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For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT.
most importantly, think before you
act and be careful.
World's Leader in Welding and Cutting Products
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
RETURN TO MAIN INDEX
WIRE-MATIC 255
10166,
10167.
And,
SERVICE MANUAL
Sales and Service through Subsidiaries and Distributors Worldwide
SVM 119-A
20
18
22
300
16
24
250
350
14
26
200
400
150
450
28
100
500
50
550
600
1
ON
0
OFF
Premier Manufacturer of Industrial Motors
January 1996
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Summary of Contents for Lincoln Electric WIRE-MATIC 255 SVM 119-A
- Page 1 WIRE-MATIC 255 For use with machines having Code Numbers: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part.
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Page 2: Electric Shock Can Kill
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER- FORMED ONLY BY QUALIFIED INDIVIDUALS. - Page 3 WELDING SPARKS can cause fire or explosion. 4.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
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Page 4: Electric And Mag- Netic Fields
FOR ENGINE powered equipment. 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 7.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ____________________________________________________ 7.c. Do not add the fuel near an open flame welding arc or when the engine is run- ning. - Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 NOTES WIRE-MATIC 255...
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Page 7: Table Of Contents
Safety ............i - v Installation . - Page 8 TABLE OF CONTENTS (continued) Theory of Operation ........Section E Power Supply Operation Thermal Protection .
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Page 9: Installation
INSTALLATION TABLE OF CONTENTS - INSTALLATION SECTION - INSTALLATION SECTION ... Section A Technical Specifications ...A-1 Safety Precautions ...A-2 Select Proper Location...A-2 Stacking...A-2 Tilting ...A-2 Input Connections ...A-2 Fuse and Wire Sizes ...A-3 Input Power Connections and Ground Connections...A-3 Connect Shielding Gas...A-4 Reconnect Procedure...A-5 Connect Output Components...A-7 Install the Work Clamp ...A-7... -
Page 10: Technical Specifications
TECHNICAL SPECIFICATIONS - Wire-Matic-255 INPUT - SINGLE PHASE/ 60 HERTZ ONLY Standard Voltage 208/230/1/60 230/460/575 Duty Cycle 100% Current Range 30A - 250A RECOMMENDED INPUT WIRE & FUSE SIZE Input Voltage/ Fuse (Superlag) Frequency or Breaker Size 208/60 230/60 460/60 575/60 HEIGHT 28.2”... -
Page 11: Safety Precautions
Read entire Installation Section before installing the WIRE-MATIC 255 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should install this machine. • Turn the input power OFF at the dis- connect switch or fuse box before working on the equipment. •... -
Page 12: Fuse And Wire Sizes
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. -
Page 13: Connect Shielding Gas
For the 230/460/575V/ 60 HZ model which is not equipped with a plug, an input cord, or a receptacle, the input power supply leads must be connected directly to the Reconnect Panel as shown in Figure A.3. Refer to Technical Specifications at the begin- ning of this chapter for proper wire sizes. -
Page 14: Reconnect Procedure
7. Attach the flow regulator to the cylinder valve and tighten the union nut(s) securely with a wrench. a. NOTE: If connecting the flow regulator to 100% 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. - Page 15 ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHER OF THE TWO INPUT VOLTAGES LISTED ON THE NAMEPLATE. TO CHANGE VOLTAGE CONNECTION PROCEED AS FOLLOWS: 1. REMOVE THE OUTER STEEL HEX NUT FROM THE TERMINAL WHERE THE TRANSFORMER INPUT LEAD IS CONNECTED.
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Page 16: Connect Output Components
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. -
Page 17: Wire Size Conversion Parts
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 . GUN AND CABLE INSTALLATION WARNING Turn the welder Power Switch OFF before chang- ing output connection. - Page 18 NOTES WIRE-MATIC 255...
