Lincoln Electric WIRE-MATIC 255 SVM 119-A manual

WIRE-MA TIC 255 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 19-A January 1996 Safety Depends on Y ou Lincoln arc welding and cutting[...]

W ARNING i SAFETY i WIRE-MA TIC 255 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 addition[...]

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[...]

iii SAFETY iii WIRE-MA TIC 255 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 [...]

iv SAFETY iv WIRE-MA TIC 255 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[...]

NOTES WIRE-MA TIC 255 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

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

vi Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E Power Supply Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5 SCR Operation . . . . . . . . . . . . . . . [...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION WIRE-MA TIC 255 INST ALLA TION SECTION ........................................ Section A T echnical Specifications ...................................................A-1 Safety Precautions ...........................................................A-[...]

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 255 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 [...]

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 255 SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should install this machine. • T[...]

A-3 INST ALLA TION WIRE-MA TIC 255 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[...]

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 255 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[...]

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 255 A-5 7. Attach the flow regulator to the cylinder valve and tighten the union nut(s) securely with a wrench. a. NOTE: If connecting the flow reg[...]

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 1. ALL MACHINES ARE SHIPPED FROM THE F ACTOR Y CONNECTED FOR THE HIGHEST NAME- PLA TED SINGLE PHASE INPUT VOL T AGE. TO CHANGE CONNECTIONS FOR A DIFFERENT INPUT VOL T AGE, RECONN[...]

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 [...]

A-8 INST ALLA TION WIRE-MA TIC 255 A-8 WIRE SIZE CONVERSION P ARTS 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 INST ALLA TION T urn the welder Power Switch OFF before chang- ing output connection. _____________[...]

NOTES WIRE-MA TIC 255 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[...]

OPERA TION WIRE-MA TIC 255 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 [...]

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 255. SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. When using a Wire-Matic 255 power[...]

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[...]

B-3 OPERA TION B-3 WIRE FEEDER FEA TURES: Wire Loading - Adjustable brake spindle mounts Readi-Reel® Adapter , included with WIRE-MA TIC 255, or most any 2" (51mm) I.D. wire spool. Accommodating standard 12" (305mm) and 8" (203mm) diameter coils, the spindle’s adjustable brake provides appropriate dereeling drag to prevent wire re[...]

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 255 ON. 2. PILOT LIGHT : [...]

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 255 USING THE WIRE DRIVE ROLL The drive roll provided with the WIRE-MA TIC 255 has two grooves, one for .030-.035" (0.8-0.9mm) solid steel ele[...]

B-6 OPERA TION B-6 T o 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. If using an 8” (200mm) spool, place the K468 Adapter on the spindle first. The hole in the Adapter arm is [...]

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

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 255 NOTE: Arc starting characteristics may be affected when using the fast run-in mode since optimum start- ing processes are being overriden. When[...]

NOTES WIRE-MA TIC 255 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[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ACCESSORIES WIRE-MA TIC 255 ACCESSORIES SECTION ....................................... Section C Other Available Magnum 250L Gun and Cable Assembly ..........................................................C-1 Magnum Gun Connection Kit (Optional K466-6) ...........[...]

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 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 install[...]

C-2 ACCESSORIES C-2 MAKING A WELD WITH THE SPOOL GUN ADAPTER (K672-1) INST ALLED 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 ho[...]

C-3 ACCESSORIES C-3 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[...]

C-4 ACCESSORIES C-4 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 [...]

C-5 ACCESSORIES C-5 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. WIRE-M[...]

MAINTENANCE WIRE-MA TIC 255 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[...]

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[...]

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 255 FAN MOTORS CONTROL PC BOARD MAIN TRANSFORMER SCR RECTIFIER BRIDGE CHOKE[...]

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 [...]

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 [...]

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.[...]

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 K673-1 3/64” (1.2 mm) Aluminum Feeding Kit. 5356 alloy aluminum wire recom- mended to alleviate potential soft wire feeding problems with pu[...]

NOTES WIRE-MA TIC 255 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[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION WIRE-MA TIC 255 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 .....................................[...]

E-1 THEOR Y OF OPERA TION E-1 WIRE-MA TIC 255 INPUT LINE VOL T AGE AND MAIN TRANSFORMER The desired single phase input power is connected to the WIRE-MA TIC 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 o[...]

E-2 THEOR Y OF OPERA TION E-2 WIRE-MA TIC 255 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-[...]

E-3 THEOR Y OF OPERA TION E-3 WIRE-MA TIC 255 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[...]

E-4 THEOR Y OF OPERA TION E-4 WIRE-MA TIC 255 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 [...]

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 255 THERMAL PROTECTION A thermostat protects the machine from excessive operating temperatures. Excessive operating temper- atures may b[...]

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 255 A silicon controlled rectifier (SCR) is a three terminal device used to control rather large currents to a load. An SCR acts very mu[...]

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 255[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR WIRE-MA TIC 255 TROUBLESHOOTING & REP AIR SECTION ........................................................................ Section F How to use T roubleshooting Guide .................................................................[...]

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 255 This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three[...]

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 255 _______________________________ CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems ca[...]

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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understan[...]

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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) PO[...]

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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) PO[...]

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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual FUNCTION PROBLEMS PROBLEMS (SYMPTOMS) [...]

