTRODE IN THE CAPACITORS IS TOXIC DO NOT TOUGH THE CAPAC ITORS 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 O o E 515 0 PEN 9 gt g 8 5 2 aja Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 dai TROUBLESHOOTING amp REPAIR CAPACITOR BANK REMOVAL REPLACEMENT CONTINUED PROCEDURE 6 Remove the 204 lead from the pos itive buss bar See Figure F 15 for location of Capacitor Bank Removal and Replacement com Remove the shunt from the negative Capacitor bank buss bar using a 1 2 Return to Section TOC Return to Master TOC nents EIS socket wrench with a universal tool adapter LEADS X2 AND X3 a Two people may be requ
100. nges the high voltage low current input power to a low voltage high current out put In addition the main transformer also has an iso lated center tapped 30 VAC auxiliary winding that sup plies 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 WIRE MATIC 255 LINCOLN 5 O o 515 0 PEN 2 2 5 2 im Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC O o 515 0 PEN mlt 5 5 im Return to Section TOC Return to Master TOC Return to Master TOC THEORY OF OPERATION a OUTPUT RECTIFICATION AND FEEDBACK WIRE GAS SPEED SOLENOID ARC VOLTAGE CONTROL BOARD GUN TRIGGER AND THUMB SWITCH LINE TRANSFORMER SGH ir FEEDBACK POSITIVE TERMINAL SCR RECTIFIER ODOA OFVSO AOo uomrm FAN NEGATIVE MOTORS TERMINAL 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 Th
101. o 9 9 Read meter for zero voltage not pass the above tests 212 a the voltage reading is higher 18 Replace all Molex Plugs onto the than zero the SCR is shorted Control Board and connect leads X2 5 WIRE MATIC 255 LINCOLN 5 TROUBLESHOOTING amp REPAIR ds WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel 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 pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 O o 515 0 PEN 2 2 mlt 5 2 im Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 eee T
102. o Master TOC Return to Section TOC Return to Master TOC o o 2 3 Return to Section Return to Master TOC o 5 MAKING A WELD WITH THE SPOOL GUN ADAPTER K672 1 INSTALLED A 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 posi tioned 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 elec trically HOT 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 electrical ly HOT 3 Operation with Wire Matic 255 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
103. ous 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known 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 WIRE MATIC 255 LINCOLN 5 Return to Master TOC Return to Master TOC o 7 5 Return to Master TOC SAFETY PRECAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Proteg
104. ove the gas nozzle and nozzle insulator SETSCREW BRASS CABLE CONNECTOR 2 Locate the set screw in the gas diffuser which is used to hold the old liner in place 1 1 4 1 25 3 Loosen the set screw with 5 64 2 0mm Allen t 31 8MM wrench LINER TRIM 4 Remove the gas diffuser from the gun tube 5 Lay the gun and cable out straight on a flat sur face 6 Loosen the set screw located in the brass connec tor at the feeder end of the cable and pull the liner GAS DIFFUSER out of the cable NOZZLE INSULATOR 7 Insert a new untrimmed liner into the connector end of the cable GAS NOZZLE a Check the liner bushing stencil to make sure it is the appropriate one for the wire size being FIGURE D 2 Liner maintenance used WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q 9 o 2 Return to Section Return to Master TOC o 7 E 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 CAUTION This screw shoul
105. r 2 Remove the contact tip from the gun 3 With an air hose at the gas diffuser end use low pressure to gently blow out the cable liner CAUTION Excessive pressure at the start may cause the dirt to form a plug 4 Flex the cable over its entire length and again blow out the cable 5 Repeat this procedure until no more dirt comes out 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 zii MAINTENANCE ad CONTACT TIP AND GAS NOZZLE INSTALLATION 1 Choose the correct size contact tip for the elec trode 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 1 0 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 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Retu
106. r 6 Pivot the SCR Assembly counter clockwise to provide access to the right side heat sink See Figure F 14 Return to Section TOC Return to Master TOC DISCONNECT LEADS 208 AND X1 FIGURE 12 Heat Sink lead discon nection 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 FIGURE F 14 Heat Sink Lead 3 Remove the diode lead from the 8 Disconnection negative capacitor band buss bar on the right side of the machine using a slot head screwdriver and 3 8 open end wrench 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 O o E S8 0 PEN 9 gt g 8 5 2 8 Clear the leads 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 LEAD HEAVY LEAD FIGURE 13 Heat Sink lead discon nection Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 Ps TROUBLESHOOTING amp REPAIR dius CAPACITOR BANK REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in danger to the technician or the machi
107. res use of the optional gas regulator and a supply of shielding gas DESIGN FEATURES AND ADVANTAGES 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 pro vided 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 weld ing gun and work cable Adjustable Flow Regulator Accomodates CO 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 sup port of a single gas cylinder lt is not necessary to completely lift the gas cylinder when placing it on the platform Easy Accessibility The door on the wire feeder enclosure protects wire and wire drive from dirt dust and damage pis OPERATION He 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 con nection Power Switch Front panel toggle switch turns inpu
