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Lincoln Electric WIRE-MATIC 255, Service Manual

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Lincoln Electric WIRE-MATIC 255 Service Manual Download Page 75

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F-24

TROUBLESHOOTING & REPAIR

F-24

WIRE-MATIC 255

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.  Each
vertical division represents 20 volts and
each horizontal division represents 5 mil-
liseconds in time.  The machine was loaded
with a resistance grid bank.

Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-)
probe to work.

Volts/Div  . . . . . . . . . . . . . . . . .20 V/Div.

Horizontal Sweep   . . . . . . . . . .5 ms/Div.

Coupling  . . . . . . . . . . . . . . . . . . . . .DC.

Trigger  . . . . . . . . . . . . . . . . . . .Internal.

SCOPE SETTINGS

MACHINE LOADED TO 220 AMPS AT 22 VDC

ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

ONE OUTPUT SCR NOT FUNCTIONING

Summary of Contents for WIRE-MATIC 255

Page 1: ...ety 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 THR...

Page 2: ...e Control 1 c In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 1 d Always be sure the work cable makes...

Page 3: ...ng 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 opening...

Page 4: ...ll 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: ...vaillant proximit au soudage l aide d crans appropri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l hu...

Page 6: ...NOTES WIRE MATIC 255 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 7: ...672 1 Installed C 1 Making a Weld with the Spool Gun Adapter K672 1 Installed C 2 Timer Kit K585 1 C 3 Timer Kit Installation Optional K585 1 C 3 Making Spot and Stitch Welds with Timer Kit Installed...

Page 8: ...nd Repair Section F How to use Troubleshooting Guide F 1 PC Board Troubleshooting Procedures F 2 Troubleshooting Guide F 3 Test Procedures F 10 Oscilloscope Waveforms F 22 Replacement Procedures F 27...

Page 9: ...tion 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 Comp...

Page 10: ...Breaker Size Copper conduit AWG Ground Wire in Conduit IEC Sizes Runs to Runs over 100ft 30m 100ft 30m 208 60 60 8 10mm2 6 16mm2 10 6mm2 230 60 60 10 6mm2 8 10mm2 10 6mm2 460 60 30 14 2 5mm2 12 4mm2...

Page 11: ...a stable level surface so it will not topple over Do not place the machine on an incline A 2 INSTALLATION WIRE MATIC 255 A 2 INPUT CONNECTIONS All input power must be electrically disconnected before...

Page 12: ...input cord and plug connected to the welder mount the matching receptacle supplied with the machine 1 Mount the receptacle in a suitable location using the screws provided 2 Locate the receptacle wit...

Page 13: ...xplosive Always keep gas cylinders in an upright position and always keep chained to undercarriage or sta tionary Y support See American National Standard Z 49 1 Safety in Welding and Cutting publishe...

Page 14: ...a turn a When the cylinder pressure gage pointer stops moving open the valve fully NEVER STAND DIRECTLY IN FRONT OF OR BEHIND THE FLOW REGULATOR WHEN OPENING THE CYLINDER VALVE ALWAYS STAND TO ONE SI...

Page 15: ...2 AT THE UPPER COR NER OF THE PANEL TORQUE TO 16 IN LBS 3 CONNECT A GROUNDING LEAD TO THE GROUND STUD ON THE MACHINE NEAR THE TER MINAL BLOCK A 6 INSTALLATION WIRE MATIC 255 A 6 FIGURE A 5 Reconnect D...

Page 16: ...ork cable which is attached to the work clamp is to be connected to the positive labeled output terminal A 7 INSTALLATION WIRE MATIC 255 A 7 GUN LINER AND CONTACT TIP INSTALLATION The Magnum 250L gun...

Page 17: ...4 Connect the gun trigger connector from the gun and cable to the mating receptacle on the front panel Make sure that the keyways are aligned insert and tighten retaining ring NOTE If a gun and cable...

Page 18: ...NOTES WIRE MATIC 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...

Page 19: ...es 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 Loading t...

Page 20: ...m a reliable high performance welding system Simple controls consisting of continuous full range cal ibrated voltage control and wire feed speed control provide versatility with ease of use WIRE MATIC...

Page 21: ...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 0 9mm stainless steel 3 64 1 2mm aluminum 045 1 2mm Outershield 035 0...

