WIRE-MATIC 250 SERVICE MANUAL Sales and Service through Subsidiaries and Distributors Worldwide 22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100 World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors SVM 117-A December 1995 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety 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 THROUGHOUT. And, most importantly, think before you act and be careful. For use with machines having Code Numbers: WIRE-MATIC 250 20 18 16 14 22 24 26 28 VOLTS 300 250 200 150 350 400 450 500 WIRE SPEED 100 550 50 600 1 ON 0 OFF 9799, 9800, 10003, 10004. RETURN TO MAIN INDEX Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC View Safety Info View Safety Info View Safety Info View Safety Info
Lincoln Wirematic 250 SVM117A
Oct 16, 2014
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WIRE-MATIC 250
SERVICE MANUAL
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
SVM 117-ADecember 1995
Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However,your overall safety can beincreased by proper installation... and thoughtful operation onyour part. DO NOT INSTALL,OPERATE OR REPAIR THISEQUIPMENT WITHOUT READ-ING THIS MANUAL AND THESAFETY PRECAUTIONS CON-TAINED THROUGHOUT. And,most importantly, think before youact and be careful.
For use with machines having Code Numbers:
WIRE-MATIC 250
201816
14
22242628
VOLTS
300250200
150
350400450
500
WIRE SPEED
100
55050600
1 ON
0OFF
9799,9800,
10003,10004.
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PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDRENAWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from theLincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER-FORMED ONLY BY QUALIFIED INDIVIDUALS.
ARC RAYS can burn.2.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.
2.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.
2.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can kill.1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands.
1.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.
In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.
1.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.
1.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.
1.e. Ground the work or metal to be welded to a good electrical(earth) ground.
1.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.
1.g. Never dip the electrode in water for cooling.
1.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.
1.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
1.j. Also see Items 4.c. and 6.
WARNING ARC WELDING can be hazardous.
FUMES AND GASEScan be dangerous.3.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.
3.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.
3.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.
3.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.
3.e. Also see item 7b. Apr. ‘93
CYLINDER may explodeif damaged.5.a. Use only compressed gas cylinders
containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.
5.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
5.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.
• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.
5.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
5.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
5.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
5.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLYpowered equipment.
6.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.
6.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.
6.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
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Feb. ‘95
WELDING SPARKS cancause fire or explosion.4.a. Remove fire hazards from the welding area.
If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot
materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.
4.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.
4.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contact cancause overheating and create a fire hazard.
4.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
4.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
4.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.
4.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate circuits.This can create fire hazards or overheat lifting chains orcables until they fail.
4.h. Also see item 7c.
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Mar. ‘93
ELECTRIC AND MAG-NETIC FIELDSmay be dangerous
8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
8.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.
8.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.
8d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
8.d.1. Route the electrode and work cables together - Securethem with tape when possible.
8.d.2. Never coil the electrode lead around your body.
8.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.
8.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.
8.d.5. Do not work next to welding power source.
FOR ENGINEpowered equipment.
7.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.
____________________________________________________
7.b. Operate engines in open, well-ventilatedareas or vent the engine exhaust fumes
outdoors.
____________________________________________________
7.c. Do not add the fuel near an open flamewelding arc or when the engine is run-ning. Stop the engine and allow it to coolbefore refueling to prevent spilled fuelfrom vaporizing on contact with hotengine parts and igniting. Do not spillfuel when filling tank. If fuel is spilled,wipe it up and do not start engine untilfumes have been eliminated.
____________________________________________________
7.d. Keep all equipment safety guards, coversand devices in position and in good repair.Keep hands, hair, clothing and tools awayfrom V-belts, gears, fans and all othermoving parts when starting, operating orrepairing equipment.
____________________________________________________
7.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.
7.f. Do not put your hands near the engine fan. Do notattempt to override the governor or idler by pushing onthe throttle control rods while the engine is running.
7.g. To prevent accidentally starting gasoline engines whileturning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.
___________________________________________________
7.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.
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Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:
Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un plancher met-allique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble desoudage et la machine à souder en bon et sûr état defonc-tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.
e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à soud-er parce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.
2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:
a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.
c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protection libresde l’huile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible dela zone de travail qu’il est pratique de le faire. Si on place lamasse sur la charpente de la construction ou d’autres endroitséloignés de la zone de travail, on augmente le risque de voirpasser le courant de soudage par les chaines de levage,câbles de grue, ou autres circuits. Cela peut provoquer desrisques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voirle code “Code for safety in welding and cutting” CSA StandardW 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seronteffectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leurplace.
Mar. ‘93
NOTES
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Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section ATechnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Select Proper Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5Connect Output Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section BSafety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . .B-2Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2Machine Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4Using the Wire Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5Operating Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section CReplacement Magnum 250L Gun and Cable Assembly . . . . . . . . . . . . . .C-1K607-1 Spool Gun Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1Installing the K607-1 Spool Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . .C-1Making a Weld with the Spool Gun Adapter (K607-1) Installed . . . . . . . .C-5Timer Kit (K585-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-6Timer Kit Installation (Optional K585-1) . . . . . . . . . . . . . . . . . . . . . . . . . .C-6Making Spot and Stitch Welds with Timer Kit Installed . . . . . . . . . . . . . . .C-7Adjustable Gas Regulator and Hose Kit (K586-1) . . . . . . . . . . . . . . . . . .C-7Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section DSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1Drive Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3Drop-In Reel Spindle and Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3Cable Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3Gun Tubes and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3Contact Tip and Gas Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . .D-3Liner Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Liner Removal, Installation, and Trimming Instructions for Magnum 250L D-4Gun Handle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5Accessories and Expendable Replacement Parts forMagnum 250L Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . .D-6
TABLE OF CONTENTS
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Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section EPower Supply Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section FHow to use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . .F-2Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-10Oscilloscope Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-22Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-218
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INSTALLATION
WIRE-MATIC 250
INSTALLATION SECTION ........................................ Section ATechnical Specifications ...................................................A-1Safety Precautions ...........................................................A-2Select Proper Location.....................................................A-2
Stacking.......................................................................A-2Tilting ...........................................................................A-2
Input Connections ............................................................A-2Fuse and Wire Sizes ...................................................A-3Input Power Connections and Ground Connections...A-3Connect Shielding Gas................................................A-4
Reconnect Procedure.......................................................A-5Connect Output Components...........................................A-7
Install the Work Clamp ................................................A-7Output Polarity Connection .........................................A-7Gun Liner and Contact Tip Installation........................A-7Wire Size Conversion Parts ........................................A-8Gun and Cable Installation..........................................A-8
TABLE OF CONTENTS- INSTALLATION SECTION -
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WIRE-MATIC 250
Duty Cycle Amps Volts at Rated Amps
100% 145 amps 26
60% 200 amps 28
35% 250 amps 26
Current Range Maximum Open Circuit Voltage Wire Speed Range
30A - 250A 40V 50 - 600 IPM(1.27-15.2 m./minute)
Input Voltage/ Fuse (Superlag) Type 750C wire in Type 750C CopperFrequency or 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) 10 (6mm2)575/60 25 14 (2.5mm2) 12 (4mm2) 10 (6mm2)
HEIGHT Width DEPTH WEIGHT(W/GUN)
28.2” 18.8” 40.1” 220 lbs.(719mm) (480mm) (1019mm) (100 Kg.)
Standard Voltage Input Current at Rated Output
208/230/1/60 53/49 Amps
230/460/575 50/25/20 Amps
A-1INSTALLATION A-1
TECHNICAL SPECIFICATIONS - Wire-Matic-250
INPUT - SINGLE PHASE/ 60 HERTZ ONLY
RATED OUTPUT
OUTPUT
PHYSICAL DIMENSIONS
STORAGE OPERATING± 400C -200C to 400C
OPERATING TEMPERATURE
RECOMMENDED INPUT WIRE & FUSE SIZE
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the WIRE-MATIC 250
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.• Only qualified personnel should
install this machine.
• Turn the input power OFF at the dis-connect switch or fuse box before working on the equipment.
• Do not touch electrically hot parts.
• Always connect the WIRE-MATIC 250 ground-ing terminal to a good electrical earth groundthrough the cable plug per the NationalElectrical Code.
• Set the Wire-Matic 250 ON/OFF Power switch tothe OFF position when connecting power cordto input power.
____________________________________
SELECT PROPER LOCATION
Place the WIRE-MATIC 250 where clean, cooling aircan freely circulate in through the case back louversand out through the case front louvers. Dirt, dust, orany foreign material that can be drawn into themachine case back louvers should be kept at a mini-mum. Not following these precautions can result in thenuisance shutdown of the machine because of exces-sive operating temperatures.
STACKING
The WIRE-MATIC 250 cannot be stacked.
TILTING
The Wire-Matic 250 must be placed on a stable, levelsurface so it will not topple over. Do not place themachine on an incline.
A-2INSTALLATION
WIRE-MATIC 250
A-2
INPUT CONNECTIONS
All input power must be electricallydisconnected before proceeding.
____________________________________1. Before starting the installation, check with the local
power company to determine if there is any ques-tion about whether your power supply is adequatefor the voltage, amperes, phase, and frequencyspecified on the welder nameplate. Be sure theplanned installation will meet the U.S. NationalElectrical Code and local code requirements. Thiswelder may be operated from a single phase lineor from one phase of a two or three phase line.
2. Models that have multiple input voltages specifiedon the nameplate (e.g., 208/230) are shipped con-nected for the highest voltage. If the welder is tobe operated at a lower voltage, it must be recon-nected according to the instructions on the insideof the removable panel (Reconnect Access Door)near the top left side of the Case Back Assembly.See the Reconnect Section of this manual fordetails on reconnecting the machine to operate atdifferent voltages.
3. Be sure the voltage, phase, and frequency of theinput power is as specified on the machine ratingplate. See Figure A.1 for the location of themachine's input cord entry, Reconnect AccessDoor, and Reconnect Panel, and Rear Nameplate.
FIGURE A.1 - Case Back Assembly: Input PowerCable Entry Connections.
WARNING
WARNING
A-3INSTALLATION
WIRE-MATIC 250
A-3
FUSE AND WIRE SIZES
Protect the input circuit with the super lag fuses ordelay type circuit breakers listed on the TechnicalSpecifications page of this manual for the machinebeing used. The tripping action of delay type circuitbreakers decreases as the magnitude of the currentincreases. They are also called inverse time or ther-mal/magnetic circuit breakers.
DO NOT use fuses or circuit breakers with a lower amprating than recommended. This can result in "nui-sance" tripping caused by inrush current even whenmachine is not being used for welding at high outputcurrents.
Use input and grounding wire sizes that meet localelectrical codes or see the Technical Specificationspage in this manual.
INPUT POWER CONNECTIONS AND GROUND CONNECTIONS
Have a qualified electrician connect the receptacle orcable to the input power lines and the system groundaccording to the U.S. National Electrical Code and anyapplicable local codes.
1. Follow the Input Supply Connection Diagram onthe inside of the Reconnect Panel Access Door.
2. Use a single-phase line or one phase of a three-phase line.
For the 208V/230V/ 60 HZ model WIRE-MATIC 250shipped with a 10 ft. input cord and plug connected tothe welder, mount the matching receptacle suppliedwith the machine.
1. Mount the receptacle in a suitable location usingthe screws provided.
2. Locate the receptacle within reach of the 10 ft.input cord attached to the welder.
3. Mount the receptacle with the grounding terminalat the top. This allows the power cable to hangdown without bending. See Figure A.2.
a. The center terminal in the receptacle is for thegrounding connection.
b. Fuse the two hot lines of the receptacle withsuper lag type fuses as shown in Figure A.2. Agreen wire in the input cord connects this ter-minal to the frame of the welder. This ensuresproper grounding of the welder frame when thewelder plug is inserted into the receptacle.
4. Use proper wire sizes. See the TechnicalSpecification table for proper wire sizes. Forcable lengths over 100 feet, larger copper wiresshould be used.
Connect to a system grounding wire. See theUnited States National Electrical Code and localcodes for other details and means for propergrounding.
Connect to hot wires of a three-wire, single phasesystem or to one phase of a two or three phasesystem.
____________________________________
FIGURE A.2. - Ground Connections.
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CAUTION
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A-4INSTALLATION
WIRE-MATIC 250
A-4
For the 230/460/575V/ 60 HZ model which is notequipped with a plug, an input cord, or a receptacle,the input power supply leads must be connecteddirectly to the Reconnect Panel as shown in FigureA.3. Refer to Technical Specifications at the begin-ning of this chapter for proper wire sizes.
1. Connect the input power leads to terminals L1 andL2 on the Reconnect Panel Assembly.
a. For input power supply leads of 10 AWG orsmaller are used, connect leads to ReconnectPanel using the ferrules (S19117-1) provided.
b. Strip 1/2" (13mm) of insulation from the inputpower supply leads.
c. Place ferrule over wire.
d. Torque the terminal screws to 16 in.-lbs.(1.8nm).
FIGURE A.3 - Input Power Connection For230/460/575 Volt Models.
CONNECT SHIELDING GAS
Customer must provide cylinder of appropriate type ofshielding gas for gas metal arc welding for the processbeing used. See Figure A.4 for the location of the com-ponents used to connect the air supply cylinder.
NOTE: For CO2 or Argon blend gas, the optionalK586-1 Adjustable Gas Regulator and Hose Kit shouldbe used. See Accessories Section of this manual.
Gas under pressure is explosive.Always keep gas cylinders in anupright position and always keepchained to undercarriage or sta-tionary Y support. See AmericanNational Standard Z-49.1, “Safetyin Welding and Cutting” published
by the American Welding Society.
____________________________________
1. Set the gas cylinder on the rear platform of theWIRE-MATIC 250.
2. Hook the chain in place to secure cylinder to rearof welder.
3. Remove the cylinder cap.
4. Inspect the cylinder valves for damaged threads,dirt, dust, oil or grease.
a. Remove dust and dirt with a clean cloth.
NOTE: DO NOT ATTACH THE REGULATOR IF OIL,GREASE OR DAMAGE IS PRESENT! Inform yourgas supplier of this condition. Oil or grease in the pres-ence of high pressure oxygen is explosive.
5. Stand to one side away from the outlet and openthe cylinder valve for an instant to blow away anydust or dirt which may have accumulated in thevalve outlet.
BE SURE TO KEEP YOUR FACE AWAY FROM THEVALVE OUTLET WHEN OPENING THE VALVE.
6. Inspect the regulator for damaged threads, dirt,dust, oil or grease.
a. Remove dust and dirt with a clean cloth.
NOTE: DO NOT USE THE REGULATOR IF OIL,GREASE OR DAMAGE IS PRESENT! Have anauthorized repair station clean the regulator or repairany damage.
WARNING
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A-5INSTALLATION
WIRE-MATIC 250
A-5
7. Attach the flow regulator to the cylinder valve andtighten the union nut(s) securely with a wrench.
a. NOTE: If connecting the flow regulator to100% CO2 cylinder, insert the regulatoradapter provided with the optional K-586-1 Kitbetween the regulator and cylinder valve. Ifadapter is equipped with a plastic washer, besure it is seated properly to connect to the CO2
cylinder.
8. Connect one end of the inlet gas hose to the outletfitting of the flow regulator.
9. Connect the other end of the inlet gas hose to theWIRE-MATIC 250 rear fitting.
10. Tighten both the union nuts securely with awrench.
11. Before opening the cylinder valve, turn the regula-tor adjusting knob counter-clockwise until the pres-sure is released from the adjusting spring.
12. Open the cylinder valve slowly a fraction of a turn.
a. When the cylinder pressure gage pointer stopsmoving, open the valve fully.
NEVER STAND DIRECTLY IN FRONT OF ORBEHIND THE FLOW REGULATOR WHEN OPENINGTHE CYLINDER VALVE. ALWAYS STAND TO ONESIDE.
NOTE: The Optional K586-1 flow regulator isadjustable. Adjust the flow regulator for the flow raterecommended for the procedure and process beingused before making the weld.
