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Lincoln Electric SVM 117-A manuel d'utilisation

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Table des matières du manuel d’utilisation

  • Page 1

    WIRE-MA TIC 250 SER VICE MANUAL Sales and Service through Subsidiaries and Distributors Worldwide 22801 St. Clair A ve. Cleveland, Ohio 441 17-1 199 U.S.A. T el. (216) 481-8100 World's Leader in W elding and Cutting Products Premier Manufacturer of Industrial Motors SVM 1 17-A December 1995 Safety Depends on Y ou Lincoln arc welding and cuttin[...]

  • Page 2

    i SAFETY i WIRE-MA TIC 250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJUR Y OR DEA TH. KEEP CHILDREN A W A Y . P ACEMAKER WEARERS SHOULD CONSUL T WITH THEIR DOCTOR BEFORE OPERA TING. Read and understand the following safety highlights. For additional safety[...]

  • Page 3

    CYLINDER may explode if damaged. 5.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. 5.b. Always keep cylinders in an upright positi[...]

  • Page 4

    iii SAFETY iii WIRE-MA TIC 250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Mar . ‘93 ELECTRIC AND MAG- NETIC FIELDS may be dangerous 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). W elding current creates EMF fields around welding cables and welding [...]

  • Page 5

    iv SAFETY iv WIRE-MA TIC 250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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[...]

  • Page 6

    NOTES WIRE-MA TIC 250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 7

    v Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safety Precautions[...]

  • Page 8

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC vi Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E Power Supply Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Thermal Protection . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 9

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION WIRE-MA TIC 250 INST ALLA TION SECTION ........................................ Section A T echnical Specifications ...................................................A-1 Safety Precautions ...........................................................A-[...]

  • Page 10

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC WIRE-MA TIC 250 Duty Cycle Amps V olts at Rated Amps 100% 145 amps 26 60% 200 amps 28 35% 250 amps 26 Current Range Maximum Open Circuit V oltage Wire Speed Range 30A - 250A 40V [...]

  • Page 11

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Read entire Installation Section before installing the WIRE-MA TIC 250 SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should install this machine. • T[...]

  • Page 12

    A-3 INST ALLA TION WIRE-MA TIC 250 A-3 FUSE AND WIRE SIZES Protect the input circuit with the super lag fuses or delay type circuit breakers listed on the T echnical 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 cal[...]

  • Page 13

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-4 INST ALLA TION WIRE-MA TIC 250 A-4 For the 230/460/575V/ 60 HZ model which is not equipped with a plug, an input cord, or a receptacle, the input power supply leads must be c[...]

  • Page 14

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-5 INST ALLA TION WIRE-MA TIC 250 A-5 7. Attach the flow regulator to the cylinder valve and tighten the union nut(s) securely with a wrench. a. NOTE: If connecting the flow reg[...]

  • Page 15

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC A-6 INST ALLA TION WIRE-MA TIC 250 A-6 FIGURE A.5 - Reconnect Diagram For 208/230/1/60 Machines. FIGURE A.6 - Reconnect Diagram For 230/460/575/1/60 Machine. ALL MACHINES ARE SHI[...]

  • Page 16

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC CONNECT OUTPUT COMPONENTS INST ALL 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 [...]

  • Page 17

    A-8 INST ALLA TION WIRE-MA TIC 250 A-8 WIRE SIZE CONVERSION P ARTS The Wire-Matic 250 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 INST ALLA TION T urn the welder Power Switch OFF before chang- ing output connection. _____________[...]

  • Page 18

    NOTES WIRE-MA TIC 250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 19

    OPERA TION WIRE-MA TIC 250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION SECTION ............................................ Section B Safety Instructions ............................................................B-1 General Description..........................................................B-1 [...]

  • Page 20

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-1 OPERA TION B-1 Read and understand this entire section before operat- ing your WIRE-MA TIC 250. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. When using a Wire-Matic 250 power[...]

  • Page 21

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER SOURCE FEA TURES: 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-co[...]

