AUTO ARC 255 Page 1 Owner'S Manual Download

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Auto Arc 255

And M-25 Gun

Processes

Description

MIG (GMAW) Welding

Flux Cored (FCAW) Welding

Arc Welding Power Source And

Wire Feeder

OM-157 066V

November 2000



For Warranty Claims And Technical Support, Contact:
Milweld Inc., National Distributor
P.O. Box 338, Hortonville, WI 54944-0338
Tel 920-779-0916 Fax 920-779-0924

Summary of Contents for 255

Page 1: ...MAW Welding Flux Cored FCAW Welding Arc Welding Power Source And Wire Feeder OM 157 066V November 2000 For Warranty Claims And Technical Support Contact Milweld Inc National Distributor P O Box 338 Hortonville WI 54944 0338 Tel 920 779 0916 Fax 920 779 0924 ...

Page 2: ......

Page 3: ...inks 9 2 11 Electrical Service Guide 10 2 12 Selecting A Location And Connecting Input Power 10 2 13 Threading Welding Wire 11 SECTION 3 OPERATION 12 3 1 Front Panel Controls 12 3 2 Center Baffle Controls 13 3 3 Weld Parameter Chart 14 SECTION 4 MAINTENANCE TROUBLESHOOTING 16 4 1 Routine Maintenance 16 4 2 Circuit Breaker CB1 16 4 3 Fuses F1 And F2 17 4 4 Changing Drive Roll And Wire Inlet Guide 1...

Page 4: ......

Page 5: ... or that cord plug is connected to a properly grounded receptacle outlet D When making input connections attach proper grounding conductor first double check connections D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill D Turn off all equipment when not in use D Do not use worn damaged undersized or poorly spliced cables D Do n...

Page 6: ... welding wire at contact tip when not in use D Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap D Remove any combustibles such as a butane lighter or matches from your person before doing any welding FLYING METAL can injure eyes D Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off sla...

Page 7: ...d maintained D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots D Be sure all equipment in the welding area ...

Page 8: ...s is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one ...

Page 9: ...d Steel Stainless Steel Flux Cored Aluminum Wire Feed Speed Range Overall Dimensions Weight 023 045 in 0 6 1 2 mm 030 035 in 0 8 0 9 mm And 3 64 in 1 2 mm Alu 90 1030 IPM 2 9 26 2 m min Length 37 in 940 mm Width 19 in 483 mm Height 32 in 889 mm 225 lb 102 kg While idling Operating Temperature Range 20C to 40C Storage Temperature Range 30C to 50C 2 2 Volt Ampere Curve The volt ampere curves show th...

Page 10: ...t 200 Amperes 2 4 Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty Do not weld at rated load longer than shown below Using gasless flux cored wire reduces gun duty cycle warn7 1 8 93 Duty Cycle is percentage of 10 minutes that gun can weld at rated load without overheating Continuous Welding SB1 1 8 93 0 10 Minutes Definition 023 ...

Page 11: ...re as shown Close door ST 800 918 C 1 2 3 4 in 1 2 3 4 5 Tools Needed 2 6 Installing Gas Supply ST 154 623 A Ref ST 109 492 1 Cylinder Rack 2 Chain Obtain gas cylinder and chain cylinder to rack 3 Gas Hose Fitting 4 CO2 Washer 5 Regulator Install washer and regulator onto cylinder 6 Gas Hose Connection Obtain gas hose with fittings and install between regulator and welding power source 7 Flow Adju...

Page 12: ...ough opening until it bottoms against drive assembly Tighten nut 4 Gun Trigger Plug Insert plug into receptacle and tighten threaded collar Close door 1 2 4 3 2 8 Installing Wire Spool And Adjusting Hub Tension ST 072573 B When a slight force is needed to turn spool tension is set 15 16 in Use compression spring with 8 in 200 mm spools Tools Needed ...

Page 13: ...f 190 821 A 2 10 Positioning Jumper Links Ref ST 800 922 C Check input voltage available at site 1 Jumper Links Access Door Open door 2 Jumper Link Label 3 Jumper Links Location Move jumper links to match input voltage and label on unit Close and secure access door 1 3 2 200 VOLTS 230 VOLTS S 153 980 460 VOLTS 575 VOLTS S 156 140 230 VOLTS 3 8 in Tools Needed ...

Page 14: ...use 2 Time Delay fuses are UL class RK5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above Y Caution Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard 2 12 Selecting A Location And Connecting Input Power 1 Rating Label Supply correct input power 2 Plug ...

