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F-20

TROUBLESHOOTING & REPAIR

F-20

WIRE-MATIC 255

TEST PROCEDURE

NOTE: POLARITY

MUST

OBSERVED FOR THESE TESTS.

Test for Correct Wire Drive Motor
Armature Voltage

Disconnect main input power to the
machine.

Remove the Case Top and Side
Panels using a 5/16" nut driver.

Locate Plug J5 on the G2803
Control Board. See Figure F.8.

FIGURE F.8 - Plug J5 Location on
G2803 PC Control Board.

WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (CONTINUED)

J10

#541 (W)

(13J5)

#206B

(2J5)

#555
(1J5)

#539 (B)

(12J5)

#515B

(3J5)

G2803

WM-255 CONTROL

Содержание WIRE-MATIC 255

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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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