FIGURE A.4 - Input Air Supply Connections
RECONNECT PROCEDURE
Multiple voltage machines are shipped connected tothe highest input voltage listed on the machine's ratingplate. Before installing the machine, check that theReconnect Panel in the Input Box Assembly is con-nected for the proper voltage.
Failure to follow these instructions can causeimmediate failure of components within themachine.___________________________________
To reconnect a dual or triple voltage machine to a dif-ferent voltage, change the position of the leads or linkson the Reconnect Panel based on the type ofmachine. Follow The Input Supply ConnectionDiagram located on the inside of the Case BackReconnect Panel Access Door.
For 208/230/1/60 machine(s), see Figure A.5.
For 230/460/575/1/60 machine(s), see Figure A.6.
CAUTION
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A-6INSTALLATION
WIRE-MATIC 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 SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHER OF THE TWOINPUT VOLTAGES LISTED ON THE NAMEPLATE. TO CHANGE VOLTAGE CONNECTION PROCEED ASFOLLOWS:
1. REMOVE THE OUTER STEEL HEX NUT FROM THE TERMINAL WHERE THE TRANSFORMERINPUT LEAD IS CONNECTED.
2. SHIFT THE TRANSFORMER INPUT LEAD TO THE TERMINAL THAT THE UNIT IS TO OPERATEON AND FASTEN SECURELY WITH THE HEX NUT REMOVED IN STEP1. (MAKE CERTAIN THATBRASS NUTS ARE TIGHT.)
1. ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHEST NAME-PLATED SINGLE PHASE INPUT VOLTAGE. TO CHANGE CONNECTIONS FOR A DIFFERENT INPUTVOLTAGE, RECONNECT BOTH COPPER JUMPERS PER DIAGRAM BELOW. ALWAYS CONNECTJUMPERS BETWEEN OUTER STEEL NUT AND INNER BRASS NUT ON TERMINAL STUDS.
2. CONNECT THE INPUT POWER TO THE INPUT TERMINAL BLOCK, L1 AND L2 AT THE UPPER COR-NER OF THE PANEL. FOR INPUT LEADS 10AWG AND SMALLER USE FERRULES PROVIDED.TORQUE TO 16 IN-LBS.
3. CONNECT A GROUNDING LEAD TO THE GROUND STUD ( ) ON THE MACHINE NEAR THE TER-MINAL BLOCK.
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INSTALL THE WORK CLAMP
Attach the work clamp to the cable which extends fromthe front of the machine using the following procedure:
1. Insert the lug on the end of the work cable throughthe strain relief hole in the work clamp handle. SeeFigure A.7.
2. Slide the work cable through the hole up to the boltand nut.
3. Fasten work cable using the bolt and nut provided.
FIGURE A.7 - Installing The Work Clamp.
OUTPUT POLARITY CONNECTION
Turn the welder Power Switch OFF before chang-ing output connection.
____________________________________
The welder is shipped from the factory connected forelectrode positive (+) polarity. This is the normal polar-ity for GMA welding.
If negative (-) polarity is required, interchange the con-nection of the two cables located in the wire drive com-partment near the front panel. The negative lead is thelead closest to the front panel (where the leads comeout of the floor of the compartment) and should bereconnected to the brass conductor tube of the gunconnector. The positive lead is stamped (+) on its ter-minal and should be reconnected to the work lead ter-minal.
A-7INSTALLATION
WIRE-MATIC 250
A-7
GUN LINER AND CONTACT TIPINSTALLATION
The Magnum 250L gun and cable provided with theWIRE-MATIC 250 is factory installed with a liner for a.035-.045” (0.9-1.2mm) diameter electrode and an.035” (0.9mm) contact tip.
1. If a .045” diameter wire size is to be used, installthe .045” contact tip (also provided).
2. For other wire sizes, use the following procedurefor contact tip and gas nozzle installation. SeeFigure A.8.
a. Choose the correct size contact tip for theelectrode being used (wire size is stenciled onthe side of the contact tip) and screw it snuglyinto the gas diffuser.
b Be sure the nozzle insulator is fully screwedonto the gun tube and does not block the gasholes in the diffuser.
c. Slip the appropriate gas nozzle onto the noz-zle insulator. Either a standard .50" (12.7mm)or optional .62” (15.9mm) I.D. slip-on gas noz-zle may be used and should be selectedbased on the welding application.
d. Adjust the gas nozzle for the GMAW processto be used.
For the short-circuiting transfer process, the contact tipend should be flush to extended to .12" (3.2mm). SeeFigure A.8.
For the spray transfer process, the contact tip shouldbe flush to recessed .12" (3.2mm). See Figure A.8.
FIGURE A.8 - Contact Tip and ElectrodeConnections.
WARNING
A-8INSTALLATION
WIRE-MATIC 250
A-8
WIRE SIZE CONVERSION PARTS
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 INSTALLATION
Turn the welder Power Switch OFF before chang-ing output connection.____________________________________
1. Lay the cable out straight.
2. Locate the wing screw on conductor block insidewire feed compartment. Unscrew it until the tip ofthe screw no longer protrudes into gun opening asseen from front of machine.
3. Insert the brass connector on the end of the guncable into conductor block through opening in thefront panel. Make sure the connector is fully insert-ed and tighten wing screw.
4. Connect the gun trigger connector from the gunand cable to the mating receptacle on the frontpanel. Make sure that the keyways are aligned,insert and tighten retaining ring.
NOTE: If a gun and cable other than the Magnum250L is used, it must conform to connector specifica-tions and the gun trigger switch must be capable ofswitching 5 milliamps at 15 volts DC -resistive.
The gun trigger switch connected to the gun trig-ger control cable must be a normally open,momentary switch. The terminals of the switchmust be insulated from the Welding circuit.Improper operation of or damage to the WIRE-MATIC 250 might result if this switch is common toan electrical circuit other than the WIRE-MATIC 250trigger circuit.____________________________________
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WARNING
CAUTION
NOTES
WIRE-MATIC 250
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OPERATION
WIRE-MATIC 250
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OPERATION SECTION ............................................ Section BSafety Instructions............................................................B-1General Description..........................................................B-1Recommended Processes and Equipment......................B-2Design Features and Advantages....................................B-2
Unit Features...............................................................B-2Power Source Features...............................................B-2Wire Feeder Features .................................................B-3
Machine Capability ...........................................................B-3Limitations ........................................................................B-3Controls and Settings.......................................................B-4Using the Wire Drive Roll .................................................B-5
Procedure for Changing Drive Roll .............................B-5Loading the Wire Reel.................................................B-5Feeding Electrode .......................................................B-6Proper Wire Feeding ...................................................B-6Setting Idle Roll Pressure............................................B-7
Operating Steps ...............................................................B-7Starting the Welder......................................................B-7Changing Run-In Mode ...............................................B-7
Enter Fast Run-In Mode .........................................B-7Enter Slow Run-In Mode.........................................B-7
Making a Weld.............................................................B-8
TABLE OF CONTENTS- OPERATION SECTION -
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B-1OPERATIONB-1
Read and understand this entire section before operat-ing your WIRE-MATIC 250.
SAFETY INSTRUCTIONS
ELECTRIC SHOCK can kill.
When using a Wire-Matic 250 power source therewill be a small spark if the electrode contacts thework or ground within several seconds afterreleasing the trigger.
____________________________________
GENERAL DESCRIPTION
The WIRE-MATIC 250 is a complete semiautomaticconstant voltage DC arc welding machine built to meetNEMA specifications. It combines a constant voltagepower source, a constant speed wire feeder, and amicrocomputer-based controller to form 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 250
WARNING
FUMES AND GASEScan be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust toremove fumes from breathingzone.
ARC RAYScan burn.
• Wear eye, ear and bodyprotection.
WELDING, CUTTING and GOUGING SPARKScan cause fire or explosion
• Keep flammable material away.
• Do not weld, cut or gouge oncontainers that have heldcombustibles.
CAUTION
• Do not touch electrically liveparts such as output terminalsor internal wiring.
• Insulate yourself from the workand ground.
• Always wear dry insulatinggloves.
____________________________________
Only qualified personnel should operate this equip-ment. Observe all safety information throughout thismanual.
____________________________________
____________________________________
____________________________________
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10 Ft. (3.0m) Input Power Cable - Includes plug andmating receptacle for 208/230V unit. Convenient rearreconnect panel allows easy access for 208V re-con-nection.
Power Switch - Front panel toggle switch turns inputpower on and off.
Pilot Light - Indicates when power is applied tomachine.
Thermostatically-Controlled Fans - Cools trans-former and other components only when required. Thefan motors stays off when used intermittently or at lowcurrent procedures, reducing the amount of dust anddirt drawn into the machine. This also reduces powerconsumption.
Electronic Overload Protection - Protects machinefrom short circuit or high current overloading.
Power Source Line Voltage Regulation - PreciseSCR phase control circuit holds the voltage setting at aconstant level to maintain weld quality even when theinput voltage fluctuates +/- 10%.
Solid State Contactor -Output is turned on and off bySCR's instead of a mechanical contactor providingextra long life in highly repetitive welding applications.
Output Terminals - Easily accessible in wire drivecompartment for quick cable connection and polarityreversal.
Work Cable - 10 ft. (3.0m) long with work clamp.
B-2OPERATIONB-2
RECOMMENDED PROCESSES ANDEQUIPMENT
The WIRE-MATIC 250 is recommended for GMA weld-ing processes using 10 to 30 lb. (4.5 to 13.6 kg) 2"(51mm) I.D. spools or Readi-Reel coils (with optionaladapter) 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" (0.9mm) and .045" (1.2mm) Innershield self-shielding electrodes.
The WIRE-MATIC 250 is factory equipped to feed.035" (0.9mm) and .045" (1.2mm) electrodes. Itincludes a 12 ft. (3.6m) GMAW gun and cable assem-bly equipped for these wire sizes with a duty cycle rat-ing of 200A, 60% or 250A, 35%. Using GMAWprocesses requires use of the optional gas regulatorand a supply of shielding gas.
DESIGN FEATURES ANDADVANTAGES
UNIT FEATURES:
Continuous Voltage and Wire Speed Control -Large, easy to use control knobs provide continuousfull-range calibrated control of both wire speed andvoltage. A "ready-reference Procedure Chart” is pro-vided on the inside of the wire drive section door givingsuggested settings for popular welding processes andplate thickness. Wire speed control has fine resolutioncalibrated dial for repeatable and precise setting.
Undercarriage for Hand Mobility - Heavy duty 10"(254mm) wheels and 4" (102mm) casters are factoryinstalled. The handle can be used for storing the weld-ing gun and work cable.
Gas cylinder Platform - Factory installed on theundercarriage, it permits platform mounting and sup-port of a single gas cylinder. It is not necessary tocompletely lift the gas cylinder when placing it on theplatform.
Easy Accessibility - The innovative, small door on thewire feeder enclosure protects wire and wire drive fromdirt, dust, and damage. However, the door allowseasy top access for convenient "drop-in" wire reel load-ing or to service the wire drive.
WIRE-MATIC 250
B-3OPERATIONB-3
WIRE FEEDER FEATURES:
Drop-in Wire Loading - The innovative spindle snapsinto the Readi-Reel adapter (optional) or most any 2"(51mm) I.D. wire spool. The wire spindle drops into thetop-loading WIRE-MATIC 250 case design.Accommodating standard 12" (305mm) and 8"(203mm) diameter coils, the unique spindle and sup-port design automatically provides appropriate de-reel-ing drag to prevent wire reel overrun and loop-offswithout manual brake adjustment.
Tachometer Controlled Wire Drive - Precision con-trol of permanent magnet motor provides proper wirefeed acceleration and speed accuracy, independent offluctuations in line voltage and wire loading. This givesreliable arc starting and weld consistency.
Low Speed Start - When the trigger is pulled, the wirefeeder feeds wire at low speed regardless of the setwire feed speed until welding current is drawn or 2 sec-onds has expired. This feature enhances starting andmakes setting stickout easy. The 2 second limit per-mits high speed loading of the gun and cable. In laterversions of the WIRE-MATIC 250, a user selectablefeature allows the wire feeder to feed wire directly atthe set speed, thus bypassing the 2 second slow start.
Solid State Overload Protection - No circuit breakerto reset. Simply pull the trigger to resume weldingonce the overload condition has been cleared.
Unique Drive Roll and Guide Tube Design -Precisely aligned guide tubes and drive rolls providelong life. The design also permits quick reload by sim-ply starting wire into ingoing guide tube. Adjustabletension setting minimizes 'birdnesting', eliminatesmilling through the wire, and gives positive feeding.The double groove, reversible drive roll included withthe WIRE-MATIC 250 allows use of .030" (0.8mm)through .045" (1.2mm) diameter wire. Drive roll kits forother sizes and types of wire are also available.
Quick-Connect Welding Gun - Gun connector hasintegrated welding power and gas connection with sep-arate front-panel twist-lock trigger connection mount.
Gun and Cable - A 12 ft. (3.6m) GMAW gun and cableassembly, rated 200 amps 60% duty, or 250 amps 35%duty, is provided with the WIRE-MATIC 250. A liner,diffuser and contact tips for .035" (0.9mm) and .045"(1.2mm) electrodes are included.
MACHINE CAPABILITY
The WIRE-MATIC 250 is rated on the following dutycycles based on a 10-minute time period (i.e., for 60%duty cycle, it is 6 minutes on and 4 minutes off).
LIMITATIONS
The WIRE-MATIC 250 may not operate satisfactorily ifpowered with a portable or in-plant generating system.
WIRE-MATIC 250
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Duty Cycle
100%
60%
35%
Amps.
145
200
250
Volts
26
28
26
B-4OPERATIONB-4
CONTROLS AND SETTINGS
All operator controls are located on the FrontPanel/Nameplate of the machine. See Figure B.1 forthe location of each control.
Figure B.1 - Operator Controls.
1. POWER SWITCH: Toggle switch to turn inputpower ON and OFF. Place the lever in the ONposition to turn the WIRE-MATIC 250 ON.
2. PILOT LIGHT: The red LED pilot light located nextto the POWER SWITCH is lit when the power isON.
3. VOLTAGE CONTROL POTENTIOMETER KNOB:Provide continuous adjustment of power sourceoutput voltage over the rated 12 to 28 volt range.Voltage can be adjusted while welding.
4. WIRE SPEED CONTROL POTENTIOMETERKNOB: Controls the wire speed from 50 to 600
inches per minute (1.2 to 15.2 m/min). The controlcan be preset on the dial to the setting specified onthe Procedure Decal on the inside of the wire com-partment door. Wire speed is not affected whenchanges are made in the voltage control.
NOTE: When the trigger is pulled, the wire feederfeeds wire at low speed regardless of the wire feedspeed set on the control until the welding arc starts or2 seconds has elapsed. This feature enhances start-ing and makes it easier to set the stickout. The 2 sec-ond limit permits high speed loading of the gun andcable.
WIRE-MATIC 250
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ON
OFF
WIRE-MATIC 250LINCOLNELECTRIC
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B-5OPERATIONB-5
WIRE-MATIC 250
USING THE WIRE DRIVE ROLL
The drive roll provided with the WIRE-MATIC 250 hastwo grooves, one for.030-.035" (0.8-0.9mm) solid steelelectrode, and the other for .045" (1.2mm) solid steelelectrode. The welder is shipped with the drive rollinstalled in the .030-.035" (0.8-0.9mm) position as indi-cated by the stenciling on the exposed side of the driveroll. If .045" (1.2mm) electrode is to be used or one ofthe optional drive rolls is required, then the drive rollmust be reversed or changed per the following instruc-tions. This information also appears on the ProcedureDecal on the door inside the wire compartment.
PROCEDURE FOR CHANGING DRIVEROLL
Different wire sizes may require changing the drive roll.The applicable wire sizes are stamped on the drive roll.Dual groove rolls must be installed so the side with theproper wire size stamp faces out.