108. rm the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 WIRE MATIC 255 LINCOLN 5 dinis TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel 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 pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 O o E S8 0 PEN 9 gt g 8 5 2 aja Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 Return to
109. rn to Master TOC Q 9 o 2 3 Return to Section Return to Master TOC o 7 5 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 Diameter of Replacement Liner Size Stenciled on Fixed Nozzle Gas Adjustable Nozzle Electrodes Used Part Number End of Liner Diffuser Part No M Diffuser Part Bushing and Stencil and Stencil 025 030 Steel M16087 2 030 0 8mm 19418 3 19418 2 0 6 0 8 035 045 Steel M16087 1 045 1 2mm 19418 3 19418 1 0 9 1 2 3 64 Aluminum M17714 1 3 64 1 2mm 519418 3 519418 1 1 2 LINER REMOVAL INSTALLATION 8 Fully seat the liner bushing into the connector AND TRIMMING INSTRUCTIONS 9 Tighten the setscrew on the brass cable connector FOR MAGNUM 250L NOTE Do not install the gas diffuser onto the end of NOTE The variation in cable lengths prevents the the gun tube at this time interchange ability of liners between guns Once a liner installed in another gun unless it can meet the liner cut 216 insulator removed from the gun tube off length requirement Liners are shipped with the jacket of the liner extended the proper amount 11 Trim the liner to the length shown in FIGURE D 2 1 Rem
110. rom your welding distributor or from the manufacturer Apr 93 WIRE MATIC 255 LINCOLN Return to Master TOC Return to Master TOC o 7 5 Return to Master TOC SAFETY 2 WELDING SPARKS lt gt 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 Remember that welding sparks and hot 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 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 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 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 though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Ha
111. rvice department for technical troubleshooting assistance before you proceed Call 216 383 2531 or 800 833 9353 WELD Return to Section TOC Return to Master TOC MATERIALS NEEDED Large slot head screwdriver 5 16 Nut Driver Small slot head screwdriver O o 5 5 PEN 9 gt 4 mlt 5 2 im Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F 30 PROCEDURE 1 Disconnect main input power to the machine Remove the Case Top and Side Panels Using the 5 16 Nutdriver remove the gear box top cover Remove the two sheet metal screws located on the left rear side of the gear box housing using a 5 16 nut driver Remove the drive roll See Figure 11 a Remove the thumb screw drive hub and the spacer Remove the screw holding the gun connector assembly to the Case Front Panel See Figure F 11 Slide the entire wire drive assembly carefully toward the Case Back and TROUBLESHOOTING amp REPAIR WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT CONTINUED WS 59 approximately 2 51 mm away from the center baffle to gain access to the drive motor and wiring FIGURE F 11 Wire Drive Assembly Removal 10 Disconnect molex plugs J15 J12 a The gas hose and gun connec and J11 See wiring diagram tor leads will lim
112. s 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 pre cautions 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 Return to Section TOC Return to Master TOC 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 O o 515 0 PEN 2 2 5 2 im Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O o 5 5 PEN 9 gt g 8 mlt 5 2 im Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR F 17 ACTIVE SCR RECTIFIER ASSEMBLY TEST CONTINUED TEST PROCEDURE 1 Disconnect main AC input power to the machine Disconnect Molex Plugs
113. s use of standard Magnum 200 300 or 400 gun and cable assemblies K672 1 SPOOL GUN ADAPTER KIT A 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 SP 255 5 255 and Wire Matic 255 wire feed welder machines 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 al ACCESSORIES id 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 equip ment 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 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 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return t
114. ssories and Expendable Replacement Parts for Magnum 250L Gun and Cable Assemblies D 6 WIRE MATIC 255 LINCOLN vi RETURN TO MAIN INDEX TABLE OF CONTENTS continued Page Theory of Operation Section E Power Supply Operation 1 Thermal Protection E 5 SCH Operation 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 xoxo seas o C Rn don CORRI ac Roe bes F 10 Oscilloscope Waveforms F 22 Replacement Procedures F 27 Electrical Diagrams Section G Paris CSS bade es oe P 258 WIRE MATIC 255 LINCOLN 5 vi INSTALLATION 9 TABLE OF CONTENTS INSTALLATION SECTION INSTALLATION SECTION Section 2 Technical 1 Safety Precautions sre riter bbs eee it ua Ra See b UE A 2 Select Proper 2 suc a A 2 Cs