Page 15: ...l and hold wire cut off end Push wire thru guides into gun continue to hold wire Close and tighten pressure assembly and let go of wire Remove gun nozzle and contact tip Turn On Press gun trigger until wire comes out of gun Reinstall contact tip and nozzle Feed wire to check drive roll pressure Tighten knob enough to prevent slipping Cut off wire Close and latch door Tools Needed 6 5 3 2 Tighten 1...

Page 16: ...43 A Controls For Standard Units 1 Wire Speed Control The scale around the control is percent not wire feed speed 2 Voltage Switch Use control and Voltage Range Selector see Section 3 2 to set arc voltage Step 6 of Low range and Step 1 of High range overlap 3 Pilot Light 4 Power Switch 1 4 3 2 ...

Page 17: ... control of wire speed use the Low position when wire speed is between 90 and 670 ipm Use the Full position when wire speed is between 150 ipm and 1030 ipm 2 Voltage Range Selector Place switch in desired position 1 2 DO NOT SWITCH UNDER LOAD CB1 PRESS TO RESET LOW FULL LOW HIGH WIRE MODE VOLTAGE RANGE ...

Page 18: ...OM 157 066 Page 14 3 3 Weld Parameter Chart ...

Page 19: ...OM 157 066 Page 15 Ref 200 062 ...

Page 20: ...r Or Replace Cracked Cables And Cords 6 Months Blow Out Or Vacuum Inside Remove drive roll and carrier Apply light coat of oil or grease to drive motor shaft 4 2 Circuit Breaker CB1 Ref ST 800 924 C 1 Circuit Breaker CB1 If CB1 opens wire feeding stops 2 Welding Gun Check gun liner for blockage or kinks 3 Wire Drive Assembly Check for jammed wire binding drive gear or misaligned drive rolls Allow ...

Page 21: ...ve Roll And Wire Inlet Guide ST 150 227 D 1 Securing Screw 2 Inlet Wire Guide Loosen screw Slide tip as close to drive rolls as possible without touching Tighten screw 3 Anti Wear Guide Install guide as shown 4 Drive Roll Install correct drive roll for wire size and type 5 Drive Roll Securing Nut Turn nut one click to secure drive roll 5 64 in 7 16 in Tools Needed 1 3 2 4 5 4 5 Replacing Gun Conta...

Page 22: ...ighten wire outlet guide Cut liner off 3 4 in 20 mm 3 8 in 9 5 mm for aluminum from head tube Install adapter contact tip and nozzle Lay gun cable out straight before installing new liner Head tube 3 8 in Remove liner Remove nozzle contact tip adapter and wire outlet guide Blow out gun casing Y Disconnect gun first Tools Needed ...

Page 23: ...ecure with handle locking nut If replacing head tube continue to end of figure 3 Slide handle 4 Secure head tube in vice 5 Loosen jam nut Remove from vice and turn head tube out by hand 6 Install existing shock washer onto new head tube Hand tighten head tube into connector cable 7 Place head tube in vice and tighten until nuts are tight 8 Remove from vice Reposition handle and install switch hous...

Page 24: ...on 4 5 Low weld output Connect unit to proper input voltage or check for low line voltage see Section 2 12 Wire Drive Gun Trouble Remedy Electrode wire feeding stops during welding Straightengun cable and or replace damaged parts see Section 4 6 Adjust drive roll pressure see Section 2 13 Readjust hub tension see Section 2 8 Replace contact tip if blocked see Section 4 5 Clean or replace wire inle...

Page 25: ...OM 157 066 Page 21 SECTION 5 ELECTRICAL DIAGRAM SB 173 544 E Figure 5 1 Circuit Diagram For Welding Power Source ...

Page 26: ...OM 157 066 Page 22 Notes ...

Page 27: ...a Mkgs Item No Figure 6 1 Main Assembly Quantity 1 146 168 PANEL center enclosure 1 PLG7 083 526 HOUSING RECEPTACLE SOCKETS consisting of 1 009 418 TERMINAL female 1skt 20 14 wire 12 2 Figure 6 2 BAFFLE center w components 1 3 T1 171 658 TRANSFORMER pwr main 200 230 1 3 T1 172 520 TRANSFORMER pwr main 230 460 575 1 5 186 758 WHEEL polyprolene 10 in dia x 2 250 wide x 750 bore 2 6 Z1 171 213 STABIL...

Page 28: ... 121 614 RING retaining ext 750 shaft x 085grv depth 2 17 R1 091 685 RESISTOR WW fxd 50W 25 ohm 1 18 008 999 CASTER plstc swvl 4 in dia 2 19 Figure 6 5 PANEL front w components 1 20 169 596 GUN 12 ft 030 035 wire Fig 6 4 1 192 121 REGULATOR FLOWMETER 10 50 CFH 1 144 108 HOSE gas 5ft 1 130 750 CLAMP ground 350A 1 600 318 CABLE weld cop strd No 3 order by ft 10ft When ordering a component originally...