1. Turn POWER SWITCH to OFF.
2. Release the pressure on the idle roll by swingingthe pressure arm off the idle roll arm.
3. Remove the wire from the drive system.
4. Remove the wing screw from the drive roll.
5. Turn the drive roll over or change to another roll asrequired.
6. Replace the wing screw.
7. Check that the gun liner and contact tip are prop-erly sized for wire being used.
LOADING THE WIRE REEL
To mount a 22-30 lb. (10-14 kg) Readi-Reel packageusing the optional Readi-Reel Adapter (K363P):
1. Pull the spindle up out of the WIRE-MATIC 250spindle mounting clips (V-brackets).
2. Snap the spindle into the Readi-Reel adapter sothe spindle drive pin is engaged with the hole pro-vided in the Adapter.
3. Rotate the spindle and adapter so the retainingspring is at the 12 o'clock position.
4. Position the Readi-Reel so that it will rotate in acounterclockwise direction (as viewed from retain-ing spring side of Adapter) when wire is dereeledfrom the top of the coil as shown in Figure B.2.
FIGURE B.2 - Wire Reel Loading.
5. Set one of the Readi-Reel inside cage wires on theslot in the retaining spring tab.
6. Lower the Readi-Reel to depress the retainingspring and align the other inside cage wires withthe grooves in the molded adapter.
7. Slide the cage all the way onto the adapter until theretaining spring "pops" up fully.
Check to be sure the retaining spring has fullyreturned to the locking position and has securelylocked the Readi-reel cage in place. Retainingspring must rest on the cage not the welding elec-trode.
____________________________________
8. Check that the mating surfaces of the spindle hubsand spindle mounting clips (V-brackets) are clearof dirt and debris, and that the adapter is fullyengaged onto the spindle.
9. Lower the loaded spindle into the spindle mountingclips (V-brackets) so wire dereels from top of coiltoward wire drive.
WARNING
B-6OPERATIONB-6
NOTE: The retaining spring side of the adapter shouldbe facing the center (inner) panel of the WIRE-MATIC250.
10. Remove Readi-Reel from Adapter by depressingthe retaining spring tab with thumb while pullingthe Readi-Reel cage from the molded adapter withboth hands. Do not remove adapter from spindle.
To mount 10 to 30 lb. spools (8" and 12" diameter):
1. Remove the optional Readi-Reel adapter from the2 inch dia. spindle, if installed.
2. Check the mating surfaces of the spindle hubs andspindle mounting clips (V-brackets) to be sure theyare clear of dirt and debris.
3. Place the spool on the spindle. Make certain thebrake driving pin enters one of the holes in theback side of the spool.
4. Lower the loaded spindle into the spindle mount-ing clips (V-brackets) so the wire dereels from thetop of the reel toward the wire drive.
NOTE: The WIRE-MATIC 250 Spindle was designedto mount 12" (300mm) and 8" (200mm) diameterspools meeting international spool size specifications.If the spool being used is too narrow to keep the brakedriving pin* engaged with the spool pin hole, a 2"(51mm) I.D. shim washer could be used between thespool and the spindle retaining clip to take up thespace.
* Later spindle design uses a longer D-shaped pin toassure engagement.
FEEDING ELECTRODE
When inching, the electrode and drive mechanismare electrically hot to work and ground. The elec-trode remains hot several seconds after the guntrigger is released.
____________________________________
NOTE: Check that the proper drive rolls and gun partsfor the wire size and type are being used.
1. Turn the Readi-Reel or spool until the free end ofthe electrode is accessible.
2. Tightly holding the electrode, cut off the bent endand straighten the first six inches.
a. If the electrode is not properly straightened, itmay not feed properly into the outgoing guidetube 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 intothe drive roll.
a. If the electrode fails to thread itself into the out-going guide tube of the wire drive
• open the quick release idle roll arm
• thread the electrode manually
• re-close the arm.
6. Inch the electrode through the gun.
NOTE: Due to the low speed starting feature of theWIRE-MATIC 250, the wire will feed at low speed for 2seconds while inching, then come up to the set speed.To change run-in mode, see the Changing the Run InMode Section.
PROPER WIRE FEEDING
Wire feeding problems can be avoided by observingthe following gun handling procedures:
• Do not kink or pull cable around sharp corners.
• Keep the electrode cable as straight as possiblewhen welding or loading electrode through cable.
• Do not allow dolly wheels or trucks to run overcables.
• Keep cable clean by following maintenanceinstructions.
• Use only clean, rust-free electrode. The Lincolnelectrodes have proper surface lubrication.
• Replace contact tip when the arc starts to becomeunstable or the contact tip end is fused ordeformed.
• Keep drop-in spindle and spindle mounting clipcontacting surfaces clear of dirt and debris.
WIRE-MATIC 250
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WARNING
B-7OPERATIONB-7
SETTING IDLE ROLL PRESSURE
The idle roll pressure wing screw is set at the factorybacked out 2-1/2 turns from full pressure. This is anapproximate setting. The optimum idle roll pressurevaries with type of wire, wire diameter, surface condi-tions, lubrication, and hardness. As a general rule,hard wires may require greater pressure, and soft, oraluminum wire, may require less pressure than the fac-tory setting. The optimum idle roll setting can be deter-mined as follows:
1. Push the end of gun against a solid object that iselectrically isolated from the welder output.
2. Press the gun trigger for several seconds.
a. If the wire "birdnests", jams, or breaks at thedrive roll, the idle roll pressure is too great.Back the wing screw out 1/2 turn, run new wirethrough gun, and repeat steps 1 and 2.
b. If the drive roll slips, loosen the wing screw onthe conductor block and pull the gun cable for-ward about 6" (15 cm). There should be aslight waviness in the exposed wire. If there isno waviness, the pressure is too low. Tightenthe wing screw 1/4 turn, reinstall the guncable, and repeat steps 1 and 2.
OPERATING STEPS
Before operating the machine, be sure you have allthe materials needed to perform the work. Be sureyou are familiar with and have taken all possiblesafety precautions before starting the work. It isimportant that you follow these operating stepseach time you use the machine.___________________________________
STARTING THE WELDER
1. Turn the POWER switch to ON. This illuminatesthe red LED pilot light.
2. Select the correct voltage and wire speed for thewelding process required.
3. Operate the gun trigger for welder output and toenergize the wire feeder motor.
NOTE: When the POWER SWITCH is ON, the fanmotor is thermostatically controlled to provide coolingfor the transformer and other components only whenthe machine needs cooling. When the machine doesnot require fan cooling the fan does not run, such aswhen first turned on, when welding at low current, or atlow duty cycle procedures.
CHANGING RUN-IN MODE (Later modelsonly)
The WIRE-MATIC 250 is factory set for slow run-inmode. This means the machine will initially feed wireat 50 IPM until output current is sensed or for 2.0 sec-onds, whichever occurs first. After which it will accel-erate to the preset wire feed speed.
In the Fast run-in mode, the machine will acceleratedirectly to the preset wire feed speed.
ENTER FAST RUN-IN MODE
1. Turn POWER SWITCH to OFF on front panel ofWIRE-MATIC 250.
2. Turn the WIRE SPEED CONTROL POTEN-TIOMETER KNOB fully clockwise to maximum.
3. Close the gun trigger switch and turn the POWERSWITCH to ON.
a. The gas solenoid will actuate four times to sig-nal that the unit has entered the fast run-inmode. The gun trigger need only be closeduntil the first gas solenoid actuation is heard.
NOTE: Arc starting characteristics may be effectedwhen using the fast run-in mode since normal startingprocesses are being overridden.
ENTER SLOW RUN-IN MODE
1. Turn POWER SWITCH to OFF on front panel ofWIRE-MATIC 250.
2. Turn the WIRE SPEED CONTROL POTEN-TIOMETER KNOB fully counterclockwise to mini-mum.
3. Close the gun trigger and turn the POWERSWITCH to ON.
a. The gas solenoid will actuate two times to sig-nal that the unit has entered the slow run-inmode. The gun trigger need only be closeduntil the first gas solenoid actuation is heard.
WIRE-MATIC 250
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WARNING
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B-8OPERATIONB-8
WIRE-MATIC 250
NOTE: The unit will remember the run-in mode fromthe previous power down and return you to that samestate the next time you power up. Therefore, it is notnecessary to repeat either of the above procedureseach time the unit is powered up. You need only per-form one of the above procedures when you want tochange the run-in mode.
NOTE. When the gun trigger is first closed before turn-ing on the welder, there is no output power or wire feeduntil the trigger is opened and re-closed, regardless ofthe WIRE SPEED CONTROL POTENTIOMETERKNOB setting.
MAKING A WELD
1. Check that the electrode polarity is correct for theprocess being used.
2. Turn the POWER SWITCH to ON.
3. Set desired arc voltage and wire speed for theelectrode wire, material type and thickness, andgas (for GMAW) being used.
NOTE: Use the Application Chart on the door insidethe wire compartment as a quick reference for somecommon welding procedures.
NOTE: If Timer Kit is installed, see the AccessoriesSection of this manual to select the desired mode andfor additional welding information Spot and Stitchmodes.
4. Inch the electrode through the gun and cable.
5. Cut the electrode within approximately 3/8"(10mm) of the end of the contact tip or 3/4" (20mm)for Outershields.
NOTE: When the trigger is pulled, the wire feederfeeds wire at low speed regardless of the set wire feedspeed until the welding arc starts or 2 seconds haselapsed. This feature enhances starting and makes iteasier to set the stickout. The 2 second limit permitshigh speed loading of the gun and cable. To changerun-in mode, refer to Changing Run In Mode Section.
6. If welding gas is to be used, turn on the gas supplyand set the required flow rate (typically 25-35 CFH;12-16 Liters/min).
NOTE: When using Innershield electrode, the gasnozzle may be removed from the insulation on the endof the gun. This will give improved visibility and elimi-
nate the possibility of the gas nozzle overheating.
7. Connect the work cable to metal to be welded.Work clamp (if used) must make good electricalcontact to the work. The work must be grounded.
When using an open arc process, it is necessary touse correct eye, head and body protection.
____________________________________
8. Position electrode over joint. End of electrode maybe lightly touching the work.
9. Lower welding helmet, close gun trigger, and beginwelding. Hold the gun so the contact tip to workdistance is about 3/8 inch (10mm) or 3/4" (20mm)for Outershield.
10. To stop welding, release the gun trigger and thenpull the gun away from the work after the arc goesout.
11. When no more welding is to be done, close thevalve on gas cylinder (if used), momentarily oper-ate gun trigger to release gas pressure.
12. Turn POWER SWITCH to OFF.
WARNING
NOTES
WIRE-MATIC 250
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ACCESSORIES
WIRE-MATIC 250
ACCESSORIES SECTION ....................................... Section CReplacement Magnum 250L Gun and
Cable Assembly ..........................................................C-1K607-1 Spool Gun Adapter Kit.........................................C-1Installing the K607-1 Spool Adapter Kit ...........................C-1
Spool Gun Module Board Installation .........................C-2Spool Gun Connection Box Installation ......................C-3Spool Gun Preparation................................................C-4Spool Gun Connection................................................C-4
Making a Weld with the Spool Gun Adapter (K607-1)Installed .......................................................................C-5
Timer Kit (K585-1)............................................................C-6Timer Kit Installation (Optional K585-1) ...........................C-6Making Spot and Stitch Welds with Timer Kit Installed ...C-7Adjustable Gas Regulator and Hose Kit (K586-1) ...........C-7Drive Roll Kits ..................................................................C-7
TABLE OF CONTENTS- ACCESSORIES SECTION -
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C-1ACCESSORIESC-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 Gun (with remotespeed control) or the K469 Spool Gun (requiring K518Connection Adapter) for use with the WIRE-MATIC250.
It also provides single switch transfer between themachine's feeder gun or the spool gun for same polar-ity welding with different wire and gas processes.
The kit includes a spool gun module board and a con-nection box assembly with connecting plug and leadharnesses, mounting hardware, installation instruc-tions, and operating instructions.
INSTALLING THE K607-1 SPOOLGUN ADAPTER KIT
The spool gun module mounts inside the control sec-tion of the machine. It provides control and inter-con-nection between the machine's control board and thespool gun kit connection box.
The connection box mounts to the front of themachine's base. It provides for inlet connection of the
OPTIONS/ACCESSORIES
REPLACEMENT MAGNUM 250LGUN AND CABLE ASSEMBLY
The following GMAW gun and cable assemblies areavailable for use with the WIRE-MATIC 250. Each israted 200 amps 60% duty cycle or 250 amps 35% dutycycle. The gun and cable assemblies are equippedwith the integrated connector, twist-lock trigger con-nector, and includes a liner, diffuser, and contact tipsfor the wire sizes specified:
WIRE-MATIC 250
spool gun gas supply hose, as well as up-front easyconnection of the spool gun gas line, control plug, andelectrode lead (using the Twist-Mate plug provided withthe kit). An Installation and Operation Manual is includ-ed with the kit.
LENGTH PART NO.
10' (3.0 m)12' (3.6 m)15’ (4.5 m)
10' (3.0 m)12' (3.6 m)15’ (4.5 m)
K533-1K533-2*K533-3
K533-4K533-5K533-6
.035-.045”(0.9-1.2mm)
.025-.030”(0.6-0.8mm)
WIRE SIZE
C-2ACCESSORIESC-2
SPOOL GUN MODULE BOARD INSTALLATION
NOTE: The K607-1 Spool Gun Adapter Kit is designedfor use with WIRE-MATIC 250 model codes above9900. Model Codes below 9900 may be used withaddition of holes to the case as described in the instal-lation instructions below.
Do not operate with covers removed. DisconnectAC input power before servicing. Do not touchelectrically live parts. Only qualified electriciansshould install, use. or service this equipment.
____________________________________
1. Disconnect AC input power to the machine beforeinstalling the Spool Gun Module Board.
2. Remove the six screws from the Left Case Sideand Door and Hinge Assembly.
3. Lift the Left Case Side and Door and HingeAssembly up and over the lip of the center dividerpanel while pulling the case side away from theunit. Slide it out of the slots in the base.
4. Locate the four snap-mount fasteners mounted tothe side panel of the P.C. board compartment. SeeFigure C.1.
FIGURE C.1 - Spool Gun Module Board Installation.
5. Position the Spool Gun Module Board over thesnap-mount fasteners with the lead plug connec-tors at the top.
6. Gently press the board onto the fasteners, makingsure all the fasteners snap into place.
7. Remove the hex-head screw from beneath the gasconnector on the wire drive side of the machine torelease the small metal cover. See Figure C.2.
FIGURE C.2 - Spool Gun Installation.
8. Slide the metal cover out from behind the motorbracket.
9. Turn the cover over so the screw hole is in the topright corner, then reinstall as a spacer plate withthe hex-head screw. See Figure C.2.
10. Locate the panel receptacle lead harness includedin the kit. See Figure C.1.
11. Insert the panel receptacle into the hole on thecontrol board side of the panel, making sure thepanel receptacle mounting plate is positioned sothe grounding screw is in the lower left corner ofthe plate. See Figure C.1.
NOTE: For model codes below 9900, small notchesmay need to be filed at top and bottom of panel hole toallow clearance of the plastic mounting ears.
WIRE-MATIC 250
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WARNING
C-3ACCESSORIESC-3
Collect metal filings with a rag to protect againstpossible metal contamination of the control boardor other internal electrical components.
____________________________________
12. Fasten the panel receptacle to the case with thethree #6-32 x 3/8" self tapping screws provided.
a. Insert the screws from wire drive side, throughthe sheet metal, and into the receptaclemounting plate holes.
13. Plug the 10-pin, 8-pin, and 6-pin connector plugsfrom the other end of the receptacle lead harnessinto the 10-pin, 8-pin, and 6-pin connectors (Molexplugs J12, J11, and J13) at the top of the SpoolGun Module Board.
a. Plug the 8-pin connector at the opposite end ofthis harness into the unused 8-pin connectoron the WIRE-MATIC 250 control board (Molexplug J4).
14. Disconnect the 4-pin gas solenoid plug from thereceptacle (Molex plug J8) on the upper right cor-ner of the Control Board as shown Figure C.1.Reconnect this plug to the 4-pin receptacle (Molexplug J14) on the top of the Spool Gun ModuleBoard.
15. Plug the 4 pin connector plug, included with thepanel receptacle harness connected in step 13above, into the Control Board receptacle (J8), dis-connected in step 14 above.