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Page 19: Operation
OPERATION TABLE OF CONTENTS - OPERATION SECTION - OPERATION SECTION ... Section B Safety Instructions...B-1 General Description...B-1 Recommended Processes and Equipment...B-2 Design Features and Advantages ...B-2 Unit Features...B-2 Power Source Features...B-2 Wire Feeder Features ...B-3 Machine Capability ...B-3 Limitations ...B-3 Controls and Settings...B-4 Using the Wire Drive Roll...B-5 Procedure for Changing Drive Roll ...B-5... -
Page 20: Operation
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. -
Page 21: Recommended Processes And Equipment
RECOMMENDED PROCESSES AND EQUIPMENT The WIRE-MATIC 255 is recommended for GMA weld- ing processes using 10 to 44 lb. (4.5 to 20 kg) 2" (51mm) I.D. spools or Readi-Reel coils (with optional adapter) of: .025" through .045" (0.6-1.2mm) solid steel. .035"... -
Page 22: Machine Capability
WIRE FEEDER FEATURES: Wire Loading - Adjustable brake spindle mounts Readi-Reel® Adapter, included with WIRE-MATIC 255, most 2" (51mm) I.D. Accommodating standard 12" (305mm) and 8" (203mm) diameter coils, the spindle’s adjustable brake provides appropriate dereeling drag to prevent wire reel overrun and loop-offs. -
Page 23: Controls And Settings
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. LINCOLN ELECTRIC Figure B.1 - Operator Controls. 1. POWER SWITCH: Toggle switch to turn input power ON and OFF. Place the lever in the ON position to turn the WIRE-MATIC 255 ON. -
Page 24: Using The Wire Drive Roll
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 in the .030-.035" (0.8-0.9mm) position as indi- cated by the stenciling on the exposed side of the drive roll. -
Page 25: Feeding Electrode
To mount a 10 to 44 lb. (4.5 to 20 kg) spools: 8” (200mm) [Use K468 Adapter] and 12” (300mm) diameter: 1. Remove the locking collar and the Readi-Reel Adapter (if installed) on the 2 inch (51mm) diame- ter spindle. 2. -
Page 26: Operating Steps
SETTING IDLE ROLL PRESSURE The idle roll pressure thumb screw is set at the factory backed out 2-1/2 turns from full pressure. This is an approximate setting. The optimum idle roll pressure varies with type of wire, wire diameter, surface condi- tions, lubrication, and hardness. -
Page 27: Making A Weld
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. - Page 28 NOTES WIRE-MATIC 255...
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Page 29: Accessories
ACCESSORIES TABLE OF CONTENTS - ACCESSORIES SECTION - ACCESSORIES SECTION ... Section C Other Available Magnum 250L Gun and Cable Assembly ...C-1 Magnum Gun Connection Kit (Optional K466-6) ...C-1 K672-1 Spool Gun Adapter Kit...C-1 Making a Weld with the Spool Gun Adapter and Spool Gun (K672-1) Installed...C-1 Making a Weld with the Spool Gun Adapter (K672-1) Installed ...C-2... -
Page 30: Other Available Magnum 250L Gun And Cable Assembly
(L9696) 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™... -
Page 31: Making A Weld With The Spool Gun Adapter (K672-1) Installed
MAKING A WELD WITH THE SPOOL GUN ADAPTER (K672-1) INSTALLED CAUTION In either transfer switch position, closing the gun trigger will cause the electrode of both guns to be electrically "HOT." Be sure unused gun is posi- tioned so the electrode or the tip will not contact metal case or other metal common to the work. -
Page 32: Timer Kit (K585-1
TIMER KIT (K585-1) 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: •... -
Page 33: Aluminum Feeding Kit (K673-1)
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. -
Page 34: Dual Cylinder Mounting (K671-1
ACCESSORIES DUAL CYLINDER MOUNTING KIT (K671-1) Permits stable side-by-side mounting of two full size (9” dia. x 5’ high) gas cylinders with “no lift” loading. Simple installation with installation kick stand and easy instructions provided (L9687). Includes upper and lower cylinder supports, wheel axles and mounting hardware. -
Page 35: Maintenance
MAINTENANCE TABLE OF CONTENTS - MAINTENANCE SECTION - MAINTENANCE SECTION ... Section D Safety Precautions ...D-1 Routine and Periodic Maintenance ...D-1 Component Locations ...D-2 Drive Rolls and Guide Tubes ...D-3 Cable Cleaning...D-3 Gun Tubes and Nozzles...D-3 Contact Tip and Gas Nozzle Installation...D-3 Liner Removal and Replacement...D-4 Liner Removal, Installation, and Trimming Instructions for Magnum 250L ...D-4... -