Page 29: ...7 066 Page 25 ST 800 931 D Hardware is common and not available unless listed 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 18 17 20 21 22 23 25 26 27 28 Fig 6 3 29 30 31 24 19 Figure 6 2 Baffle Center w Components ...

Page 30: ...1 18 F2 012 658 FUSE mintr gl slo blo 2A 125V 1 19 F1 073 426 FUSE mintr gl slo blo 5A 125V 1 PLG3 165 896 CONNECTOR SOCKETS 1 PLG4 135 558 CONNECTOR SOCKETS 1 PLG5 165 745 CONNECTOR SOCKETS 1 20 CB1 083 431 CIRCUIT BREAKER man reset 1P 5A 250VAC 1 21 S3 011 609 SWITCH tgl SPDT 15A 125VAC 1 22 S4 171 610 SWITCH selector 2 position When ordering this part order 186 058 also 1 186 058 COVER dust ran...

Page 31: ...gged rolls for extremely soft shelled wires usually hard surfacing types 4 V Knurled rolls for hard shelled cored wires 5 Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved Wire Diameter Fraction Decimal Metric 023 025 in 030 in 035 in 045 in 023 025 in 030 in 035 in 045 in 0 6 mm 0 8 mm 0 9 mm 1 2 mm Kit No 087 131 079 594 079 595 07...

Page 32: ...ting of 1 193 633 KEY woodruff 118 x 380 1 193 634 WASHER wave 405 ID x 740 OD 2 193 635 RING rtng ext 394 shaft x 1 15 079 633 FITTING hose brs barbed M 3 16tbg 1 16 601 966 SCREW 375 16 x 1 25hexhd 2 18 604 538 WASHER flat stl SAE 312 1 19 124 778 KNOB plstc T 1 000 lg x 312 18 x 2 000 bar 1 20 173 619 CARRIER drive roll w components 1 21 174 609 SCREW M 4 7 x 12 1 22 174 610 SCREW M 6 1 0 x 20 ...

Page 33: ...dtunnel 1 8 SR1 152 742 RECTIFIER si diode consisting of 1 9 152 862 GROMMET SCR 250 panel hole 3 8 10 D3 D4 037 957 DIODE rect 275A 300V RP DO 9 2 11 C1 C4 048 420 CAPACITOR cer disc 01u 4 12 026 947 STAND OFF INSLU 250 20 X 1 0 2 13 TP1 171 600 THERMOSTAT NC open 230F 1 14 605 886 WASHER tooth 769 ID x 1 24 OD 4 15 605 884 NUT 750 16 1 12 hex 44H stl plated 4 16 D1 D2 037 956 DIODE rect 275A 300...

Page 34: ... PLATE control 1 4 155 418 PANEL front control 1 5 R2 035 897 POTENTIOMETER CP STD slot 1T 2W 1K linear 1 6 175 060 PANEL front 1 7 143 974 HANDLE running gear 1 8 186 058 COVER dust 1 9 S2 153 197 SWITCH selector 6 position when ordering this part order 186058 also 1 10 RC1 048 282 RECEPTACLE W SOCKETS 1 11 S1 128 755 SWITCH tgl dpst 40 A 600 VAC 1 12 NAMEPLATE order by model and serial number 1 ...

Page 35: ...OM 157 066 Page 31 Ref 800 792 B 1 2 3 4 5 6 7 8 9 10 14 17 11 12 11 12 13 9 15 16 Figure 6 6 Exploded View Of Gun ...

Page 36: ...APTER nozzle 1 5 170 467 RING retaining 1 6 170 468 O RING 1 7 169 730 WASHER shock 1 8 169 731 TUBE head 1 9 169 738 NUT locking handle 2 10 194 523 NUT jam 1 11 169 737 HANDLE 2 12 169 741 STRAIN RELIEF cable 2 13 180 433 CORD trigger assembly 1 14 079 974 O RING 500 ID x 103CS rbr 2 15 194 010 LINER monocoil 023 025 wire x 15ft consisting of 1 15 194 011 LINER monocoil 030 035 wire x 15ft consi...

Page 37: ...Notes ...

Page 38: ...Notes ...

Page 39: ...accessories These items are covered by the manufacturer s warranty if any 3 Equipment that has been modified by any party other than manufacturer or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications ...

Page 40: ...rial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Owner s Manuals Circuit Diagrams Contact the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department Resources Available Owner s Record Fil...

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