  • Page 22

    B-3 OPERA TION B-3 WIRE FEEDER FEA TURES: Drop-in Wire Loading - The innovative spindle snaps into the Readi-Reel adapter (optional) or most any 2" (51mm) I.D. wire spool. The wire spindle drops into the top-loading WIRE-MA TIC 250 case design. Accommodating standard 12" (305mm) and 8" (203mm) diameter coils, the unique spindle and s[...]

  • Page 23

    B-4 OPERA TION B-4 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. Figure B.1 - Operator Controls. 1. POWER SWITCH: T oggle switch to turn input power ON and OFF . Place the lever in the ON position to turn the WIRE-MA TIC 250 ON. 2. PILOT LIGHT : [...]

  • Page 24

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-5 OPERA TION B-5 WIRE-MA TIC 250 USING THE WIRE DRIVE ROLL The drive roll provided with the WIRE-MA TIC 250 has two grooves, one for .030-.035" (0.8-0.9mm) solid steel ele[...]

  • Page 25

    B-6 OPERA TION B-6 NOTE: The retaining spring side of the adapter should be facing the center (inner) panel of the WIRE-MA TIC 250. 10. Remove Readi-Reel from Adapter by depressing the retaining spring tab with thumb while pulling the Readi-Reel cage from the molded adapter with both hands. Do not remove adapter from spindle. T o mount 10 to 30 lb.[...]

  • Page 26

    B-7 OPERA TION B-7 SETTING IDLE ROLL PRESSURE The idle roll pressure wing screw is set at the factory backed out 2-1/2 turns from full pressure. This is an approximate setting. The optimum idle roll pressure varies with type of wire, wire diameter , surface condi- tions, lubrication, and hardness. As a general rule, hard wires may require greater p[...]

  • Page 27

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-8 OPERA TION B-8 WIRE-MA TIC 250 NOTE: The unit will remember the run-in mode from the previous power down and return you to that same state the next time you power up. Therefo[...]

  • Page 28

    NOTES WIRE-MA TIC 250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 29

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ACCESSORIES WIRE-MA TIC 250 ACCESSORIES SECTION ....................................... Section C Replacement Magnum 250L Gun and Cable Assembly ..........................................................C-1 K607-1 Spool Gun Adapter Kit ..............................[...]

  • Page 30

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC C-1 ACCESSORIES C-1 * Included with the K578-1. K607-1 SPOOL GUN ADAPTER KIT The K607-1 Spool Gun Adapter Kit provides "up front" direct connection of the K487 Spool Gu[...]

  • Page 31

    C-2 ACCESSORIES C-2 SPOOL GUN MODULE BOARD INST ALLA TION NOTE: The K607-1 Spool Gun Adapter Kit is designed for use with WIRE-MA TIC 250 model codes above 9900. Model Codes below 9900 may be used with addition of holes to the case as described in the instal- lation instructions below . Do not operate with covers removed. Disconnect AC input power [...]

  • Page 32

    C-3 ACCESSORIES C-3 Collect metal filings with a rag to protect against possible metal contamination of the control board or other internal electrical components. ____________________________________ 12. Fasten the panel receptacle to the case with the three #6-32 x 3/8" self tapping screws provided. a. Insert the screws from wire drive side, [...]

  • Page 33

    C-4 ACCESSORIES C-4 FIGURE C.4 - Spool Gun Connection Box Installation. 7. Route the electrode lead of the connection box up through the same opening in the front louver . 8. Remove the positive electrode lead from its con- nection on the wire drive with the machine con- nected for electrode positive (refer to Output Polarity Connection in Installa[...]

  • Page 34

    C-5 ACCESSORIES C-5 MAKING A WELD WITH THE SPOOL GUN ADAPTER (K607-1) INST ALLED The toggle switch on the front of the spool gun adapter box permits quick transfer when you want to switch between using the WIRE-MA TIC 250 Feeder Gun and the connected Spool Gun when the electrodes are at the same polarity . In either transfer switch position, closin[...]

  • Page 35

    C-6 ACCESSORIES C-6 TIMER KIT (K585-1) The T imer 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 we[...]