16. Using the cable tie included in the kit, tie the twoharnesses together approximately 3.50 inches(88.9 mm) from the end of the lead plugs as shownin Figure C.1.
17. Replace the Case into the slots in the base. Makesure the lip of the case side is lifted over the topedge of the center panel during installation.
a. Fasten Case Side with the six screwsremoved.
SPOOL GUN CONNECTION BOX INSTALLATION
NOTE: Model codes below 9900 require the addition ofthree holes to the front of the machine's base as shownin Figure C.3.
FIGURE C.3 - Spool Gun Connection BoxInstallation Mounting Holes.
1. Remove the plug button, if present, from the cen-ter hole in the front of the machine's base.
2. Insert the two #10 thread forming screws (provid-ed with the kit) and partially thread them into thetwo small holes on both sides of the center hole.
3. Route a user provided gas supply hose from theflow regulator of the spool gun gas cylinder, overthe rear axle of the machine, and out to the frontthrough the center hole in the front of the base.
4. Connect the gas hose to the 5/8-18 female inertgas fitting on the back of the connection box.
5. Slip the connection box mounting keyholes overthe screw heads installed in Step 2 above. Pivotthe box clockwise to engage and level the box andthen tighten the screws.
6. Route the control cable of the connection box upthrough the opening provided for the work lead inthe front louver and then up behind the wire drive.
a. Connect the plug to the kit receptacle wheninstalling the Spool Gun Module Board. SeeFigure C.4.
WIRE-MATIC 250
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CAUTION
C-4ACCESSORIESC-4
FIGURE C.4 - Spool Gun Connection BoxInstallation.
7. Route the electrode lead of the connection box upthrough 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 OutputPolarity Connection in Installation Chapter).
9. Reconnect with the connection box electrode leadon the bolt under the positive electrode lead so theconnection box electrode lead is sandwichedbetween the positive electrode lead terminal andthe wire drive contact surface.
a. Tighten snugly being careful not to strip thethreads.
SPOOL GUN PREPARATION
1. Cut the terminal lug off the end of the spool gunelectrode lead and slip the rubber boot, included inthe kit, over the lead jacket. See Figure C.5.
FIGURE C.5 - Spool Gun Preparation.
2. Strip .50" (12.7 mm) of insulation jacket off the leadend and slip the supplied copper tube ferrule overthe stripped end.
3. Insert the lead end with ferrule completely into thebrass Twist-Mate plug and tighten the set screw fora positive electrical connection.
4. Pull the rubber boot over the plug to insulate theconnection.
SPOOL GUN CONNECTION
The spool gun module is intended for use withLincoln Electric Magnum Spool Guns only. Usewith other units may cause damage to the equip-ment. For Spool Gun operation, refer to theinstruction manual provided with the MagnumSpool Gun.
____________________________________
1. Connect the spool gun control cable 6-pin plug tothe mating receptacle on the front of the spool gunadapter connection box installed during Spool GunBox Connection
NOTE: If using a K469 spool gun with 4 pin plug, usethe K518 adapter.
2. Insert the Twist-Mate plug installed when preparingthe spool gun into the mating receptacle on thefront of the connection box and twist to lock theconnection.
3. Attach the spool gun gas line to the gas outlet fit-ting on the front of the connection box.
NOTE: Refer to the Instruction Manual included withthe K487 or K469 Spool Gun for more details aboutSpool Gun set-up and operation.
WIRE-MATIC 250
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CAUTION
C-5ACCESSORIESC-5
MAKING A WELD WITH THE SPOOLGUN ADAPTER (K607-1) INSTALLED
The toggle switch on the front of the spool gun adapterbox permits quick transfer when you want to switchbetween using the WIRE-MATIC 250 Feeder Gun andthe connected Spool Gun when the electrodes are atthe same polarity.
In either transfer switch position, closing the guntrigger will cause the electrode of both guns to beelectrically energized, or "HOT." Be sure theunused gun is positioned so the electrode or thetip will not contact metal case or other metal com-mon to the work.
____________________________________
When the transfer switch is in the Feeder Gun position:
a. The Spool Gun trigger, wire feed, and gas out-put are disabled.
b. Closing the Feeder Gun trigger Starts FeederGun welding and makes the Feeder Gun andthe Spool Gun electrodes electrically "HOT."
When the transfer switch is in the Spool Gun position:
a. The Feeder Gun, wire feed, and gas outputare disabled.
b. Closing the Spool Gun trigger makes both theFeeder Gun and Spool Gun electrodes electri-cally "HOT" and activates Spool Gun gas out-put.
MAKING THE WELD:
1. Set the transfer switch in the SPOOL GUN posi-tion.
2. Turn input power ON by setting the POWERSWITCH in the ON position.
3. Adjust the VOLTAGE CONTROL KNOB toincrease or decrease your welding Voltage.
4. Adjusting the Wire Speed Control will increase ordecrease the Spool Gun Wire Feed Speed. Thisrepresents the set speed for the K469 Spool Gunand the maximum set speed for the K487 SpoolGun with the remote control in gun handle at max-imum.
The remote control turned to minimum will giveapproximately 50% of the maximum set WFS.
NOTE: The WIRE-MATIC 250 speed calibrated dialmarkings are not accurate when used for setting theSpool Gun speed.
The following procedure settings can be used as initialsettings for making test welds to determine final set-tings:
5. To return to normal WIRE-MATIC 250 welding, setthe transfer switch to FEEDER GUN position andreset feeder gun weld procedure settings.
WIRE-MATIC 250
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CAUTION
Wire Diameter
.030” (.8mm)
.035” (.9mm)3/64” (1.2mm)
Wire FeedSpeed Setting
270250210
Arc VoltageSetting
15 V16 V21 V
C-6ACCESSORIESC-6
TIMER KIT (K585-1)
The Timer Kit provides selectable 4-step trigger inter-lock, spot and stitch functions, and manual adjustmentof burnback time. This kit installs easily using only ascrewdriver. It replaces the blank upper panel on CaseFront. It offers the following mode selections:
• The Normal Welding mode provides weldingpower only while gun trigger is pressed.
• The 4-Step Trigger mode eliminates the need tohold gun trigger while welding. It operates in 4steps:
1. Close trigger and establish welding arc.
2. Release trigger and continue welding.
3. Re-close trigger near end of weld.
4. Release trigger again to stop welding.
• The Spot Weld mode allows a single timed weldcycle each time the gun trigger is held closed.Duration is set with SPOT/STITCH ON TIME knob.
• The Stitch Weld mode allows repeated timed weldcycles while gun trigger is held closed. Weld on-time is set with SPOT/STITCH ON TIME knob, andweld off time is set with STITCH OFF TIME knob.
The BURNBACK TIME knob is used to manually setarc power delay at the end of any above selected weldmode to prevent wire sticking in the weld. With theTimer Kit not installed, a preselected delay is automat-ically set by the machine.
TIMER KIT INSTALLATION(OPTIONAL K585-1)
Remove all input power to the WIRE-MATIC 250before proceeding.
____________________________________
1. Verify that the following items have been includedin the kit:
a. Timer Board and Panel Assembly.
b. Two sheet metal screws.
c. Wiring harness.
2. Turn the POWER SWITCH to OFF.
3. Disconnect AC input power to the machine.
4. Remove the Cover Plate Assembly from the frontof the machine by removing the two screws whichfasten it using a screwdriver, a 5/16" (8mm) nut dri-ver, or other suitable tool.
5. Reach through the exposed panel opening andattach the rectangular 8-pin plug connector on theTimer Kit wiring harness to the available matingreceptacle connector on the upper left corner ofthe Control Board inside the machine.
a. Be sure that the latch on the connector isaligned with that on the Control Board andinsert it until the latch engages.
b. Check that the remaining connector on theopposite end of the wiring harness is firmlyattached to the mating connector on the PCBoard on the Timer Kit panel, and that thelatch is engaged.
6. Align the Timer Kit panel so you can carefully insertthe printed circuit board and wiring harnessthrough the opening in the front panel.
a. Make sure the wiring harness is not pinchedbetween panels or between printed circuitboard and front panel.
7. Fasten the Timer Kit assembly with either the twosupplied screws or with the original screws to com-plete the installation.
WIRE-MATIC 250
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WARNING
C-7ACCESSORIESC-7
MAKING SPOT AND STITCH WELDSWITH TIMER KIT INSTALLED
TO MAKE SPOT PLUG WELDS:
The SPOT WELD MODE is used to make spot plugwelds when continuous welds are not needed or tohold thin sheet metal together prior to stitch welding orcontinuous welding.
Plug welds are made by using a punch to make a 3/16"(5mm) diameter hole in the top sheet and arc weldingthrough the hole into the back sheet.
1. Punch 3/16" (5mm) holes in the top sheet.
2. Set the SPOT/STITCH ON-TIME control toapproximately 1.2 seconds.
3. Set the procedure for the metal thickness to bewelded.
4. Install spot weld nozzle (if available) on gun andpress it against the top sheet so the top and bot-tom sheets are tight together.
5. Close trigger and hold it closed until the arc goesout.
a. If a spot weld nozzle is not used, smootherwelds will result by moving the welding wire ina small circle during the weld.
TO MAKE A STITCH WELD:
The STITCH WELD MODE is used to weld thin mater-ial when warpage and burn through are a problem.Proper adjustment of the Spot/Stitch On-Time, StitchOff-Time, and arc travel speed permits welding thinsheet metal with small welds, minimum distortion, andno burnthrough.
1. The SPOT/STITCH ON-TIME KNOB sets weldingtime.
a. Start with a dial setting of 0.5 seconds. Raisesetting to increase penetration and weld size.Lower setting to reduce burnthrough and dis-tortion.
2. The STITCH OFF-TIME KNOB sets off timebetween welds.
a. Start with a dial setting of 0.5 seconds. Raisesetting to reduce burnthrough. Lower settingto make weld flatter and smoother.
3. Set the procedure for the metal thickness to bewelded.
4. Close trigger and hold it closed for length of seam.
a. Hold gun in one place during ON time andmove gun just beyond edge of molten metalduring OFF time.
NOTE: For smoothest welds on thinner metal, pointgun slightly toward the direction of travel.
ADJUSTABLE GAS REGULATOR AND HOSE KIT (K586-1)
The kit can be used with CO2 or Argon blend gas. Itincludes a cylinder pressure gauge, a dual scale flowgauge, and a gas hose to connect the regulator to theWIRE-MATIC 250 gas inlet.
DRIVE ROLL KITS
The following drive rolls and Magnum 250L gun andcable parts are available to feed different sizes andtypes of electrodes.
WIRE-MATIC 250
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Steel Wire Sizes:.025 - .035" (0.6-0.9mm).030 - .045" (0.8-1.2mm)
.045" Cored (1.2mm)
Aluminum Wire Sizes: 3/64" (1.2mm)
Part NumberM14932M15809
S14541-052 (2 Req’d)
S17092-3/64A
MAINTENANCE
WIRE-MATIC 250
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MAINTENANCE SECTION ...................................... Section DSafety Precautions ...........................................................D-1Routine and Periodic Maintenance..................................D-1Component Locations ......................................................D-2Drive Rolls and Guide Tubes ...........................................D-3Drop-In Reel Spindle and Clips .......................................D-3Cable Cleaning.................................................................D-3Gun Tubes and Nozzles...................................................D-3Contact Tip and Gas Nozzle Installation..........................D-3Liner Removal and Replacement.....................................D-4Liner Removal, Installation, and Trimming Instructions
for Magnum 250L........................................................D-4Gun Handle Disassembly ................................................D-5Accessories and Expendable Replacement Parts forMagnum 250L Gun and Cable Assemblies .....................D-6
TABLE OF CONTENTS- MAINTENANCE SECTION -
D-1MAINTENANCED-1
SAFETY PRECAUTIONS
• Have a qualified electrician do the maintenanceand troubleshooting work.
• Disconnect the input power off using the dis-connect switch at the main input supply beforeworking inside machine.
• Unplug the power cable if it is connected to areceptacle.
____________________________________
Read the Safety Precautions in the front of this manu-al before working on this machine.
ROUTINE AND PERIODICMAINTENANCE
1. Disconnect input AC power supply lines to themachine before performing periodic maintenance,tightening, cleaning, or replacing parts. SeeFigure D.1.
Perform the following daily:
1. Check that no combustible materials are in thewelding or cutting area or around the machine.
2. Remove any debris, dust, dirt, or materials thatcould block the air flow to the machine.
3. Inspect the electrode cables for any slits, punc-tures in the cable jacket, or any condition thatwould affect the proper operation of the machine.
Perform Periodically:
Clean the inside of the machine with low pressure airstream. Clean the following parts. Refer to Figure D.1.
Main transformer and choke.Electrode and work cable connections.SCR rectifier bridge and heat sink fins.Fan Motor Assembly.Control Printed Circuit Board.
NOTE: The fan motor has sealed bearings whichrequire no maintenance.
WIRE-MATIC 250
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WARNING
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D-2MAINTENANCED-2
Figure D.1 - Component Locations.
WIRE-MATIC 250
D-3MAINTENANCED-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 cleaningthe idle roll because it may wash the lubricant out ofthe bearing. All drive rolls are stamped with the wiresizes they will feed. If a wire size other than thatstamped on the roll is used, the drive roll must bechanged.
DROP-IN REEL SPINDLE ANDCLIPS
Before loading a coil of wire onto the WIRE-MATIC 250drop-in spindle, inspect the mating surfaces of thespindle hubs and the spindle mounting clips (V-brack-ets) and, if necessary, wipe or blow out any dirt anddebris which may have accumulated on these sur-faces.
CABLE CLEANING
Clean the cable liner after using approximately 300pounds (136 kg) of electrode.
1. Remove the cable from the wire feeder and lay itout straight on the floor.
2. Remove the contact tip from the gun.
3. With an air hose at the gas diffuser end, use lowpressure to gently blow out the cable liner.
Excessive pressure at the start may cause the dirtto form a plug.
____________________________________
4. Flex the cable over its entire length and again blowout the cable.
5. Repeat this procedure until no more dirt comesout.
GUN TUBES AND NOZZLES
1. Replace worn contact tips as required.
2. Remove spatter from the inside of the gas nozzleand tip every 10 minutes of arc time or as required.
CONTACT TIP AND GAS NOZZLEINSTALLATION
1. Choose the correct size contact tip for the elec-trode being used (wire size is stenciled on the sideof the contact tip) and screw it snugly into the gasdiffuser.
a. Be sure the nozzle insulator is fully screwedonto the gun tube and does not block the gasholes in the diffuser.
2. Slip or screw the appropriate gas nozzle onto thenozzle insulator.
Note: Either a standard .50" (12.7mm) or optional .62"(15.9mm) I.D. slip-on gas nozzle may be used andshould be selected based on the welding application.
3. Adjust the gas nozzle as appropriate for theGMAW process to be used.
a. Typically, the contact tip end should be flush toextended .12" (3.2mm) for the short-circuitingtransfer process and recessed .12" (3.2mm)for spray transfer.
WIRE-MATIC 250
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CAUTION
D-4MAINTENANCED-4
LINER REMOVAL ANDREPLACEMENT
NOTE: When you change wire size, a replacementgas diffuser is required. Use the table below to selectthe proper diffuser so the liner is held securely in place.
LINER REMOVAL, INSTALLATION,AND TRIMMING INSTRUCTIONSFOR MAGNUM 250L
NOTE: The variation in cable lengths prevents theinterchange ability of liners between guns. Once a linerhas been cut for a particular gun, it should not beinstalled in another gun unless it can meet the liner cutoff length requirement. Liners are shipped with thejacket of the liner extended the proper amount.
1. Remove the gas nozzle and nozzle insulator.
2. Locate the set screw in the gas diffuser which isused to hold the old liner in place.
3. Loosen the set screw with a 5/64" (2.0mm) Allenwrench.
4. Remove the gas diffuser from the gun tube.
5. Lay the gun and cable out straight on a flat sur-face.
6. Loosen the set screw located in the brass connec-tor at the feeder end of the cable and pull the linerout of the cable.