Page 22: ...oll and Guide Tube Design Precisely aligned guide tubes and drive rolls provide long life The design also permits quick reload by sim ply starting wire into ingoing guide tube Adjustable tension setti...

Page 23: ...speed from 50 to 600 inches per minute 1 2 to 15 2 m min The control can be preset on the dial to the setting specified on the Procedure Decal on the inside of the wire com partment door Wire speed i...

Page 24: ...re prop erly sized for wire being used LOADING THE WIRE REEL To mount a 22 30 lb 10 14 kg Readi Reel package using the Readi Reel adapter provided 1 Remove the locking collar from the 2 51mm O D spind...

Page 25: ...ot feed properly into the outgoing guide tube or welding gun causing a birdnest 3 Cut off the first inch 4 Push the wire through the ingoing guide tube 5 Press the gun trigger and push the electrode i...

Page 26: ...t and to energize the wire feeder motor NOTE When the POWER SWITCH is ON the fan motor is thermostatically controlled to provide cooling for the transformer and other components only when the machine...

Page 27: ...Cut the electrode within approximately 3 8 10mm of the end of the contact tip or 3 4 20mm for Outershields NOTE If set to slow run in when the trigger is pulled the wire feeder feeds wire at low speed...

Page 28: ...NOTES WIRE MATIC 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...

Page 29: ...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 Timer Kit K585 1 C 3 Timer Kit Installation Op...

Page 30: ...Magnum Connection kit for the Wire Matic permits use of standard Magnum 200 300 or 400 gun and cable assemblies K672 1 SPOOL GUN ADAPTER KIT Remove all input power to the Wire Matic 255 before procee...

Page 31: ...tic input power ON and the transfer switch is to be in the SPOOL position b Adjusting the voltage control will increase or decrease your welding Voltage c Adjusting the wire speed control will increas...

Page 32: ...__________________ 1 Verify that the following items have been included in the kit a Timer Board and Panel Assembly b Two sheet metal screws c Wiring harness 2 Turn the POWER SWITCH to OFF 3 Disconnec...

Page 33: ...ion 2 The STITCH OFF TIME KNOB sets off time between welds a Start with a dial setting of 0 5 seconds Raise setting to reduce burnthrough Lower setting to make weld flatter and smoother 3 Set the proc...

Page 34: ...ing Simple installation with installation kick stand and easy instructions provided L9687 Includes upper and lower cylinder supports wheel axles and mounting hardware WIRE MATIC 255 Return to Section...

Page 35: ...ponent 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 Installati...

Page 36: ...materials are in the welding or cutting area or around the machine 2 Remove any debris dust dirt or materials that could block the air flow to the machine 3 Inspect the electrode cables for any slits...

Page 37: ...ection 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 MATIC 255 FAN MOTORS CONTRO...

Page 38: ...more dirt comes out GUN TUBES AND NOZZLES 1 Replace worn contact tips as required 2 Remove spatter from the inside of the gas nozzle and tip every 10 minutes of arc time or as required CONTACT TIP AND...

Page 39: ...le 7 Insert a new untrimmed liner into the connector end of the cable a Check the liner bushing stencil to make sure it is the appropriate one for the wire size being used 8 Fully seat the liner bushi...

Page 40: ...viced if necessary The gun handle consists of two halves that are held together with a collar on each end To open up the handle 1 Turn the collars approximately 60 degrees coun terclockwise the same d...

Page 41: ...9 5 mm 12 1 mm 15 9 mm 9 5 mm 15 9 mm 15 9 mm 0 6 1 2 mm 12 7 mm 15 9 mm 0 6 0 8 mm 0 9 1 2mm ENGLISH SIZE 025 030 035 045 3 64 Alum Wire 025 030 035 045 035 045 025 030 035 045 3 64 Alum wire 3 8 1 2...

Page 42: ...NOTES WIRE MATIC 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...

Page 43: ...tage 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 TABLE OF CONTENTS THE...

Page 44: ...ry winding that sup plies power to the Control Board for SCR gate drive and gas solenoid operation The weld power windings connect to the Control Board as well as to the main SCR Rectifier Figure E 2...

Page 45: ...e firing of the SCRs thus con trolling the output of the machine See SCR Operation The control board also powers and com mands the gas solenoid and the wire drive motor Figure E 3 Output Rectification...