  • Page 36

    C-7 ACCESSORIES C-7 MAKING SPOT AND STITCH WELDS WITH TIMER KIT INST ALLED TO MAKE SPOT PLUG WELDS: The SPOT WELD MODE is used to make spot plug welds when continuous welds are not needed or to hold thin sheet metal together prior to stitch welding or continuous welding. Plug welds are made by using a punch to make a 3/16" (5mm) diameter hole [...]

  • Page 37

    MAINTENANCE WIRE-MA TIC 250 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE SECTION ...................................... Section D Safety Precautions ...........................................................D-1 Routine and Periodic Maintenance ..................................D-1 Component Locati[...]

  • Page 38

    D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS • 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 Saf[...]

  • Page 39

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-2 MAINTENANCE D-2 Figure D.1 - Component Locations. WIRE-MA TIC 250[...]

  • Page 40

    D-3 MAINTENANCE D-3 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 [...]

  • Page 41

    D-4 MAINTENANCE D-4 LINER REMOV AL 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. LINER REMOV AL, INST ALLA TION, AND TRIMMING INSTRUCTIONS FOR MAGNUM 250L NOTE: The variation in cable lengths prevents the interchange [...]

  • Page 42

    D-5 MAINTENANCE D-5 12 Remove any burrs from the end of the liner . 13. Screw the gas diffuser onto the end of the gun tube and tighten. NOTE: Be sure the gas diffuser is correct for the liner being used. (See table and diffuser stencil.) 14. Slightly tighten the set screw in the side of the gas diffuser against the cable liner using 5/64" (2.[...]

  • Page 43

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-6 MAINTENANCE D-6 * Included with WIRE-MA TIC 250 ** 5356 alloy aluminum wire and 45 0 gun tube are recommended to alleviate potential soft wire feed- ing problems with push-ty[...]

  • Page 44

    NOTES WIRE-MA TIC 250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 45

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION WIRE-MA TIC 250 Figure E.1 -Block Logic Diagram NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion THEORY OF OPERA TION SECTION ...................... Section E Power Supply Operation .....................................[...]

  • Page 46

    E-1 THEOR Y OF OPERA TION E-1 WIRE-MA TIC 250 INPUT LINE VOL T AGE AND MAIN TRANSFORMER The desired single phase input power is connected to the WIRE-MA TIC 250 through a line switch located on the front panel. A reconnect panel allows the user to configure the machine for the desired input voltage. This AC input voltage is applied to the primary o[...]

  • Page 47

    E-2 THEOR Y OF OPERA TION E-2 WIRE-MA TIC 250 OUTPUT RECTIFICA TION AND FEEDBACK CONTROL The AC output from the main transformer secondary weld winding is rectified and controlled through the SCR rectifier assembly . Output voltage and current are sensed at the shunt and output terminals and are fed back to the control board. The control board com-[...]

  • Page 48

    E-3 THEOR Y OF OPERA TION E-3 WIRE-MA TIC 250 CONST ANT VOL T AGE 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- st[...]

  • Page 49

    E-4 THEOR Y OF OPERA TION E-4 WIRE-MA TIC 250 WIRE DRIVE MOT OR 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 [...]

  • Page 50

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-5 THEOR Y OF OPERA TION E-5 WIRE-MA TIC 250 THERMAL PROTECTION A thermostat protects the machine from excessive operating temperatures. Excessive operating temper- atures may b[...]

  • Page 51

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-6 THEOR Y OF OPERA TION E-6 WIRE-MA TIC 250 A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load. An SCR acts very mu[...]

  • Page 52

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES WIRE-MA TIC 250[...]

  • Page 53

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR WIRE-MA TIC 250 TROUBLESHOOTING & REP AIR SECTION ........................................................................ Section F How to use T roubleshooting Guide .................................................................[...]

  • Page 54

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-1 TROUBLESHOOTING & REP AIR F-1 WIRE-MA TIC 250 This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three[...]

  • Page 55

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-2 TROUBLESHOOTING & REP AIR F-2 WIRE-MA TIC 250 _______________________________ CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems ca[...]

  • Page 56

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-3 TROUBLESHOOTING & REP AIR F-3 WIRE-MA TIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understan[...]