7. Insert a new untrimmed liner into the connectorend of the cable.
a. Check the liner bushing stencil to make sure itis the appropriate one for the wire size beingused.
8. Fully seat the liner bushing into the connector.
9. Tighten the setscrew on the brass cable connector.
NOTE: Do not install the gas diffuser onto the end ofthe gun tube at this time.
10. Straighten the cable with the gas nozzle and noz-zle insulator removed from the gun tube.
11. Trim the liner to the length shown in FIGURE D.2.
FIGURE D.2 - Liner maintenance.
WIRE-MATIC 250
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Electrode Diameter
.025-.030" Steel(0.6-0.8mm)
.035-.045" Steel(0.9-1.2mm)
3/64" Aluminum(1.2mm)
Replacement LinerPart Number
M16087-2
M16087-1
M16107-1
Size Stenciled on the Endof the Liner Bushing
.030 (0.8mm)
.045 (1.2mm)
(Plastic Liner)
Gas Diffuser Part Number (and Stencil)
S19418-2
S19418-1
S19418-1
D-5MAINTENANCED-5
12 Remove any burrs from the end of the liner.
13. Screw the gas diffuser onto the end of the gun tubeand tighten.
NOTE: Be sure the gas diffuser is correct for the linerbeing used. (See table and diffuser stencil.)
14. Slightly tighten the set screw in the side of the gasdiffuser against the cable liner using 5/64" (2.0mm)Allen wrench.
This screw should only be gently tightened. Overtightening will split or collapse the liner and causepoor wire feeding.
____________________________________
GUN HANDLE DISASSEMBLY
The internal parts of the gun handle may be inspectedor serviced if necessary.
The gun handle consists of two halves that are heldtogether with a collar on each end.
To open up the handle:
1. Turn the collars approximately 60 degrees coun-terclockwise (the same direction as removing aright hand thread) until the collar reaches a stop.
2. Pull the collar off the gun handle.
NOTE: If the collars are difficult to turn, position thegun handle against a corner, place a screwdriveragainst the tab on the collar and give the screwdriver asharp blow to turn the collar past an internal locking rib.See Figure D.3.
FIGURE D.3 - Gun Handle disassembly.
WIRE-MATIC 250
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CAUTION
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D-6MAINTENANCED-6
* Included with WIRE-MATIC 250
** 5356 alloy aluminum wire and 450 gun tube arerecommended to alleviate potential soft wire feed-ing problems with push-type wire feeding.
ACCESSORIES AND EXPENDABLEREPLACEMENT PARTS FOR MAGNUM 250L GUN AND CABLEASSEMBLIES
WIRE-MATIC 250
METRIC SIZE
0.6 - 0.8 mm0.9 - 1.2 mm
1.2 mm (Alum. Wire)
0.6 mm0.8 mm0.9 mm1.2 mm
0.9 mm1.2 mm
0.6 mm0.8 mm0.9 mm1.2 mm
0.6 - 0.8 mm0.9 - 1.2 mm
12.7 mm15.9 mm
ENGLISH SIZE
.025- .030"
.035- .045"3/64" (Alum. Wire)
.025"
.030"
.035"
.045"
.035"
.045"
.025"
.030"
.035"
.045"
0.25 - .030"0.35 - .045"
1/2"5/8"
PART NO.
M16087-2M16087-1*M17701-1**
S19391-6S19391-7S19391-1*S19391-2*
S19392-1S19292-2
S19393-5S19393-6S19393-1S19393-2
S19418-2S19418-1
M16093-2*M16093-1
S19417-1*
M16938
S18920*S19890**
DESCRIPTION
Cable LinerFor 15' (4.5m) or Shorter Cable
Contact TipsStandard Duty
Heavy Duty
Tapered
Gas Diffuser Assembly
Gas NozzlesAdjustable Slip-On
(Requires Nozzle Insulator Assembly.)
Nozzle Insulator Assembly
Gasless Nozzle (for Innershield®)
Gun Tube AssemblyStandard (60 Degrees)45 Degrees
NOTES
WIRE-MATIC 250
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THEORY OF OPERATION
WIRE-MATIC 250
Figure E.1 -Block Logic Diagram
NOTE: Unshaded areas of Block LogicDiagram are the subject of discussion
THEORY OF OPERATION SECTION ...................... Section EPower Supply Operation .................................................E-1
Input Line Voltage and Main Transformer ...................E-1Output Rectification and Feedback Control ................E-2Constant Voltage Output .............................................E-3Wire Drive Motor and Feedback .................................E-4
Thermal Protection ...........................................................E-5SCR Operation .................................................................E-6
TABLE OF CONTENTS- THEORY OF OPERATION SECTION -
LINE SWITCH
MAINTRANSFORMER
RECONNECT
FAN MOTORS
SCRRECTIFIER
CAPACITORS
SHUNT
CHOKE
WIREDRIVE
MOTOR
TACH
POSITIVETERMINAL
NEGATIVETERMINAL
GASSOLENOID
WIRESPEED
ARCVOLTAGE
CONTROL BOARD
FEEDBACK
GUN TRIGGER AND THUMB SWITCH
FEEDBACK
GATE
IGN
S
AL
E-1THEORY OF OPERATIONE-1
WIRE-MATIC 250
INPUT LINE VOLTAGE AND MAIN TRANSFORMER
The desired single phase input power is connected tothe WIRE-MATIC 250 through a line switch located onthe front panel.
A reconnect panel allows the user to configure themachine for the desired input voltage. This AC inputvoltage is applied to the primary of the main trans-former and to the thermostatically controlled fanmotors. The transformer changes the high voltage, lowcurrent input power to a low voltage, high current out-put. In addition, the main transformer also has an iso-lated center tapped 30 VAC auxiliary winding that sup-plies power to the Control Board for SCR gate driveand gas solenoid operation. The weld power windingsconnect to the Control Board as well as to the mainSCR Rectifier.
Figure E.2 - Input Line Voltage and Main Transformer.
INPUT LINE VOLTAGE AND MAIN TRANSFORMER
LINE SWITCH
MAINTRANSFORMER
RECONNECT
FAN MOTORS
SCRRECTIFIER
CAPACITORS
SHUNT
CHOKE
WIREDRIVE
MOTOR
TACH
POSITIVETERMINAL
NEGATIVETERMINAL
GASSOLENOID
WIRESPEED
ARCVOLTAGE
CONTROL BOARD
FEEDBACK
GUN TRIGGER AND THUMB SWITCH
FEEDBACK
GATE
IGN
S
AL
NOTE: Unshaded areas of Block LogicDiagram are the subject of discussion
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E-2THEORY OF OPERATIONE-2
WIRE-MATIC 250
OUTPUT RECTIFICATION ANDFEEDBACK CONTROL
The AC output from the main transformer secondaryweld winding is rectified and controlled through theSCR rectifier assembly. Output voltage and currentare sensed at the shunt and output terminals and arefed back to the control board. The control board com-pares the commands of the ARC Voltage Controlpotentiometer with the feedback signals. The appro-priate gate firing pulses are generated by the controlboard and applied to the SCR rectifier assembly. Thecontrol board controls the firing of the SCRs, thus con-trolling the output of the machine. See SCROperation. The control board also powers and com-mands the gas solenoid and the wire drive motor.
Figure E.3 - Output Rectification and Feedback.
OUTPUT RECTIFICATION AND FEEDBACK
LINE SWITCH
MAINTRANSFORMER
RECONNECT
FAN MOTORS
SCRRECTIFIER
CAPACITORS
SHUNT
CHOKE
WIREDRIVE
MOTOR
TACH
POSITIVETERMINAL
NEGATIVETERMINAL
GASSOLENOID
WIRESPEED
ARCVOLTAGE
CONTROL BOARD
FEEDBACK
GUN TRIGGER AND THUMB SWITCH
FEEDBACK
GATE
IGN
S
AL
NOTE: Unshaded areas of Block LogicDiagram are the subject of discussion
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E-3THEORY OF OPERATIONE-3
WIRE-MATIC 250
CONSTANT VOLTAGE OUTPUT
The controlled DC output from the SCR rectifierassembly is filtered by the capacitor bank resulting is aconstant voltage DC output. Since the output choke isin series with the positive leg of the rectifier and also inseries with the gun and welding load, a filtered con-stant voltage output is applied to the output terminalsof the machine.
Figure E.4 - Constant Voltage Output.
CONSTANT VOLTAGE OUTPUT
LINE SWITCH
MAINTRANSFORMER
RECONNECT
FAN MOTORS
SCRRECTIFIER
CAPACITORS
SHUNT
CHOKE
WIREDRIVE
MOTOR
TACH
POSITIVETERMINAL
NEGATIVETERMINAL
GASSOLENOID
WIRESPEED
ARCVOLTAGE
CONTROL BOARD
FEEDBACK
GUN TRIGGER AND THUMB SWITCH
FEEDBACK
GATE
IGN
S
AL
NOTE: Unshaded areas of Block LogicDiagram are the subject of discussion
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E-4THEORY OF OPERATIONE-4
WIRE-MATIC 250
WIRE DRIVE MOTOR AND FEEDBACK
The wire drive motor is controlled by the control board.A motor speed feedback signal is generated at themotor tach and sent to the control board. The controlboard compares this feedback signal with the com-mands set forth by the Wire Speed Control poten-tiometer and sends the appropriate armature voltageto the wire drive motor. The drive motor speed is thuscontrolled which in turn regulates the electrode wirefeed speed through the gun.
Figure E.5 - Wire Drive Motor and Feedback.
WIRE DRIVE MOTOR AND FEEDBACK
LINE SWITCH
MAINTRANSFORMER
RECONNECT
FAN MOTORS
SCRRECTIFIER
CAPACITORS
SHUNT
CHOKE
WIREDRIVE
MOTOR
TACH
POSITIVETERMINAL
NEGATIVETERMINAL
GASSOLENOID
WIRESPEED
ARCVOLTAGE
CONTROL BOARD
FEEDBACK
GUN TRIGGER AND THUMB SWITCH
FEEDBACK
GATE
IGN
S
AL
NOTE: Unshaded areas of Block LogicDiagram are the subject of discussion
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E-5THEORY OF OPERATIONE-5
WIRE-MATIC 250
THERMAL PROTECTION
A thermostat protects the machine from excessiveoperating temperatures. Excessive operating temper-atures may be caused by a lack of cooling air or oper-ating the machine beyond the duty cycle and outputrating. There are three thermostats within the WIRE-MATIC 250 machine. One of the thermostats, locatedon the output choke, energizes the cooling fan motorswhen required. The other choke thermostat "opens"the trigger circuit, preventing machine weld output andwire feed, if excessive operating temperatures aredetected. The third thermostat insures that the fanmotors are operating when required.
The thermostats are self-resetting once the machinecools sufficiently. If the thermostat shutdown is causedby excessive output or duty cycle and the fans areoperating normally, the power switch may be left onand the reset should occur within a 15 minute period.If the fans are not turning or the air intake louvers areobstructed, then the input power must be removed andthe fan problem or air obstruction be corrected.
THERMAL PROTECTION
NOTE: Unshaded areas of Block LogicDiagram are the subject of discussion
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E-6THEORY OF OPERATIONE-6
WIRE-MATIC 250
A silicon controlled rectifier (SCR) is a three terminaldevice used to control rather large currents to a load.An SCR acts very much like a switch. When a gate sig-nal is applied to the SCR it is turned ON and there iscurrent flow from anode to cathode. In the ON state theSCR acts like a closed switch. When the SCR is turnedOFF there is no current flow from anode to cathodethus the device acts like an open switch. As the namesuggests, the SCR is a rectifier, so it passes currentonly during positive half cycles of the AC supply. Thepositive half cycle is the portion of the sine wave inwhich the anode of the SCR is more positive than thecathode.
When an AC supply voltage is applied to the SCR, thedevice spends a certain portion of the AC cycle time inthe off state and the remainder of the time in the onstate. 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 gate.This gate pulse must be more positive than the cath-ode voltage. Since there is a standard PN junctionbetween gate and cathode, the voltage between theseterminals must be slightly greater than 0.6V. Once theSCR has fired it is not necessary to continue the flowof gate current. As long as current continues to flowfrom anode to cathode the SCR will remain on. Whenthe anode to cathode current drops below a minimumvalue, called holding current, the SCR will shut off. Thisnormally occurs as the AC supply voltage passesthrough zero into the negative portion of the sine wave.If the SCR is turned on early in the positive half cycle,the conduction time is longer resulting in greater SCRoutput. If the gate firing occurs later in the cycle theconduction time is less resulting in lower SCR output.
Figure E.6 - SCR Operation
SCR OPERATION
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NOTES
WIRE-MATIC 250
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TROUBLESHOOTING & REPAIR
WIRE-MATIC 250
TROUBLESHOOTING & REPAIR SECTION ........................................................................ Section FHow to use Troubleshooting Guide ....................................................................................................F-1PC Board Troubleshooting Procedures..............................................................................................F-2Troubleshooting Guide .......................................................................................................................F-3Test Procedures
Main Transformer Test................................................................................................................F-10Static Output Rectifier Bridge Test .............................................................................................F-13Active SCR Rectifier Assembly Test ...........................................................................................F-16Wire Drive Motor and Tachometer Feedback Test .....................................................................F-19
Oscilloscope Waveforms ..................................................................................................................F-22Normal Open Circuit Voltage Waveform ....................................................................................F-22Typical Output Voltage Waveform - Machine Loaded ................................................................F-23Abnormal Output Voltage Waveform - Machine Loaded One Output SCR Not Functioning.....F-24Abnormal Open Circuit Voltage Output Capacitor Bank Not Functioning..................................F-25Typical SCR Gate Voltage Waveform ........................................................................................F-26
Replacement ProceduresControl PC Board Removal and Replacement...........................................................................F-27Wire Drive Assembly Removal and Replacement......................................................................F-29SCR Output Rectifier Removal and Replacement .....................................................................F-31Capacitor Bank Removal and Replacement ..............................................................................F-33Main Transformer Removal and Replacement...........................................................................F-35Fan Motor and Fan Removal and Replacement ........................................................................F-37Retest After Repair .....................................................................................................................F-40
TABLE OF CONTENTS- TROUBLESHOOTING & REPAIR SECTION -
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F-1TROUBLESHOOTING & REPAIRF-1
WIRE-MATIC 250
This Troubleshooting Guide is provided tohelp you locate and repair possible machinemalfunctions. Simply follow the three-stepprocedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM(SYMPTOMS)”. This column describes pos-sible symptoms that the machine may exhib-it. Find the listing that best describes thesymptom that the machine is exhibiting.Symptoms are grouped into the followingcategories: output problems, function prob-lems, wire feeding problems, and weldingproblems.
Step 2. PERFORM EXTERNAL TESTS.The second column labeled “POSSIBLEAREAS OF MISADJUSTMENT(S)” lists theobvious external possibilities that may con-tribute to the machine symptom. Performthese tests/checks in the order listed. Ingeneral, these tests can be conducted with-out removing the case wrap-around cover.
Step 3. RECOMMENDED COURSE OFACTION
The last column labeled “RecommendedCourse of Action” lists the most likely com-ponents that may have failed in yourmachine. It also specifies the appropriatetest procedure to verify that the subject com-ponent is either good or bad. If there are anumber of possible components, check thecomponents in the order listed to eliminateone possibility at a time until you locate thecause of your problem.
All of the referenced test proceduresreferred to in the Troubleshooting Guide aredescribed in detail at the end of this chapter.Refer to the Troubleshooting and RepairTable of Contents to locate each specificTest Procedure. All of the specified testpoints, components, terminal strips, etc. canbe found on the referenced electrical wiringdiagrams and schematics. Refer to theElectrical Diagrams Section Table ofContents to locate the appropriate diagram.