Page 36: Safety Precautions
SAFETY PRECAUTIONS 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. -
Page 37: Component Locations
MAINTENANCE CONTROL PC BOARD FAN MOTORS SCR RECTIFIER BRIDGE CHOKE MAIN TRANSFORMER Figure D.1 - Component Locations. WIRE-MATIC 255... -
Page 38: Drive Rolls And Guide Tubes
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. -
Page 39: 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 Electrodes Used Part Number .025-.030"... -
Page 40: Gun Handle Disassembly
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. -
Page 41: Accessories And Expendable Replacement Parts For Magnum 250L Gun And Cable Assemblies
ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES DESCRIPTION Cable Liner For 15' (4.5m) or Shorter Cable Contact Tips Standard Duty Heavy Duty Tapered Tab (For Aluminum) Gas Nozzles Fixed (Flush) (Recessed) (Requires: Gas Diffuser Assembly.) Adjustable Slip-On (Requires: Nozzle Insulator Assembly.) (Requires: Gas Diffuser Assembly) - Page 42 NOTES WIRE-MATIC 255...
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Page 43: Scr Operation
THEORY OF OPERATION TABLE OF CONTENTS - THEORY OF OPERATION SECTION - THEORY OF OPERATION SECTION ... Section E Power Supply Operation ...E-1 Input Line Voltage and Main Transformer ...E-1 Output Rectification and Feedback Control ...E-2 Constant Voltage Output ...E-3 Wire Drive Motor and Feedback ...E-4 Thermal Protection ...E-5 SCR Operation ...E-6... -
Page 44: Input Line Voltage And Main Transformer
THEORY OF OPERATION INPUT LINE VOLTAGE AND MAIN TRANSFORMER VOLTAGE MAIN LINE TRANSFORMER SWITCH RECONNECT MOTORS 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. -
Page 45: Output Rectification And Feedback Control
THEORY OF OPERATION OUTPUT RECTIFICATION AND FEEDBACK VOLTAGE MAIN LINE TRANSFORMER SWITCH RECONNECT MOTORS 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. -
Page 46: Constant Voltage Output
THEORY OF OPERATION CONSTANT VOLTAGE OUTPUT VOLTAGE MAIN LINE TRANSFORMER SWITCH RECONNECT MOTORS 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... -
Page 47: Wire Drive Motor And Feedback
THEORY OF OPERATION WIRE DRIVE MOTOR AND FEEDBACK VOLTAGE MAIN LINE TRANSFORMER SWITCH RECONNECT MOTORS 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. -
Page 48: Thermal Protection
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- ating the machine beyond the duty cycle and output rating. -
Page 49: Scr Operation
THEORY OF OPERATION INPUT CATHODE OUTPUT ANODE GATE 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. - Page 50 NOTES WIRE-MATIC 255...
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Page 51: Pc Board Troubleshooting Procedures
TROUBLESHOOTING & REPAIR - TROUBLESHOOTING & REPAIR SECTION - TROUBLESHOOTING & REPAIR SECTION ... Section F How to use Troubleshooting Guide ...F-1 PC Board Troubleshooting Procedures...F-2 Troubleshooting Guide ...F-3 Test Procedures Main Transformer Test...F-10 Static SCR Rectifier Bridge Test...F-13 Active SCR Rectifier Assembly Test ...F-16 Wire Drive Motor and Tachometer Feedback Test ...F-19 Oscilloscope Waveforms ...F-22 Normal Open Circuit Voltage Waveform ...F-22... -
Page 52: Troubleshooting And Repair
TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. -
Page 53: Pc Board Troubleshooting Procedures
TROUBLESHOOTING & REPAIR 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 failures... -
Page 54: Troubleshooting Guide
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... - Page 55 200 amps at 28 volts. 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...
- Page 56 NOT activated. 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...
- Page 57 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...
- Page 58 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...
- Page 59 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 POSSIBLE AREAS OF...
- Page 60 The arc striking is poor. 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...