Page 46: ...f the machine Figure E 4 Constant Voltage Output CONSTANT VOLTAGE OUTPUT LINE SWITCH MAIN TRANSFORMER RECONNECT FAN MOTORS SCR RECTIFIER C A P A C I T O R S SHUNT CHOKE WIRE DRIVE MOTOR TACH POSITIVE...

Page 47: ...turn regulates the electrode wire feed speed through the gun Figure E 5 Wire Drive Motor and Feedback WIRE DRIVE MOTOR AND FEEDBACK LINE SWITCH MAIN TRANSFORMER RECONNECT FAN MOTORS SCR RECTIFIER C A...

Page 48: ...cooling fan motors when required The other choke thermostat opens the trigger circuit preventing machine weld output and wire feed if excessive operating temperatures are detected The third thermosta...

Page 49: ...he AC cycle time in the off state and the remainder of the time in the on state The amount of time spent in the ON state is con trolled by the gate An SCR is fired by a short burst of current into the...

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 NOTES WIRE MATIC 255...

Page 51: ...ormal Open Circuit Voltage Waveform F 22 Typical Output Voltage Waveform Machine Loaded F 23 Abnormal Output Voltage Waveform Machine Loaded One Output SCR Not Functioning F 24 Abnormal Open Circuit V...

Page 52: ...t com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your probl...

Page 53: ...g on equipment Do not touch electrically hot parts Remove the P C Board from the static shielding bag and place it directly into the equipment Don t set the P C Board on or near paper plastic or cloth...

Page 54: ...ln Electric Service Dept 216 383 2531 or 1 800 833 9353 WELD 1 Check input power switch S1 It may be faulty 2 Check for lose or broken wires at the reconnect panel 3 Perform Main Transformer Test 4 Ch...

Page 55: ...rform the SCR Rectifier Assembly Test 4 The control board may be faulty Replace 1 Check for loose or faulty con nections of the heavy current carrying leads 2 The output capacitor bank may be faulty C...

Page 56: ...inuously or pulsing when gun trigger is NOT activated 1 Check the machine s internal trigger leads for grounds or shorts See Wiring Diagram 2 The control board may be faulty Replace 1 Remove the gun I...

Page 57: ...supply to the gas solenoid If the solenoid does NOT activate then it may be faulty Replace 2 The control broad may be faulty Replace 1 Check the motor armature cur rent Normal armature current is 1 75...

Page 58: ...h Feedback test 3 The control board may be faulty Replace 1 Perform the Wire Drive Motor and Tach Feedback Test 2 The Wire Feed Control poten tiometer may be faulty Check or replace See Wiring Diagram...

Page 59: ...ace 1 The output capacitor bank may be faulty Check for loose con nections at the capacitors Also check for leaky capacitors Replace if necessary WARNING The liquid elec trolyte in these capacitors is...

Page 60: ...Bridge Test 2 The control board may be faulty Replace 1 The control board may be faulty Replace 1 Check the welding cable con nections for loose or faulty con nections 2 Make sure the wire feed speed...

Page 61: ...ervice 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 opera...

Page 62: ..._______________________ NOTE Secondary voltages will vary proportionably with the primary input voltage 1 Disconnect the main input power supply to the machine 2 Remove the Case Top and Side Panels wi...

Page 63: ...ds between the reconnect panel and the ON OFF POWER SWITCH test the ON OFF POWER SWITCH for proper operation b If the correct nameplate voltage is being applied to the main transformer and one or more...

Page 64: ...or socket wrench 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 r...

Page 65: ...lectrically isolates the SCR bridge assembly See Figure F 2 FIGURE F 2 Remove Plugs J3 and J6 to Perform Static SCR Rectifier Assembly Test 3 Verify that the capacitors have com pletely discharged wit...

Page 66: ...ode of SCR 1 See Figure F 4 Use an analog ohmmeter Multimeter FIGURE F 4 SCR 1 Test Points 7 Test for high or infinite resistance from the cathode to the anode of SCR 1 by reversing the meter leads Se...

Page 67: ...Heat Sink Assembly Drawings 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 t...

Page 68: ...capacitor bank using a 1 2 open end wrench See Figure F 6 FIGURE F 6 Location of Leads X2 and X3 5 Separate leads X2 and X3 from the negative capacitor bank buss bar Be sure there is no electrical co...