HOW TO USE TROUBLESHOOTING GUIDE
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician andmachine operator and will invalidate your factory warranty. For your safety and to avoidElectrical Shock, please observe all safety notes and precautions detailed throughout thismanual.__________________________________________________________________________
WARNING
CAUTION
If for any reason you do not understand the test procedures or are unable to perform thetests/repairs safely, contact the Lincoln Electric Service Department for technical trou-bleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353._____________________________________________________________
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F-2TROUBLESHOOTING & REPAIRF-2
WIRE-MATIC 250
_______________________________CAUTION: Sometimes machine failuresappear to be due to PC board failures. Theseproblems can sometimes be traced to poorelectrical connections. To avoid problemswhen troubleshooting and replacing PCboards, please use the following procedure:
1. Determine to the best of your technical abil-ity that the PC board is the most likely com-ponent causing the failure symptom.
2. Check for loose connections at the PCboard to assure that the PC board is proper-ly connected.
3. If the problem persists, replace the suspectPC board using standard practices to avoidstatic electrical damage and electricalshock. Read the warning inside the staticresistant bag and perform the following pro-
cedures:P.C. Board can be dam-aged by static electricity.
- Remove your body’s stat-ic charge before openingthe static-shielding bag.Wear an anti-static wriststrap. For safety, use a 1Meg ohm resistive cordconnected to a groundedpart of the equipmentframe.
- If you don’t have a wriststrap, touch an unpainted,grounded, part of the equip-
ment frame. Keep touching the frame to pre-vent static build-up. Be sure not to touch anyelectrically live parts at the same time.
- Tools which come in contact with the P.C.Board must be either conductive, anti-static orstatic-dissipative.
ELECTRIC SHOCK can kill.
Have an electrician installand service this equipment.Turn the input power OFF atthe fuse box before work-ing on equipment. Do nottouch electrically hot parts.
- Remove the P.C. Board from the static-shielding bag and place it directly into theequipment. Don’t set the P.C. Board on ornear paper, plastic or cloth which could have astatic charge. If the P.C. Board can’t beinstalled immediately, put it back in the static-shielding bag.
- If the P.C. Board uses protective shortingjumpers, don’t remove them until installation iscomplete.
- If you return a P.C. Board to The LincolnElectric Company for credit, it must be in thestatic-shielding bag. This will prevent furtherdamage and allow proper failure analysis.
4. Test the machine to determine if the failuresymptom has been corrected by thereplacement PC board.
NOTE: It is desirable to have a spare (knowngood) PC board available for PC board trou-bleshooting.
NOTE: Allow the machine to heat up so thatall electrical components can reach their oper-ating temperature.
5. Remove the replacement PC board andsubstitute it with the original PC board torecreate the original problem.
a. If the original problem does not reappearby substituting the original board, thenthe PC board was not the problem.Continue to look for bad connections inthe control wiring harness, junctionblocks, and terminal strips.
b. If the original problem is recreated by thesubstitution of the original board, thenthe PC board was the problem. Reinstallthe replacement PC board and test themachine.
6. Always indicate that this procedure was fol-lowed when warranty reports are to be sub-mitted.
NOTE: Following this procedure and writingon the warranty report, “INSTALLED ANDSWITCHED PC BOARDS TO VERIFY PROB-LEM,” will help avoid denial of legitimate PCboard warranty claims.
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ATTENTIONStatic-SensitiveDevicesHandle only atStatic-SafeWorkstations
Reusable ContainerDo Not Destroy
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F-3TROUBLESHOOTING & REPAIRF-3
WIRE-MATIC 250
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353
OUTPUT PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENTS(S)
RECOMMENDEDCOURSE OF ACTION
Major Physical or Electrical Damageis Evident
Machine is dead- No Open CircuitVoltage output and No Wire Feedwhen gun trigger is pulled.
1. Contact The Lincoln ElectricService Dept. (216) 383-2531 or1-800-833-9353 (WELD)
1. Check input power switch (S1).It may be faulty.
2. Check for lose or broken wiresat the reconnect panel.
3. Perform Main TransformerTest.
4. Check the thermostats andassociated leads for loose orbroken connections. See wiringdiagram.
5. The control board may be faulty.Replace.
1. Contact your local LincolnElectric Authorized FieldService Facility.
1. Make certain that the inputpower switch is in the "ON" posi-tion.
2. Check the input voltage at themachine. Input voltage mustmatch the rating plate and thereconnect panel.
3. Blown or missing fuses in theinput line.
4. The thermostats may be opendue to machine overheating. Ifmachine operates normally aftera cooling off period then checkfor proper fan operation andventilation. Make certain thatthe machine's duty cycle is notbeing exceeded.
5. Check the trigger circuit. Leads#324 to #325 should have conti-nuity (zero ohms) when the guntrigger is pulled. If not then thegun may be faulty - replace.
CAUTION
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F-4TROUBLESHOOTING & REPAIRF-4
WIRE-MATIC 250
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
OUTPUT PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENTS(S)
RECOMMENDEDCOURSE OF ACTION
No Open Circuit Voltage output butwire feeds normally when gun trig-ger is pulled.
Wire feeds but welding output is lowcausing wire to "stub". Welds are"cold". Machine cannot obtain fullrated output of 200 amps at 28 volts.
1. Check for loose or broken con-nections at the output terminals,the choke, the capacitor bankand all heavy current carryingleads.
2. Make sure that the transformersecondary leads are securelyconnected to the SCR RectifierAssembly.
3. Perform the SCR RectifierAssembly Test.
4. The control board may be faulty- Replace.
1. Check for loose or faulty con-nections of the heavy currentcarrying leads.
2. The output capacitor bank maybe faulty. Check for loose con-nections at the capacitors. Alsocheck for leaky capacitors.Replace if necessary.WARNING: The liquid elec-trolyte in these capacitors istoxic. Avoid contact with anyportion of your body.
3. Perform the SCR RectifierAssembly Test.
4. Perform the Main TransformerTest.
5. The control board may be faulty.Replace.
1. Check the input voltage at themachine. Input voltage mustmatch the rating plate and thereconnect panel.
2. The gun may be faulty. Checkor replace.
1. Make sure that the proper wireand procedures are being used.
2. Check gun and work cable forloose or faulty connections.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353
CAUTION
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F-5TROUBLESHOOTING & REPAIRF-5
WIRE-MATIC 250
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
OUTPUT PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENTS(S)
RECOMMENDEDCOURSE OF ACTION
The output voltage and wire feed ispresent continuously or pulsingwhen gun trigger is NOT activated.
1. Check the machine's internaltrigger leads for grounds orshorts. See Wiring Diagram.
2. The control board may be faulty.Replace.
1. Remove the gun. If the problemis resolved the gun trigger circuitis faulty. Repair or replace.
2. If the problem is not resolvedthen contact your Local LincolnElectric Authorized FieldService Facility.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353
CAUTION
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F-6TROUBLESHOOTING & REPAIRF-6
WIRE-MATIC 250
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
FUNCTION PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENTS(S)
RECOMMENDEDCOURSE OF ACTION
No control of arc voltage. Wire feed-ing is normal.
There is no gas flow when gun trig-ger is pulled. Wire feeds and weldvoltage is present.
The machine stops feeding wirewhile welding.
1. The Arc Voltage Control poten-tiometer may be faulty. Check orreplace. See Wiring Diagram.
2. Perform the SCR RectifierAssembly Test.
3. The control board may be faulty.Replace.
1. Check the gas solenoid by dis-connecting it from the controlboard (Plug J8) and applying a12 VDC external supply to thegas solenoid. If the solenoiddoes NOT activate then it maybe faulty. Replace.
2. The control broad may be faulty.Replace.
1. Check the motor armature cur-rent. Normal armature current is1.75 amps maximum. If themotor armature current is normalthe control board may be faulty.Replace.
2. If the motor armature current ishigh (2 to 2.5 amps) and thereare NO restrictions in the wirefeeding path then the motor orgear box may be defective.Replace.
1. The Arc Voltage Control poten-tiometer may be dirty. Rotateseveral times and check if prob-lem is resolved.
1. Check gas source and hoses forleaks or kinks.
1. Check for mechanical restric-tions in the wire feeding path.The gun may be clogged.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353
CAUTION
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F-7TROUBLESHOOTING & REPAIRF-7
WIRE-MATIC 250
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
WIRE FEEDING PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENTS(S)
RECOMMENDEDCOURSE OF ACTION
No control of wire feed speed.Other machine functions are nor-mal.
There is no wire feed when gun trig-ger is pulled. Normal open circuitvoltage is present.
1. The Wire Speed Control poten-tiometer may be faulty. Checkor replace. See WiringDiagram.
2. Perform the Wire Drive Motorand Tach Feedback test.
3. The control board may be faulty.Replace.
1. Perform the Wire Drive Motorand Tach Feedback Test.
2. The Wire Feed Control poten-tiometer may be faulty. Checkor replace. See WiringDiagram.
3. The control board may be faulty.Replace.
1. The wire feed speed controlmay be dirty. Rotate severaltimes and check if problem isresolved.
1. If the drive rolls are turning thencheck for a mechanical restric-tion in the wire feed path.
2. The gun liner may be clogged.Check or Replace.
3. If the drive rolls are NOT turningwhen the gun trigger is pulledthen contact your local LincolnElectric Authorized FieldService Facility.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353
CAUTION
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F-8TROUBLESHOOTING & REPAIRF-8
WIRE-MATIC 250
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
WELDING PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENTS(S)
RECOMMENDEDCOURSE OF ACTION
The arc is unstable and or "hunting".
Weld bead is narrow or ropy. Mayhave porosity with electrode stub-bing into plate.
The contact tip seizes in the gas dif-fuser.
1. Check for loose connections atthe output terminals, the choke,the capacitor bank and all heavycurrent carrying leads.
2. Make sure that the transformersecondary leads are securelyconnected to the SCR RectifierAssembly.
3. The output capacitor bank maybe faulty. Check for loose con-nections at the capacitors. Alsocheck for leaky capacitors.Replace if necessary.WARNING: The liquid elec-trolyte in these capacitors istoxic. Avoid contact with anyportion of your body.
4. The control board may be faulty.Replace
1. The output capacitor bank maybe faulty. Check for loose con-nections at the capacitors. Alsocheck for leaky capacitors.Replace if necessary.WARNING: The liquid elec-trolyte in these capacitors istoxic. Avoid contact with anyportion of your body.
2. The control board may be faulty.Replace.
1. Check for worn or melted con-tact tip.
2. Check for loose or faulty con-nections on the work and elec-trode cables.
3. Make sure electrode polarity iscorrect or welding processbeing used.
4. Check for rusty or dirty wire.
5. Make sure machine settingsand gas are correct for processbeing used.
1. Make sure the weld procedureand electrode polarity is correctfor the process being used.
2. Make sure shielding gas is cor-rect and flow is proper.
3. Make sure the weld joint is not"contaminated".
1. The tip being over heated due toexcessive current and/or highduty cycle welding.
2. A light application of high tem-perature antisieze lubricant(such as Lincoln E2607Graphite Grease) may beapplied to the contact tipthreads.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353
CAUTION
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F-9TROUBLESHOOTING & REPAIRF-9
WIRE-MATIC 250
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
WELDING PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENTS(S)
RECOMMENDEDCOURSE OF ACTION
The welding arc is variable and slug-gish.
The arc striking is poor.
1. Perform the Output RectifierBridge 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,voltage, and shielding gas arecorrect for the process beingused.
1. Check the welding cable con-nections for loose or faulty con-nections.
2. Make sure the wire feed speed,voltage, and shielding gas arecorrect for the process beingused.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353
CAUTION
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F-10TROUBLESHOOTING & REPAIRF-10
WIRE-MATIC 250
TEST DESCRIPTION
This test will determine if the correct voltages are being:
a. Applied to the primary windings of the Main Transformer.
b. Induced on the secondary and auxiliary windings of the main transformer.
MATERIALS NEEDED
5/16" Nut Driver.Volt-Ohm Meter.
MAIN TRANSFORMER TEST
Service and repair should be performed only by Lincoln Electric factory trained per-sonnel. Unauthorized repairs performed on this equipment could result in danger tothe technician or the machine operator and will invalidate your factory warranty. Foryour safety and to avoid electrical shock, please observe all safety notes and pre-cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact the Lincoln Electric service department for technicaltroubleshooting assistance before you proceed.Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
WARNING
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F-11TROUBLESHOOTING & REPAIRF-11
WIRE-MATIC 250
MAIN TRANSFORMER TEST (CONTINUED)
TEST PROCEDURE
The ON/OFF POWER SWITCH will be"hot" during these tests.__________________________
NOTE: Secondary voltages will varyproportionably with the primary inputvoltage.
1. Disconnect the main input powersupply to the machine.
2. Remove the Case Top and SidePanels with a 5/16" nut driver.
3. Locate Plug J3 and Plug J6 on theG2332 Control PC Board.
NOTE: The location of Plugs may varydepending on the machine code.
FIGURE F.1 - G2332 Control PCBoard Main Transformer Test Points.
G2332WM-250 CONTROL
J2
J7
J4
J10
J6
J9
J3
J5
#202(1J3)
#204A (2J3)
#203(3J3)
#206(4J6) #209
(7J6)
#208(16J6)
J1
WARNING
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F-12TROUBLESHOOTING & REPAIRF-12
WIRE-MATIC 250
MAIN TRANSFORMER TEST (CONTINUED)a. Turn the machine OFF between
each test.
b. Carefully insert the meterprobes into the back of eachMolex Plug pin cavity to performthe test.G2332:
c. If any of the voltages tested areincorrect, check for loose or bro-ken leads between the testpoints and the main transformer.
d. If ALL the voltages tested areincorrect or missing, go to Step12.
12. Test for correct nameplate input volt-age between the H1 lead at theON/OFF POWER SWITCH to H2 orH3 (H5 if connected for 575 VAC) atthe reconnect panel. Voltage testedwill vary depending on Input VoltageConnection. See wiring diagram fortest point locations.
a. If the voltage test is incorrect,
- check for loose or brokenleads between the reconnectpanel and the ON/OFF POWERSWITCH.
- test the ON/OFF POWERSWITCH for proper operation.
b. If the correct nameplate voltageis being applied to the maintransformer and one or more ofthe secondary voltages aremissing or are incorrect, themain transformer may be faulty.Replace.
4. Locate the following leads on PlugJ3:G2332:
5. Connect main input power to themachine.
6. Turn the Wire-Matic 250 ON/OFFPOWER SWITCH to ON.
7. Make the following voltage tests atPlug J3.
a. Turn the machine OFF betweeneach test.
b. Carefully insert the meterprobes into the back of eachMolex Plug pin cavity to performthe test.
G2332:
8. Turn OFF the machine
9. Locate the following leads on PlugJ6 on the G2332 Control PC Board.G2332:
PLUG LOCATION
1J33J32J3
LEAD
#202#203
#204 A
FROMLEAD
#202(1J3)
#202(1J3)
#203(3J3)
TOLEAD
#203(3J3)
#204 A(2J3)
#204 A(2J3)
EXPECTEDVOLTAGE
30 VAC
15 VAC
15 VAC
PLUG LOCATION
4J616J67J6
LEAD
#206#208#209
FROMLEAD
#208(16J6)
#208(16J6)
#209(7J6)
TOLEAD
#209(7J6)
#206(4J6)
#206(4J6)
EXPECTEDVOLTAGE
60 VAC
30 VAC
30 VAC
10. Turn ON the machine.
11. Make the following voltage tests atPlug J6 on the G2332 Control PCBoard.
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F-13TROUBLESHOOTING & REPAIRF-13
WIRE-MATIC 250
TEST DESCRIPTION
This test is used to quickly determine if an SCR or diode is shorted or "leaky." See theMachine Waveform Section in this manual for normal and abnormal output waveforms.
MATERIALS NEEDED
Analog Ohmmeter (Multimeter).Wire-Matic 250 wiring diagrams (See Electrical Diagrams Section of this Manual).5/16" Nut Driver.1/2" Open end 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 result in danger tothe technician or the machine operator and will invalidate your factory warranty. Foryour safety and to avoid electrical shock, please observe all safety notes and pre-cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact the Lincoln Electric service department for technicaltroubleshooting assistance before you proceed.Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
WARNING
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F-14TROUBLESHOOTING & REPAIRF-14
WIRE-MATIC 250
STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED)
TEST PROCEDURE
1. Disconnect main AC input power tothe machine.
2. Disconnect Plugs J3 and J6 fromthe G2332 Control Board. Thiselectrically isolates the SCR bridgeassembly. See Figure F.2.