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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual WIRE FEEDING PROBLEMS PROBLEMS (SYMPTO[...]

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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual WELDING PROBLEMS PROBLEMS (SYMPTOMS) P[...]

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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual WELDING PROBLEMS PROBLEMS (SYMPTOMS) P[...]

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 255 TEST DESCRIPTION This test will determine if the correct voltages are being: a. Applied to the primary windings of the Mai[...]

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 255 MAIN TRANSFORMER TEST TEST PROCEDURE The ON/OFF POWER SWITCH will be "hot" during these tests. _______________[...]

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 255 MAIN TRANSFORMER TEST (CONTINUED) Board. a. T urn the machine OFF between each test. b. Carefully insert the meter probes [...]

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 255 TEST DESCRIPTION This test is used to quickly determine if an SCR or diode is shorted or "leaky ." See the Machi[...]

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 255 ST A TIC SCR RECTIFIER ASSEMBL Y TEST (CONTINUED) TEST PROCEDURE 1. Disconnect main AC input power to the machine. 2. Disc[...]

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 255 ST A TIC SCR RECTIFIER ASSEMBL Y TEST (CONTINUED) NOTE: DO NOT DISASSEMBLE THE SCR RECTIFIER HEA T SINK ASSEM- BL Y . 6. T[...]

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 255 ACTIVE SCR RECTIFIER ASSEMBL Y TEST TEST DESCRIPTION The Active SCR T est will determine if the device is able to be gated[...]

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 G2803 Control Board.[...]

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)[...]

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[...]

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 255 TEST PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. T est for Correct Wire Drive Motor Armature V oltage 1. Di[...]

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 255 4. T est for 2 - 25 VDC between lead plug location 12J5 #539(B) (posi- tive) (12J5) and lead #541(W) (13J5) (negative) to [...]

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 255 This is a typical DC output voltage wave- form generated from a properly operating machine. Note that each vertical divisi[...]

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 255 This is a typical DC output voltage wave- form generated from a properly operating machine. Note that each vertical divisi[...]

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 255 This is NOT a typical DC output voltage waveform. One output SCR is not function- ing. Note the increased ripple content. [...]

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 255 This is NOT the typical DC output voltage waveform. The output capacitors are not functioning. Note the lack of “filteri[...]

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 255 This is a typical SCR gate pulse voltage waveform. The machine was in an open cir- cuit condition (no load) and operating [...]

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[...]

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 255 4. Carefully remove the P .C. Board from the mounting standoffs. See Figure F .10. FIGURE F .10 - Control Board Mounting L[...]

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 255 MA TERIALS NEEDED Large slot head screwdriver . 5/16" Nut Driver . Small slot head screwdriver . WIRE DRIVE ASSEMBL Y[...]

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 255 PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels. 3. Using the 5/16” Nut[...]

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 255 MA TERIALS NEEDED 5/16" Nut driver . 1/2" Open end wrench. 1/2" Socket wrench, universal tool, and extensio[...]

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 255 PROCEDURE 1. Disconnect lead #208 and T ransformer Lead X1 from the heat sink on the left side of the machine (facing the [...]

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 255 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 . _________[...]

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 255 PROCEDURE See Figure F .15 for location of Capacitor Bank Removal and Replacement com- ponents. FIGURE F .15 - Location of[...]

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 255 MA TERIALS NEEDED 5/16" Nut Driver . 1/2" Open end wrench. 3/8" Open end wrench. 1/2" Socket wrench, e[...]

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 255 PROCEDURE 1. Disconnect main input power to the machine. 2. Remove the Case T op and Side Panels. 3. Perform the Capacitor[...]

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 255 MA TERIALS NEEDED 3/4" Open end wrench. 1/2" Socket wrench with extension. Phillips head screwdriver . F AN MOTO[...]

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 255 PROCEDURE See Figure F .16 for fan motor and fan removal components. FIGURE F .16 - Fan Motor and Fan Removal Components 1[...]

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 255 F AN MOTOR AND F AN REMOV AL AND REPLACEMENT (CONTINUED) 7. Remove the fan motor . a. Loosen and remove the two screws fro[...]

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 255 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 [...]

NOTES WIRE-MA TIC 255 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[...]

T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - WIRE-MA TIC 255 Electrical Diagram Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G Wiring Diagram (208/230) Code 10166 . . . . . . . . . . . . . . . . . . . . . . . . . G-2 Wiring Diagram (230/460/575) Code 10167 . . . . . . . . . . . . . . . . . . . . . . G-3 Co[...]

NOTES WIRE-MA TIC 255 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

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 255 Wiring Diagram (208/230) Code 10166 GENERAL INFORMATION COLOR CODE: B - BLACK W - WHITE THERMOSTAT 202 204A 203 204 208 G1 X2 X1 G2 209 SC[...]

G-3 ELECTRICAL DIAGRAMS WIRE-MA TIC 255 Wiring Diagram (230/460/575) Code 10167 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 [...]

G-4 ELECTRICAL DIAGRAMS WIRE-MA TIC 255 Control PC Board (G2803) Schematic G-4 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 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubl[...]

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-5 ELECTRICAL DIAGRAMS WIRE-MA TIC 255 Control PC Board (G2803) Layout G-5 NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troublesh[...]