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Page 61: Main Transformer Test
TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST 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. -
Page 62: Test Procedures
F-11 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST TEST PROCEDURE WARNING The ON/OFF POWER SWITCH will be "hot" during these tests. __________________________ NOTE: Secondary voltages will vary proportionably with the primary input voltage. 1. Disconnect the main input power supply to the machine. 2. - Page 63 F-12 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER TEST (CONTINUED) 4. Locate the following leads on Plug G2803: LEAD #202 #203 #204 A 5. Connect main input power to the machine. 6. Turn the Wire-Matic 255 ON/OFF POWER SWITCH to ON. 7. Make the following voltage tests at Plug J3.
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Page 64: Static Scr Rectifier Assembly Test
TROUBLESHOOTING & REPAIR STATIC SCR RECTIFIER ASSEMBLY TEST 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. - Page 65 F-14 TROUBLESHOOTING & REPAIR STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED) TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Disconnect Plugs J3 and J6 from the G2803 Control Board. electrically isolates the SCR bridge assembly. See Figure F.2. FIGURE F.2 - Remove Plugs J3 and J6 to Perform Static SCR Rectifier Assembly Test.
- Page 66 F-15 TROUBLESHOOTING & REPAIR 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).
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Page 67: Active Scr Rectifier Assembly Test
ACTIVE SCR RECTIFIER ASSEMBLY 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. - Page 68 F-17 TROUBLESHOOTING & REPAIR ACTIVE SCR RECTIFIER ASSEMBLY TEST (CONTINUED) TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Disconnect Molex Plugs J3 and J6 from the G2803 Control Board. See Figure F.5. FIGURE F.5 - Control Board Molex Plug Locations for G2803 PC Control Board.
- Page 69 F-18 TROUBLESHOOTING & REPAIR ACTIVE SCR RECTIFIER ASSEMBLY TEST (CONTINUED) 7. Connect the Tester to the SCR 1 as shown in Figure F.7. a. Connect Tester lead (A) to the anode. b. Connect Tester lead (C) to the cathode. c. Connect Tester lead (G) to the gate.
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Page 70: Wire Drive Motor And Tachometer Feedback Test
TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST 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. - Page 71 F-20 TROUBLESHOOTING & REPAIR WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (CONTINUED) TEST PROCEDURE NOTE: POLARITY OBSERVED FOR THESE TESTS. Test for Correct Wire Drive Motor Armature Voltage 1. Disconnect main input power to the machine. 2. Remove the Case Top and Side Panels using a 5/16"...
- Page 72 F-21 TROUBLESHOOTING & 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) (13J5) (negative) to determine if the correct armature voltage is being supplied.
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Page 73: Normal Open Circuit Voltage Waveform
F-22 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 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 2 milliseconds in time. Note: Scope probes connected at machine output terminals: (+) probe to electrode, (-) probe to work. -
Page 74: Typical Output Voltage Waveform - Machine Loaded
F-23 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED 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. -
Page 75: Abnormal Output Voltage Waveform - Machine Loaded One Output Scr Not Functioning
F-24 TROUBLESHOOTING & REPAIR ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED ONE OUTPUT SCR NOT FUNCTIONING MACHINE LOADED TO 220 AMPS AT 22 VDC This is NOT a typical DC output voltage waveform. One output SCR is not function- ing. Note the increased ripple content. One SCR gate was disconnected to simulate an open or non-functioning output SCR. -
Page 76: Abnormal Open Circuit Voltage Output Capacitor Bank Not Functioning
F-25 TROUBLESHOOTING & REPAIR ABNORMAL OPEN CIRCUIT VOLTAGE OUTPUT CAPACITOR BANK NOT FUNCTIONING 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. -
Page 77: Typical Scr Gate Voltage Waveform
F-26 TROUBLESHOOTING & REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORM 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. -
Page 78: Control Pc Board Removal And Replacement
TROUBLESHOOTING & REPAIR CONTROL PC BOARD REMOVAL AND REPLACEMENT 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. - Page 79 F-28 TROUBLESHOOTING & REPAIR CONTROL PC BOARD REMOVAL AND REPLACEMENT (CONTINUED) REMOVAL AND REPLACE- MENT PROCEDURE 1. Disconnect main input power the machine. 2. Remove the Case Top and Side Panels using 5/16" nut driver. 3. Disconnect all wiring harness plugs and Molex Plugs connected to the Control Board.