FIGURE F.2 - Remove Plugs J3 and J6to Perform Static SCR RectifierAssembly Test.
3. Verify that the capacitors have com-pletely discharged with an AnalogVolt-Ohm meter.
4. Disconnect leads X2 and X3 fromthe negative capacitor bank using a1/2" open end wrench. See FigureF.3.
FIGURE F.3 - Location of Leads X2and X3.
5. Separate leads X2 and X3 from thenegative capacitor bank buss bar.Be sure there is no electrical con-tact. See Figure F.3.
LEADSX2 AND X3
NEGATIVECAPACITORBANKBUSS BAR
G2332WM-250 CONTROL
J2
J7
J4
J10
J6
J9
J3
J5
J1
REMOVE PLUGS J3 & J6
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F-15TROUBLESHOOTING & REPAIRF-15
WIRE-MATIC 250
STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED)
NOTE: DO NOT DISASSEMBLE THESCR RECTIFIER HEAT SINK ASSEM-BLY.
6. Test for high or infinite resistancefrom the anode to the cathode ofSCR 1. See Figure F.4. Use ananalog ohmmeter (Multimeter).
FIGURE F.4 - SCR 1 Test Points.
7. Test for high or infinite resistancefrom the cathode to the anode ofSCR 1 by reversing the meter leads.See Figure F.4.
a. If a high or infinite resistance isindicated for both tests 6 and 7,the SCR 1 is not “shorted”.
b. If a low resistance is indicated ineither tests 6 or 7, the SCR isfaulty. Replace SCR Assembly.
8. Repeat Steps #7 to test SCR 2.
9. Reconnect leads X2 and X3.
10. Reconnect Plugs J3 and J6.
11. If this test did not identify the prob-lem or to further test the SCR, go tothe Active SCR Test.
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F-16TROUBLESHOOTING & REPAIRF-16
WIRE-MATIC 250
ACTIVE SCR RECTIFIER ASSEMBLY TEST
TEST DESCRIPTION
The Active SCR Test will determine if the device is able to be gated ON and conduct currentfrom anode to cathode.
MATERIALS NEEDED
An SCR Tester as specified in this procedure.Wire-Matic 250 wiring diagrams (See Electrical Diagrams Section of this Manual).SCR 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 tothe technician or the machine operator and will invalidate your factory warranty. Foryour safety and to avoid electrical shock, please observe all safety notes and pre-cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact the Lincoln Electric service department for technicaltroubleshooting assistance before you proceed.Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
WARNING
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TEST PROCEDURE
1. Disconnect main AC input power tothe machine.
2. Disconnect Molex Plugs J3 and J6from the G2332 Control Board.See Figure F.5.
FIGURE F.5 - Control Board MolexPlug Locations for G2332 PC ControlBoard.
3. Verify that the capacitors have com-pletely discharged with an AnalogVolt-Ohm meter.
4. Disconnect leads X2 and X3 fromthe negative capacitor bank using a1/2" open end wrench.See Figure F. 6.
FIGURE F.6 - Location of Leads X2and X3.
5. Separate leads X2 and X3 from thenegative capacitor bank buss bar.Be sure there is no electrical con-tact. See Figure F.6.
NOTE: DO NOT DISASSEMBLE THESCR RECTIFIER HEAT SINK ASSEM-BLY.
6. Construct the circuit shown in FigureF.7. One 6-volt lantern battery canbe used. R1 and R2 resistor valuesare ±10%. Set voltmeter scale low,at approximately 0-5 volts or 5-10volts.
a. Test the voltage level of the bat-tery. Short leads (A) and (C).Close switch SW-1. Batteryvoltage should be 4.5 volts orhigher. If lower, replace the bat-tery.
G2332WM-250 CONTROL
J2
J7
J4
J10
J6
J9
J3
J5
J1
LEADSX2 AND X3
NEGATIVECAPACITORBANKBUSS BAR
F-17TROUBLESHOOTING & REPAIRF-17
WIRE-MATIC 250
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7. Connect the Tester to the SCR 1 asshown in Figure F.7.
a. Connect Tester lead (A) to theanode.
b. Connect Tester lead (C) to thecathode.
c. Connect Tester lead (G) to thegate.
FIGURE F.7 - SCR Tester Circuit andSCR connections.
8. Close switch SW-1.
NOTE: Switch SW-2 should be open.
9. Read meter for zero voltage.
a. If the voltage reading is higherthan zero, the SCR is shorted.
10. Close or keep closed switch SW-1.
11. Close switch SW-2 for 2 secondsand release and read meter.
a. If the voltage is 3 - 6 volts whilethe switch is closed and afterthe switch is open, the SCR isfunctioning.
b. If the voltages is 3-6 volts onlywhen the switch is closed orthere is no voltage when theswitch is closed, the SCR isdefective.
NOTE: Be sure battery is functioningproperly. A low battery can affect theresults of the test. Repeat Battery TestProcedure in Step 6 if needed.
12. Open switch SW-1.
13. Reconnect the Tester leads. SeeFigure F.7.
a. Connect Tester lead (A) to thecathode.
b. Connect Tester lead (C) to theanode.
c. Disconnect Test lead (G) fromthe gate.
14. Close switch SW-1.
15. Read meter for zero voltage.
a. If the voltage is zero, the SCR isfunctioning.
b. If the voltage is higher thanzero, the SCR is shorted.
16. Perform the Active Test Procedureoutlined in Steps 5-13 for SCR 2.
17. Replace all SCR assemblies that donot pass the above tests.
18. Replace all Molex Plugs onto theControl Board and connect leads X2and X3.
F-18TROUBLESHOOTING & REPAIRF-18
WIRE-MATIC 250
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TEST DESCRIPTION
This test will determine if the wire drive motor and voltage feedback circuit are functioningproperly.
MATERIALS NEEDED
5/16" Nut Driver.Volt-Ohmmeter.
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST
Service and repair should be performed only by Lincoln Electric factory trained per-sonnel. Unauthorized repairs performed on this equipment could result in danger tothe technician or the machine operator and will invalidate your factory warranty. Foryour safety and to avoid electrical shock, please observe all safety notes and pre-cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact the Lincoln Electric service department for technicaltroubleshooting assistance before you proceed.Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
WARNING
F-19TROUBLESHOOTING & REPAIRF-19
WIRE-MATIC 250
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F-20TROUBLESHOOTING & REPAIRF-20
WIRE-MATIC 250
TEST PROCEDURE
NOTE: POLARITY MUST BEOBSERVED FOR THESE TESTS.
Test for Correct Wire Drive MotorArmature Voltage
1. Disconnect main input power to themachine.
2. Remove the Case Top and SidePanels using a 5/16" nut driver.
3. Locate Plug J5 on the G2332Control Board. See Figure F.8.
FIGURE F.8 - Plug J5 Location onG2332 PC Control Board.
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (CONTINUED)
G2332WM-250 CONTROL
J2
J7
J4
J10
J6
J9
J3
J5 #541 (NEGATIVE)(9J5)
#206B(2J5)
J1 #555(1J5)
#539(8J5)
#515B(3J5)
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F-21TROUBLESHOOTING & REPAIRF-21
WIRE-MATIC 250
4. Test for 2 - 25 VDC between lead#539 (positive) (8J5) and lead #541(9J5) (negative) to determine if thecorrect armature voltage is beingsupplied. See Figure F.8.
a. Insert probes in to the Molex pincavities.
5. Pull the gun trigger.
6. Read meter. Normal DC volts isfrom 2 - 25 VDC. VDC variesdepending on wire feed speed.
a. If voltage to the wire drive motorarmature is zero, check thewires between Plug J5 and thewire drive motor.
b. If the wires are okay and voltageto the drive motor armature iszero, the Control Board may befaulty. Replace.
c. If the correct DC armature volt-age is present at the wire drivemotor, the motor or motor brush-es may be faulty. Test and/orreplace.
d. If the motor is running at highspeed and the armature voltageis high and uncontrollable, pro-ceed with the tachometer test.
Test for Supply Voltage toTachometer
1. Test for 15 VDC between lead#515B (positive) (3J5) and lead#206B (negative) (2J5) . See FigureF.8 for pin locations.
a. Insert probes into Molex pincavities.
2. Pull gun trigger.
3. Read meter for 15 VDC.
a. If the 15 VDC is present, checkthe leads to the tach circuit.
b. If the leads are okay and 15VDC is present, the correct volt-age is being received from theControl Board. Go to FeedbackTest.
c. If the 15 VDC is not present andthe leads are okay, the ControlBoard may be faulty. Replace.
Test for Feedback Voltage to theControl Board
1. Test for 1.5 - 3.5 VDC between lead#555 (positive) (1J5) and lead#206B (negative) (2J5) . See FigureF.8 for pin locations.
a. Insert probes into Molex pincavities.
2. Pull gun trigger.
3. Read meter for 1.5 - 3.5 VDC.
a. If the 1.5 - 3.5 VDC is present,the tach circuit is sending thecorrect feedback signal to theControl Board.
NOTE: IF THE MOTOR IS NOT RUN-NING, THE FEEDBACK VOLTAGE MAYBE FROM 0 TO 5 VDC.
b. If the 1.5 - 3.5 VDC is not pre-sent or not correct, the ControlBoard is not receiving the prop-er feedback voltage from thetach circuit. Check the leadsfrom the tach circuit to theControl Board for loose or bro-ken connections.
c. If the leads are okay, the ControlBoard may be faulty. Replace.
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (CONTINUED)
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F-22TROUBLESHOOTING & REPAIRF-22
WIRE-MATIC 250
This is a typical DC output voltage wave-form generated from a properly operatingmachine. Note that each vertical divisionrepresents 20 volts and that each horizontaldivision represents 2 milliseconds in time.
Note: Scope probes connected at machineoutput terminals: (+) probe to electrode, (-)probe to work.
Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
Horizontal Sweep . . . . . . . . . .2 ms/Div.
Coupling . . . . . . . . . . . . . . . . . . . . .DC.
Trigger . . . . . . . . . . . . . . . . . . .Internal.
SCOPE SETTINGS
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
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F-23TROUBLESHOOTING & REPAIRF-23
WIRE-MATIC 250
This is a typical DC output voltage wave-form generated from a properly operatingmachine. Note that each vertical divisionrepresents 20 volts and that each horizontaldivision represents 5 milliseconds in time.The machine was loaded with a resistancegrid bank.
Note: Scope probes connected at machineoutput 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 250 AMPS AT 26 VDC
TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
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F-24TROUBLESHOOTING & REPAIRF-24
WIRE-MATIC 250
This is NOT a typical DC output voltagewaveform. One output SCR is not function-ing. Note the increased ripple content. OneSCR gate was disconnected to simulate anopen or non-functioning output SCR. Eachvertical division represents 20 volts andeach horizontal division represents 5 mil-liseconds in time. The machine was loadedwith a resistance grid bank.
Note: Scope probes connected at machineoutput 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 LOADEDONE OUTPUT SCR NOT FUNCTIONING
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F-25TROUBLESHOOTING & REPAIRF-25
WIRE-MATIC 250
This is NOT the typical DC output voltagewaveform. The output capacitors are notfunctioning. Note the lack of “filtering” in theoutput waveform. The output capacitorbank was disconnected. Each vertical divi-sion represents 20 volts and each horizontaldivision represents 5 milliseconds in time.
Note: Scope probes connected at machineoutput terminals: (+) probe to electrode, (-)probe to work.
Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
Horizontal Sweep . . . . . . . . . .5 ms/Div.
Coupling . . . . . . . . . . . . . . . . . . . . .DC.
Trigger . . . . . . . . . . . . . . . . . . .Internal.
SCOPE SETTINGS
ABNORMAL OPEN CIRCUIT VOLTAGEOUTPUT CAPACITOR BANK NOT FUNCTIONING
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F-26TROUBLESHOOTING & REPAIRF-26
WIRE-MATIC 250
This is a typical SCR gate pulse voltagewaveform. 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 divisionrepresents 5 milliseconds in time.
Note: Scope probes connected at Plug J3on the control board. The (+) probe to leadG2, and the (-) probe to lead 204.
Volts/Div . . . . . . . . . . . . . . . . . .2 V/Div.
Horizontal Sweep . . . . . . . . . .5 ms/Div.
Coupling . . . . . . . . . . . . . . . . . . . . .DC.
Trigger . . . . . . . . . . . . . . . . . . .Internal.
SCOPE SETTINGS
TYPICAL SCR GATE VOLTAGE WAVEFORM
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Printed Circuit Boards can be damaged by static electricity. Follow static handlingguidelines detailed in “PC Board Troubleshooting Procedures” at the beginning ofthis chapter.
_____________________________________________________________
F-27TROUBLESHOOTING & REPAIRF-27
WIRE-MATIC 250
CONTROL PC BOARD REMOVAL AND REPLACEMENT
Service and repair should be performed only by Lincoln Electric factory trained per-sonnel. Unauthorized repairs performed on this equipment could result in danger tothe technician or the machine operator and will invalidate your factory warranty. Foryour safety and to avoid electrical shock, please observe all safety notes and pre-cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact the Lincoln Electric service department for technicaltroubleshooting assistance before you proceed.Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
WARNING
CAUTION
REMOVAL AND REPLACEMENT PROCEDURE
MATERIALS NEEDED
5/16" Nutdriver.Phillips head screwdriver.Static electricity grounding strap.
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F-28TROUBLESHOOTING & REPAIRF-28
WIRE-MATIC 250
4. Remove the eight Phillips Headmounting screws using a PhillipsHead screwdriver. See Figure F.10.
FIGURE F.10 - Control BoardMounting Screw Locations mayvary with different CodeMachines.
5. Lift the Control Board straight upand out from the machine.
6. Replace all mounting screws andwiring connections wheninstalling the Control Board.
CONTROL PC BOARD REMOVAL AND REPLACEMENT (CONTINUED)
REMOVAL AND REPLACE-MENT PROCEDURE
1. Disconnect main input power themachine.
2. Remove the Case Top and SidePanels using 5/16" nut driver.
3. Disconnect all wiring harness plugsand Molex Plugs connected to theControl Board. See Figure F.9.
FIGURE F.9 - Wiring Harness andMolex Plug Locations.
G2332WM-250 CONTROL
J2J7
J4
J10
J6
J9
J3
J5
J1
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F-29TROUBLESHOOTING & REPAIRF-29
WIRE-MATIC 250
MATERIALS NEEDED
Large slot head screwdriver.5/16" Nut Driver.Small slot head screwdriver.
WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT
Service and repair should be performed only by Lincoln Electric factory trained per-sonnel. Unauthorized repairs performed on this equipment could result in danger tothe technician or the machine operator and will invalidate your factory warranty. Foryour safety and to avoid electrical shock, please observe all safety notes and pre-cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact the Lincoln Electric service department for technicaltroubleshooting assistance before you proceed. Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
WARNING
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F-30TROUBLESHOOTING & REPAIRF-30
WIRE-MATIC 250
PROCEDURE
1. Disconnect main input power to themachine.
2. Remove the Case Top and SidePanels.
3. Remove the large mounting screwwith a large slot head screwdriverlocated in front of the drive roll. SeeFigure F.11.
a. Note the placement of the insu-lators and washers for replace-ment.
FIGURE F.11 - Wire Drive AssemblyRemoval
4. Using a small slot head screw driver,loosen the set screw holding the outgoing guide tube into the drive rollassembly. Carefully slide out thewire drive assembly.
5. Disconnect the six pin plug from thevertical baffle connector.
a. The six pin plug contains thewire feed drive motor wires.
6. Remove carefully the drive motorand drive roll assembly.
WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT (CONTINUED)
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F-31TROUBLESHOOTING & REPAIRF-31
WIRE-MATIC 250
MATERIALS NEEDED
5/16" Nut driver.1/2" Open end wrench.1/2" Socket wrench, universal tool, and extension.3/8" Open end wrench.Slot head screwdriver.Wire cutters.