115. t power on and off Pilot Light Indicates when power is applied to machine Thermostatically Controlled Fans Cools trans former 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 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 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o B 5 2 tc Return to Section TOC Return to Master TOC o O 2 o E 2 WIRE FEEDER FEATURES Wire Loading Adjustable brake spindle mounts Readi Reel Adapter included with WIRE MATIC 255 or most any 2 51mm 1 0 wire spool Accommodating standard 12 305mm
116. tal 23 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 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 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 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 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 f
117. the flow rate recommended for the procedure and process being used before making the weld i INSTALLATION m m d INLET CONNECTOR CYLINDER PLATFORM ASSEMBLY 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 con nected for the proper voltage A 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 dif ferent 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 For 208 230 1 60 machine s seg Figure A 5 For 230 460 575 1 60 machine s sea Figure A 6 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 Return to Section Return to Master TOC Q 7 5 ii INSTALLATION adi ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHER OF THE TWO INPUT VOLTAGES LISTED ON THE NAME
118. tiometer may be faulty Check or replace See Wiring Diagram Perform the Wire Drive Motor and Tach Feedback test The control board may be faulty Replace Perform the Wire Drive Motor and Tach Feedback Test The Wire Feed Control poten tiometer may be faulty Check or replace See Wiring Diagram The control board may be faulty Replace A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216 383 2531 or 1 800 833 9353 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o 8 c E Return to Section Return to Master TOC o 0 5 di TROUBLESHOOTING amp REPAIR pe TROUBLESHOOTING GUIDE Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION The arc is unstable and or hunting Weld bead is narrow or ropy May have porosity with electrode stub bing into plate The contact tip seizes in the gas dif fuser WELDING PROBLEMS Check for worn or melted con tact tip Check for loose or faulty con nections on the work and elec trode cables
119. urnes F 22 Normal Open Circuit Voltage Waveform sas ssnensmmnideeemutetnenennentetnntiienenenie 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 iuuentutis Hu RE F 26 Replacement Procedures Control PC Board Removal and Replacement F 27 Wire Drive Assembly Removal F 29 SCR Output Rectifier Removal and Replacement F 31 Capacitor Bank Removal and F 33 Main Transformer Removal and nme F 35 Fan Motor and Fan Removal and F 37 acum qr He F 40 WIRE MATIC 255 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o o 2 Return to Section Return to Master TOC o 7 5 TROUBLESHOOTING amp REPAIR F 1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electr
120. uthorized 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 pre cautions 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 Return to Section TOC Return to Master TOC A 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 O o E lt gt 2 2 aja MATERIALS NEEDED 5 16 Nutdriver Phillips head screwdriver Static electricity grounding strap Return to Section TOC Return to Master TOC WIRE MATIC 255 LINCOLN 5 mee TROUBLESHOOTING amp REPAIR dins CONTROL PC BOARD REMOVAL AND REPLACEMENT CONTINUED REMOVAL AND REPLACE 4 Carefully remove the P C Board from the mounting standoffs See MENT PROCEDURE Figure F 10 Return to Section TOC Return to Master TOC 1 Disconnect main input power the machine 2 Remove the Case Top and Side Panels using 5 16 nut driver 3 Dis
121. ve to determine if the correct armature voltage is being supplied Figure F8 a Insert probes in to the Molex pin cavities 5 Pull the gun trigger 6 Read meter Normal DC volts is from 2 25 VDC VDC varies depending on wire feed speed 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 Ifthe wires are okay and voltage to the drive motor armature is zero the Control Board may be faulty Replace If the correct DC armature volt age is present at the wire drive motor the motor or motor brush es may be faulty Test and or replace d If the motor is running at high speed and the armature voltage is high and uncontrollable pro ceed with the tachometer test Test for Tachometer Supply Voltage to 1 Test for 15 VDC between lead 515B positive 345 and lead 206B negative 245 Sed Figure F 8 for pin locations a Insert probes into Molex pin cavities 2 Pull gun trigger 3 Read meter for 15 VDC a lf the 15 VDC is present check the leads to the tach circuit b the leads are okay and 15 VDC is present the correct volt age is being received from the Control Board Go to Feedback Test Ifthe 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
122. ve Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 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 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage
123. 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 dey TROUBLESHOOTING amp REPAIR ay STATIC SCR RECTIFIER ASSEMBLY TEST A WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel 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 pre cautions detailed throughout this manual Return to Section TOC Return to Master TOC 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 Return to Section TOC Return to Master TOC 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 an

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