  • Page 57

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-4 TROUBLESHOOTING & REP AIR F-4 WIRE-MA TIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) PO[...]

  • Page 58

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-5 TROUBLESHOOTING & REP AIR F-5 WIRE-MA TIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) PO[...]

  • Page 59

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-6 TROUBLESHOOTING & REP AIR F-6 WIRE-MA TIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual FUNCTION PROBLEMS PROBLEMS (SYMPTOMS) [...]

  • Page 60

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-7 TROUBLESHOOTING & REP AIR F-7 WIRE-MA TIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual WIRE FEEDING PROBLEMS PROBLEMS (SYMPTO[...]

  • Page 61

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-8 TROUBLESHOOTING & REP AIR F-8 WIRE-MA TIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual WELDING PROBLEMS PROBLEMS (SYMPTOMS) P[...]

  • Page 62

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-9 TROUBLESHOOTING & REP AIR F-9 WIRE-MA TIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual WELDING PROBLEMS PROBLEMS (SYMPTOMS) P[...]

  • Page 63

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-10 TROUBLESHOOTING & REP AIR F-10 WIRE-MA TIC 250 TEST DESCRIPTION This test will determine if the correct voltages are being: a. Applied to the primary windings of the Mai[...]

  • Page 64

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-1 1 TROUBLESHOOTING & REP AIR F-1 1 WIRE-MA TIC 250 MAIN TRANSFORMER TEST (CONTINUED) TEST PROCEDURE The ON/OFF POWER SWITCH will be "hot" during these tests. ___[...]

  • Page 65

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-12 TROUBLESHOOTING & REP AIR F-12 WIRE-MA TIC 250 MAIN TRANSFORMER TEST (CONTINUED) a. T urn the machine OFF between each test. b. Carefully insert the meter probes into th[...]

  • Page 66

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-13 TROUBLESHOOTING & REP AIR F-13 WIRE-MA TIC 250 TEST DESCRIPTION This test is used to quickly determine if an SCR or diode is shorted or "leaky ." See the Machi[...]

  • Page 67

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-14 TROUBLESHOOTING & REP AIR F-14 WIRE-MA TIC 250 ST A TIC SCR RECTIFIER ASSEMBL Y TEST (CONTINUED) TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Disc[...]

  • Page 68

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-15 TROUBLESHOOTING & REP AIR F-15 WIRE-MA TIC 250 ST A TIC SCR RECTIFIER ASSEMBL Y TEST (CONTINUED) NOTE: DO NOT DISASSEMBLE THE SCR RECTIFIER HEA T SINK ASSEM- BL Y . 6. T[...]

  • Page 69

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-16 TROUBLESHOOTING & REP AIR F-16 WIRE-MA TIC 250 ACTIVE SCR RECTIFIER ASSEMBL Y TEST TEST DESCRIPTION The Active SCR T est will determine if the device is able to be gated[...]

  • Page 70

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ACTIVE SCR RECTIFIER ASSEMBL Y TEST (CONTINUED) TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Disconnect Molex Plugs J3 and J6 from the G2332 Control Board.[...]

  • Page 71

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ACTIVE SCR RECTIFIER ASSEMBL Y TEST (CONTINUED) 7. Connect the T ester to the SCR 1 as shown in Figure F .7. a. Connect T ester lead (A) to the anode. b. Connect T ester lead (C)[...]

  • Page 72

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TEST DESCRIPTION This test will determine if the wire drive motor and voltage feedback circuit are functioning properly . MA TERIALS NEEDED 5/16" Nut Driver . V olt-Ohmmeter[...]

  • Page 73

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-20 TROUBLESHOOTING & REP AIR F-20 WIRE-MA TIC 250 TEST PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. T est for Correct Wire Drive Motor Armature V oltage 1. Di[...]

  • Page 74

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-21 TROUBLESHOOTING & REP AIR F-21 WIRE-MA TIC 250 4. T est for 2 - 25 VDC between lead #539 (positive) (8J5) and lead #541 (9J5) (negative) to determine if the correct arma[...]