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Page 80: Wire Drive Assembly Removal And Replacement
TROUBLESHOOTING & REPAIR WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT 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. - Page 81 F-30 TROUBLESHOOTING & REPAIR WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT (CONTINUED) PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case Top and Side Panels. 3. Using the 5/16” Nutdriver remove the gear box top cover. 4. Remove the two sheet metal screws located on the left rear side of the gear box housing using a 5/16”...
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Page 82: Scr Output Rectifier Removal And Replacement
TROUBLESHOOTING & REPAIR SCR OUTPUT RECTIFIER REMOVAL & REPLACEMENT 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. - Page 83 F-32 TROUBLESHOOTING & REPAIR SCR OUTPUT RECTIFIER REMOVAL & REPLACEMENT (CONTINUED) PROCEDURE 1. Disconnect Transformer Lead X1 from the heat sink on the left side of the machine (facing the front) using a 1/2" socket wrench. See Figure F.12. a. Thin lead is always on the out- board side of the connection.
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Page 84: Capacitor Bank Removal And Replacement
TROUBLESHOOTING & REPAIR CAPACITOR BANK REMOVAL AND REPLACEMENT 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. - Page 85 F-34 TROUBLESHOOTING & REPAIR CAPACITOR BANK REMOVAL AND REPLACEMENT (CONTINUED) PROCEDURE See Figure F.15 for location of Capacitor Bank Removal and Replacement com- ponents. FIGURE F.15 - Location of Capacitor Bank Removal and Replacement Components. 1. Disconnect main input power to the machine.
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Page 86: Main Transformer Removal And Replacement
TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT 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. -
Page 87: Troubleshooting And Repair
F-36 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT (CONTINUED) PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case Top and Side Panels. 3. Perform Removal Procedure. 4. Remove lead X1 from the left side SCR heat sink assembly using a 1/2"... -
Page 88: Fan Motor And Fan Removal And Replacement
TROUBLESHOOTING & REPAIR FAN MOTOR AND FAN REMOVAL AND REPLACEMENT 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. - Page 89 F-38 TROUBLESHOOTING & REPAIR FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED) PROCEDURE See Figure F.16 for fan motor and fan removal components. FIGURE F.16 - Fan Motor and Fan Removal Components 1. Remove the Case Back screws. 2. Remove the gas solenoid using a 3/4"...
- Page 90 F-39 TROUBLESHOOTING & REPAIR FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED) 7. Remove the fan motor. a. Loosen and remove the two screws from the motor mounting bracket using a slot head screw driver. b. When the motor is free from the mounting bracket, place it care- fully on the bottom of the machine.
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Page 91: Retest After Repair
F-40 F-40 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR INPUT IDLE AMPS AND WATTS Input Volts/Hertz Maximum Idle Amps Maximum Idle Watts 230/60 OPEN CIRCUIT VOLTAGE 10 to 40 VDC 35-40 VDC Strike Voltage WIRE SPEED RANGE 50 - 600 IPM (1.27 - 15.2 m/minute) WIRE-MATIC 255... - Page 92 NOTES WIRE-MATIC 255...
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Page 93: Electrical Diagrams Section
TABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagram Section ....... . . Section G Wiring Diagram (208/230) Code 10166 . - Page 94 NOTES WIRE-MATIC 255...
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Page 95: Electrical Diagrams
Wiring Diagram (208/230) Code 10166 O P T I O N A L T I M E R B O A R D J 1 6 2 5 1 W I R E S P E E D 2 5 2 2 5 6 A R C V O L T A G E 2 5 3... - Page 96 Wiring Diagram (230/460/575) Code 10167 O P T I O N A L T I M E R B O A R D J 1 6 2 5 1 W I R E S P E E D 2 5 2 2 5 6 A R C V O L T A G E 2 5 3...
- Page 97 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.
- Page 98 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.
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