Page 69: ...closed and after the switch is open the SCR is functioning b If the voltages is 3 6 volts only when the switch is closed or there is no voltage when the switch is closed the SCR is defective NOTE Be s...

Page 70: ...r 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 electr...

Page 71: ...BE 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 nut driver 3 Locate Plug...

Page 72: ...upply Voltage to Tachometer 1 Test for 15 VDC between lead 515B positive 3J5 and lead 206B negative 2J5 See Figure F 8 for pin locations a Insert probes into Molex pin cavities 2 Pull gun trigger 3 Re...

Page 73: ...s 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...

Page 74: ...ted from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time The machine was loaded with a resistance...

Page 75: ...nt One SCR gate was disconnected to simulate an open or non functioning output SCR Each vertical division represents 20 volts and each horizontal division represents 5 mil liseconds in time The machin...

Page 76: ...ut capacitors are not functioning Note the lack of filtering in the output waveform The output capacitor bank was disconnected Each vertical divi sion represents 20 volts and each horizontal division...

Page 77: ...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 mil...

Page 78: ...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 av...

Page 79: ...ifferent Code Machines 5 Lift the Control Board straight up and out from the machine 6 When re installing the Control Board carefully secure Board to mounting standoffs CONTROL PC BOARD REMOVAL AND RE...

Page 80: ...ained 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 avoi...

Page 81: ...ng a The gas hose and gun connec tor leads will limit the travel dis tance 8 Disconnect the drive motor from the drive roll assembly a Remove the three large phillips head screws on the outboard side...

Page 82: ...y 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 warr...

Page 83: ...chine using a slot head screwdriver and 3 8 open end wrench FIGURE F 13 Heat Sink lead discon nection 4 Cut the SCR gate leads G1 and G2 see wire markers and wiring dia gram using wire cutters a The e...

Page 84: ...PACITOR BANK REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained per sonnel Unauthorized repairs performed on this equipment could result in...

Page 85: ...choke lead and the heavy lead extending from the SCR Rectifier Assembly to the posi tive capacitor bank buss bar using a 1 2 open end wrench 5 Remove lead 206 and the D1 diode lead from the negative...

Page 86: ...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 you...

Page 87: ...e POWER SWITCH 9 Label and cut leads 202 203 204A a Cut lead 204A at a point just in front of the transformer b These leads must be re spliced during reassembly c An alternative to cutting these leads...

Page 88: ...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 a...

Page 89: ...open end wrench 3 Using a 5 16 wrench remove the 5 screws holding the fan motor mount ing bracket to the case back 4 Tilt the Case Back away from the machine and remove the screws holding the Case Ba...

Page 90: ...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 c Cut any necessary wire wraps bundling th...

Page 91: ...ster TOC Return to Master TOC Return to Master TOC F 40 TROUBLESHOOTING REPAIR F 40 WIRE MATIC 255 INPUT IDLE AMPS AND WATTS WIRE SPEED RANGE OPEN CIRCUIT VOLTAGE RETEST AFTER REPAIR Maximum Idle Watt...

Page 92: ...NOTES WIRE MATIC 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...

Page 93: ...l Diagram Section Section G Wiring Diagram 208 230 Code 10166 G 2 Wiring Diagram 230 460 575 Code 10167 G 3 Control PC Board G2803 Schematic G 4 Control PC Board G2803 Layout G 5 G 1 G 1 Return to Mas...

Page 94: ...NOTES WIRE MATIC 255 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 95: ...6 B 5 1 5 B 3 2 5 3 2 5 A T O W O R K N A G N D 2 0 2 2 0 3 3 2 5 A 2 0 5 2 0 6 S S H U N T 3 2 8 S 2 M O U N T E D C L O S E S T T O F A N S 3 M O U N T E D C L O S E S T T O P O W E R T R A N S F O...

Page 96: ...J 1 0 J 2 J 1 2 5 4 2 5 2 2 5 3 2 5 5 2 5 1 2 5 6 O P T I O N A L T I M E R B O A R D 1 2 3 4 5 6 7 8 2 6 0 2 6 2 2 6 1 2 6 3 2 6 5 2 6 4 J 1 6 2 5 1 2 5 6 2 5 3 2 5 4 2 5 5 R 4 R 3 W I R E S P E E D...

Page 97: ...y 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...

Page 98: ...ion 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 Operato...

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