  • Page 75

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-22 TROUBLESHOOTING & REP AIR F-22 WIRE-MA TIC 250 This is a typical DC output voltage wave- form generated from a properly operating machine. Note that each vertical divisi[...]

  • Page 76

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-23 TROUBLESHOOTING & REP AIR F-23 WIRE-MA TIC 250 This is a typical DC output voltage wave- form generated from a properly operating machine. Note that each vertical divisi[...]

  • Page 77

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-24 TROUBLESHOOTING & REP AIR F-24 WIRE-MA TIC 250 This is NOT a typical DC output voltage waveform. One output SCR is not function- ing. Note the increased ripple content. [...]

  • Page 78

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-25 TROUBLESHOOTING & REP AIR F-25 WIRE-MA TIC 250 This is NOT the typical DC output voltage waveform. The output capacitors are not functioning. Note the lack of “filteri[...]

  • Page 79

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-26 TROUBLESHOOTING & REP AIR F-26 WIRE-MA TIC 250 This is a typical SCR gate pulse voltage waveform. The machine was in an open cir- cuit condition (no load) and operating [...]

  • Page 80

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Printed Circuit Boards can be damaged by static electricity . Follow static handling guidelines detailed in “PC Board T roubleshooting Procedures” at the beginning of this ch[...]

  • Page 81

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-28 TROUBLESHOOTING & REP AIR F-28 WIRE-MA TIC 250 4. Remove the eight Phillips Head mounting screws using a Phillips Head screwdriver . See Figure F .10. FIGURE F .10 - Con[...]

  • Page 82

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-29 TROUBLESHOOTING & REP AIR F-29 WIRE-MA TIC 250 MA TERIALS NEEDED Large slot head screwdriver . 5/16" Nut Driver . Small slot head screwdriver . WIRE DRIVE ASSEMBL Y[...]

  • Page 83

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-30 TROUBLESHOOTING & REP AIR F-30 WIRE-MA TIC 250 PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels. 3. Remove the large moun[...]

  • Page 84

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-31 TROUBLESHOOTING & REP AIR F-31 WIRE-MA TIC 250 MA TERIALS NEEDED 5/16" Nut driver . 1/2" Open end wrench. 1/2" Socket wrench, universal tool, and extensio[...]

  • Page 85

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-32 TROUBLESHOOTING & REP AIR F-32 WIRE-MA TIC 250 PROCEDURE 1. Disconnect lead #208 and T ransformer Lead X1 from the heat sink on the left side of the machine (facing the [...]

  • Page 86

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-33 TROUBLESHOOTING & REP AIR F-33 WIRE-MA TIC 250 THE LIQUID ELECTRODE IN THE CAP ACIT ORS IS T OXIC. DO NOT TOUCH THE CAP AC- ITORS WITH ANY P ART OF YOUR BODY . _________[...]

  • Page 87

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-34 TROUBLESHOOTING & REP AIR F-34 WIRE-MA TIC 250 PROCEDURE See Figure F .15 for location of Capacitor Bank Removal and Replacement com- ponents. FIGURE F .15 - Location of[...]

  • Page 88

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-35 TROUBLESHOOTING & REP AIR F-35 WIRE-MA TIC 250 MA TERIALS NEEDED 5/16" Nut Driver . 1/2" Open end wrench. 3/8" Open end wrench. 1/2" Socket wrench, e[...]

  • Page 89

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-36 TROUBLESHOOTING & REP AIR F-36 WIRE-MA TIC 250 PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels. 3. Perform the Capacitor[...]

  • Page 90

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-37 TROUBLESHOOTING & REP AIR F-37 WIRE-MA TIC 250 MA TERIALS NEEDED 3/4" Open end wrench. 1/2" Socket wrench with extension. Phillips head screwdriver . F AN MOTO[...]

  • Page 91

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-38 TROUBLESHOOTING & REP AIR F-38 WIRE-MA TIC 250 PROCEDURE See Figure F .16 for fan motor and fan removal components. FIGURE F .16 - Fan Motor and Fan Removal Components 1[...]

  • Page 92

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-39 TROUBLESHOOTING & REP AIR F-39 WIRE-MA TIC 250 F AN MOTOR AND F AN REMOV AL AND REPLACEMENT (CONTINUED) 7. Remove the fan motor . a. Loosen and remove the two screws fro[...]

  • Page 93

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-40 TROUBLESHOOTING & REP AIR F-40 WIRE-MA TIC 250 INPUT IDLE AMPS AND W A TTS WIRE SPEED RANGE OPEN CIRCUIT VOL T AGE RETEST AFTER REP AIR Maximum Idle W atts Maximum Idle [...]

  • Page 94

    NOTES WIRE-MA TIC 250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 95

    T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - WIRE-MA TIC 250 Electrical Diagram Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G Wiring Diagram (230/460/575) Code 10004 . . . . . . . . . . . . . . . . . . . . . . G-2 Wiring Diagram (230/460/575) Code 10003 . . . . . . . . . . . . . . . . . . . . . . G-3 Wiri[...]

  • Page 96

    NOTES WIRE-MA TIC 250 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 97

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-2 WIRE-MA TIC 250 Wiring Diagram (230/460/575) Code 10004 GENERAL INFORMATION COLOR CODE: B - BLACK W - WHITE THERMOSTAT 202 204A 203 204 208 G1 X2 X1 G2 20[...]

  • Page 98

    G-3 ELECTRICAL DIAGRAMS WIRE-MA TIC 250 Wiring Diagram (230/460/575) Code 10003 GENERAL INFORMATION COLOR CODE: B - BLACK W - WHITE THERMOSTAT 202 204A 203 204 208 G1 X2 X1 G2 209 SCR 1 250V 470A SCR HEATSINK ASBLY SCR 2 250V 470A C1 C2 C3 C4 ++++ POWER TRANSFORMER H3 H2 H1 L1 L2 H1 LINE SWITCH S1 H2 H3 L1 GND. RECONNECT PANEL L1 L2 GND TO SINGLE P[...]

  • Page 99

    G-4 ELECTRICAL DIAGRAMS WIRE-MA TIC 250 Wiring Diagram (208/230) Code 9800 GENERAL INFORMATION COLOR CODE: B - BLACK W - WHITE THERMOSTAT 202 204A 203 204 208 G1 X2 X1 G2 209 SCR 1 250V 470A SCR HEATSINK ASBLY SCR 2 250V 470A C1 C2 C3 C4 ++++ POWER TRANSFORMER L1 L2 GND TO SINGLE PHASE SUPPLY LINE TO GROUND PER CODE 207 206 OUTPUT CHOKE NOTES N.A. [...]

  • Page 100

    G-5 ELECTRICAL DIAGRAMS WIRE-MA TIC 250 Wiring Diagram (208/230) Code 9799 GENERAL INFORMATION COLOR CODE: B - BLACK W - WHITE THERMOSTAT 202 204A 203 204 208 G1 X2 X1 G2 209 SCR 1 250V 470A SCR HEATSINK ASBLY SCR 2 250V 470A C1 C2 C3 C4 ++++ POWER TRANSFORMER H3 H2 H1 L1 L2 H1 LINE SWITCH S1 H2 H3 L1 GND. RECONNECT PANEL L1 L2 GND TO SINGLE PHASE [...]

  • Page 101

    G-6 ELECTRICAL DIAGRAMS WIRE-MA TIC 250 Control PC Board (G2332) Schematic J3 7 204 G1 H11C4 OCI2 2 1 5 6 4 562 R173 10K R163 562 R167 562 R174 40V 600mA Q40 40V 600mA Q41 J3 6 X1 14 13 12 50V 0.1 C113 +5 V 74HC373 X5 20 10 10K R176 D 204 X1 8 9 10 +15 V X1 7 6 5 562 R168 Vss Vdd MC68HC11 X6 1 26 681 R172 2.21K R166 G2 B H11C4 OCI3 2 1 5 6 4 J3 5 2[...]

  • Page 102

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC G-7 ELECTRICAL DIAGRAMS WIRE-MA TIC 250 Control PC Board (G2332) Layout G-7 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troublesh[...]