SCR OUTPUT RECTIFIER REMOVAL & REPLACEMENT
Service and repair should be performed only by Lincoln Electric factory trained per-sonnel. Unauthorized repairs performed on this equipment could result in danger tothe technician or the machine operator and will invalidate your factory warranty. Foryour safety and to avoid electrical shock, please observe all safety notes and pre-cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact the Lincoln Electric service department for technicaltroubleshooting assistance before you proceed.Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
WARNING
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F-32TROUBLESHOOTING & REPAIRF-32
WIRE-MATIC 250
PROCEDURE
1. Disconnect lead #208 andTransformer Lead X1 from the heatsink on the left side of the machine(facing the front) using a 1/2" socketwrench. See Figure F.12.
a. Thin lead is always on the out-board side of the connection.
FIGURE F.12 - Heat Sink lead discon-nection.
2. Disconnect lead #204 and heavylead from the middle heat sink with a1/2" socket wrench and 1/2" openend wrench. See Figure F.13.
3. Remove the diode lead from thenegative capacitor band buss bar onthe right side of the machine using aslot head screwdriver and 3/8" openend 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 easiest access to theseleads is from the right side of themachine.
b. Cut any necessary cable ties.
5. Remove the four screws holding theSCR Assembly to the floor of themachine using a 5/16" nut driver.
6. Pivot the SCR Assembly counter-clockwise to provide access to theright side heat sink.See Figure F.14.
FIGURE F.14 - Heat Sink LeadDisconnection
7. Remove lead #209 and TransformerLead X4 from the right side heat sinkusing a 1/2" socket wrench and 1/2"open end wrench.
8. Clear the leads and carefullyremove the SCR Rectifier Assembly.
NOTE: When installing the SCRRectifier Assembly, apply a thin coatingof Dow Corning #340 Compound to theelectrical connections.
SCR OUTPUT RECTIFIER REMOVAL & REPLACEMENT (CONTINUED)
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F-33TROUBLESHOOTING & REPAIRF-33
WIRE-MATIC 250
THE LIQUID ELECTRODE IN THE CAPACITORS IS TOXIC. DO NOT TOUCH THE CAPAC-ITORS WITH ANY PART OF YOUR BODY.
_____________________________________________________________
MATERIALS NEEDED
5/16" Nut driver.5/16" Socket wrench, extension, and universal tool.1/2" Open end wrench.3/8" Open end wrench.Slot head screwdriver.Wiring diagram.
CAPACITOR 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 danger tothe technician or the machine operator and will invalidate your factory warranty. Foryour safety and to avoid electrical shock, please observe all safety notes and pre-cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact the Lincoln Electric service department for technicaltroubleshooting assistance before you proceed.Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
WARNING
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F-34TROUBLESHOOTING & REPAIRF-34
WIRE-MATIC 250
PROCEDURE
See Figure F.15 for location of CapacitorBank Removal and Replacement com-ponents.
FIGURE F.15 - Location of CapacitorBank Removal and ReplacementComponents.
1. Disconnect main input power to themachine.
2. Test that the capacitors are dis-charged using a volt ohmmeter.Polarity must be observed.
3. Remove the two transformer sec-ondary leads (X2 and X3) for thenegative capacitor bank buss barusing two 1/2" open end wrenches.
4. Remove the output choke lead andthe heavy lead extending from theSCR Rectifier Assembly to the posi-tive capacitor bank buss bar using a1/2" open end wrench.
5. Remove lead #206 and the D1diode lead from the negative capac-itor bank buss bar using a slot headscrewdriver and 3/8" open endwrench.
6. Remove the #204 lead from the pos-itive buss bar.
7. Remove the shunt from the negativecapacitor bank buss bar using a 1/2"socket wrench with a universal tooladapter.
a. Two people may be required toremove the shunt. One personmay have to reach through fromthe left side of the machine tokeep the bolt in position whilethe other person loosens thenut.
8. Remove the two screws holding thecapacitor bank to the floor of themachine using a 5/16" nut driver.
9. Clear the leads and carefullyremove the capacitor bank assem-bly from the machine.
CAPACITOR BANK REMOVAL AND REPLACEMENT (CONTINUED)
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F-35TROUBLESHOOTING & REPAIRF-35
WIRE-MATIC 250
MATERIALS NEEDED
5/16" Nut Driver.1/2" Open end wrench.3/8" Open end wrench.1/2" Socket wrench, extender, universal adapter.Wire cutters.
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
Service and repair should be performed only by Lincoln Electric factory trained per-sonnel. Unauthorized repairs performed on this equipment could result in danger tothe technician or the machine operator and will invalidate your factory warranty. Foryour safety and to avoid electrical shock, please observe all safety notes and pre-cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact the Lincoln Electric service department for technicaltroubleshooting assistance before you proceed.Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
WARNING
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F-36TROUBLESHOOTING & REPAIRF-36
WIRE-MATIC 250
PROCEDURE
1. Disconnect main input power to themachine.
2. Remove the Case Top and SidePanels.
3. Perform the Capacitor BankRemoval Procedure.
4. Remove lead X1 from the left sideSCR heat sink assembly using a1/2" socket wrench, extender anduniversal adapter.
5. Remove lead X4 from the right sideheat sink assembly using a 1/2"socket wrench, extender and univer-sal adapter.
6. Disconnect all leads from the recon-nect panel using a 3/8" open endwrench.
7. Disconnect all leads from thePOWER SWITCH.
8. Remove the POWER SWITCH.
9. Label and cut leads #202, #203,#204A.
a. Cut lead #204A at a point just infront of the transformer.
b. These leads must be re-splicedduring reassembly.
c. An alternative to cutting theseleads is to remove them fromMolex Plug J3 and pull themfree of any wire bundles.
10. Remove all cable ties, wire mounts,- and any harness tape that couldget in the way during transformerremoval using wire cutters andscrewdriver.
11. Remove the four screws mountingthe transformer to the floor of themachine using a 5/16" nut driver.
12. Disconnect the positive output leadat the wire drive motor.
13. Remove the strain relief grommetthrough which the positive outputlead passes through the horizontalbaffle of the machine.
14. Pull down on the positive outputlead until it slides out the hole in thebaffle.
15. Carefully remove the main trans-former.
a. Be sure all leads are clear.
MAIN TRANSFORMER REMOVAL AND REPLACEMENT (CONTINUED)
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F-37TROUBLESHOOTING & REPAIRF-37
WIRE-MATIC 250
MATERIALS NEEDED
3/4" Open end wrench.1/2" Socket wrench with extension.Phillips head screwdriver.
FAN MOTOR AND FAN REMOVAL AND REPLACEMENT
Service and repair should be performed only by Lincoln Electric factory trained per-sonnel. Unauthorized repairs performed on this equipment could result in danger tothe technician or the machine operator and will invalidate your factory warranty. Foryour safety and to avoid electrical shock, please observe all safety notes and pre-cautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact the Lincoln Electric service department for technicaltroubleshooting assistance before you proceed.Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
WARNING
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F-38TROUBLESHOOTING & REPAIRF-38
WIRE-MATIC 250
PROCEDURE
See Figure F.16 for fan motor and fanremoval components.
FIGURE F.16 - Fan Motor and FanRemoval Components
1. Remove the Case Back screws.
2. Remove the gas solenoid using a3/4" open end wrench.
3. Using a 5/16” wrench, remove the 5screws holding the fan motor mount-ing bracket to the case back.
4. Tilt the Case Back away from themachine and remove the screwsholding the Case Back to the floor ofthe machine using a 1/2" socketwrench with extension.
5. Loosen the two screws holding thereconnect panel in place and a slidethe reconnect panel from the frame.
6. Remove the fan blade. Note fanblade position on motor shaft for ref-erence for replacing fan.
a. Pry the fan blade off the motor.
b. Slide the fan blade off the motorshaft.
FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED)
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F-39TROUBLESHOOTING & REPAIRF-39
WIRE-MATIC 250
FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED)
7. Remove the fan motor.
a. Loosen and remove the twoscrews from the motor mountingbracket using a slot head screwdriver.
b. When the motor is free from themounting bracket, place it care-fully on the bottom of themachine.
c. Cut any necessary wire wrapsbundling the motor leads.
d. Remove the leads from the fanmotor.
8. Install the replacement motor in thereverse order of removal.
9. Install the fan blade. Wheninstalling the fan blade, the blade isflush with the end of the motor shaft.
a. Spin the fan to be sure it is freeto rotate.
10. Reassemble the remaining compo-nents in reverse order of removal.
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F-40TROUBLESHOOTING & REPAIRF-40
WIRE-MATIC 250
INPUT IDLE AMPS AND WATTS
WIRE SPEED RANGE
OPEN CIRCUIT VOLTAGE
RETEST AFTER REPAIR
Maximum Idle WattsMaximum Idle AmpsInput Volts/Hertz
3756.4230/60
10 to 40 VDC
50 - 600 IPM (1.27 - 15.2 m/minute)
35-40 VDC Strike Voltage
NOTES
WIRE-MATIC 250
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TABLE OF CONTENTS- ELECTRICAL DIAGRAMS SECTION -
WIRE-MATIC 250
Electrical Diagram Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G
Wiring Diagram (230/460/575) Code 10004 . . . . . . . . . . . . . . . . . . . . . . G-2Wiring Diagram (230/460/575) Code 10003 . . . . . . . . . . . . . . . . . . . . . . G-3Wiring Diagram (208/230) Code 9800 . . . . . . . . . . . . . . . . . . . . . . . . . . G-4Wiring Diagram (208/230) Code 9799 . . . . . . . . . . . . . . . . . . . . . . . . . . G-5Control PC Board (G2332) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . G-6Control PC Board (G2332) Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
G-1G-1R
etur
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CR
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CR
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CR
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C
NOTES
WIRE-MATIC 250
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OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
ELECTRICAL DIAGRAMS G-2
WIRE-MATIC 250
Wiring Diagram (230/460/575) Code 10004
GENERAL INFORMATION
COLOR CODE:
B - BLACKW - WHITE
THERMOSTAT
202
204A
203
204
208G1
X2
X1
G2209
SCR 1250V470A
SCR HEATSINKASBLY
SCR 2250V470A
C1 C2 C3 C4
+ + + +
POWER TRANSFORMER
L1
L2
GND
TO SINGLE PHASESUPPLY LINE
TO GROUND PER
CODE
207
206
OUTPUTCHOKE
NOTESN.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
CURRENT AND DUTY CYCLE OF IMMEDIATE ANDFUTURE APPLICATIONS.
N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
D1300V85A
* INDICATES CONNECTOR CAVITY NO.
ELECTRICAL SYMBOLS PER E1537
OFF AND REVERSE LEAD CONNECTIONS AT CABLECONDUCTOR STRAP AND WORK STUD.
NATIONAL ELECTRICAL
C1 THRU C430,000 MFD50V
320
THERMOSTATS3 S4
"POSITIVE". TO CHANGE POLARITY, TURN THE UNIT
.
R - REDU - BLUE
X3
X4
X5
X6
X7
15 OHMS100 WR
1
12345678
1 2 3 4 5 6 7 8
555
GASSOLENOID
**
(J4)
CONTROL BOARD
1 2 3 4
* 1234
*(J7)(J8)
515
541A
495
542
543
1 2 3 4 5 6
*
(J9)
209
208
204A
204
207206
GNDG1
G2
320
1
2345
6789
101112
(J3)
*
123456789
10111213141516
*
123456789
1011121314
*(J5)
(J6)
324
206S
205
325A
324A
206A
206B515B325
539541
325A
TACH
P.M.
TOWORK
N.A.
207206 N.B.
R.F. FILTER
1
3
2
4
5
6
539
541
555
539
555
541
515B
206B
515B
206B
GND
202
203
325A
(COMPONENT SIDE OF P.C. BOARD)
1 4
5 8
1J4
J71 2
3 4
1 3
4 6
CAVITY NUMBERING SEQUENCE
J31
6 10
5
J8
J5 J6
6
7 12
1 7 1 8
9 168 14
205
206S
+-
SHUNT
R.F. CHOKE AS'BLY.
328
S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TOPOWER TRANSFORMER.
J2J1
J14
J9J10
4
SCI TESTPLUG
260262261263265264266267
}123456789
10
123456
}}
*
*
PLUG
J10
J2
J1
254252253255251256
OPTIONAL TIMERBOARD
1 2 3 4 5 6 7 8
260
262
261
263
265
264
}J14
*
251
256
253
254
255
R4
R3 WIRE SPEED
ARC VOLTAGE
+
-
N.C. THERMOSTATS MOUNTED ON CHOKE COIL
N.D. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET
N.E. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.N.C.
N.D.
SPI TEST252
266
267
325
324
2
1
2GUNTRIGGER
204
POWER-ONINDICATOR
H1
T1
L1 L2
H1
LINESWITCH
S1
H1
H4H4
H3
H5H2P2
L1
GND. RECONNECT PANEL
P2T1
FANMOTORS
T2P1 P2
S2THERMOSTAT
N.C.
L2
R22.5K10W
G
N.E.
5
1 3
4 2
H4
H5
H2
H2‰z·^ 63/64 ˆ
H3
H1
(SHOWN CONNECTEDFOR 230 VOLT.)
MOTOR/GEARBOX
541
515B
555
539
206B
WR
U
BB
2-5-93
L9077
TOSPOOL GUN
OPTION
G-2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
G-3ELECTRICAL DIAGRAMS
WIRE-MATIC 250
Wiring Diagram (230/460/575) Code 10003
GENERAL INFORMATION
COLOR CODE:
B - BLACKW - WHITE
THERMOSTAT
202
204A
203
204
208G1
X2
X1
G2209
SCR 1250V470A
SCR HEATSINKASBLY
SCR 2250V470A
C1 C2 C3 C4
+ + + +
POWER TRANSFORMERH3
H2
H1
L1 L2
H1
LINESWITCH
S1
H2 H3L1
GND. RECONNECT PANEL
L1
L2
GND
TO SINGLE PHASESUPPLY LINE
TO GROUND PER
CODE
P2T1
FANMOTORS
T2P1 P2
S2THERMOSTAT
207
206
OUTPUTCHOKE
NOTESN.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
CURRENT AND DUTY CYCLE OF IMMEDIATE ANDFUTURE APPLICATIONS.
N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
D1300V85A
* INDICATES CONNECTOR CAVITY NO.
ELECTRICAL SYMBOLS PER E1537
OFF AND REVERSE LEAD CONNECTIONS AT CABLECONDUCTOR STRAP AND WORK STUD.
NATIONAL ELECTRICAL
H4
LOW V.
L2
HIGH V.
C1 THRU C430,000 MFD50V
H1
H2
H3
H1
H4
320
THERMOSTATS3 S4
R2
"POSITIVE". TO CHANGE POLARITY, TURN THE UNIT
.
R - REDU - BLUE
2.5K10W
GX3
X4
X5
X6
X7
15 OHMS100 WR
1
12345678
1 2 3 4 5 6 7 8
555
GASSOLENOID
**
(J4)
CONTROL BOARD
1 2 3 4
* 1234
*(J7)(J8)
515
541A
495
542
543
1 2 3 4 5 6
*
(J9)
209
208
204A
204
207206
GNDG1
G2
320
1
2345
6789
101112
(J3)
*
123456789
10111213141516
*
123456789
1011121314
*(J5)
(J6)
324
206S
205
325A
324A
206A
206B515B325
539541
325A
TACH
TOWORK
N.A.
1
3
2
4
5
6
539
541
555
539
555
541
515B
206B
515B
206B
GND
202
203
325A
(COMPONENT SIDE OF P.C. BOARD)
1 4
5 8
1J4
J71 2
3 4
1 3
4 6
CAVITY NUMBERING SEQUENCE
J31
6 10
5
J8
J5 J6
6
7 12
1 7 1 8
9 168 14205
206S
+-
SHUNT
R.F. CHOKE AS'BLY.
328
S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TOPOWER TRANSFORMER.
J2J1
J14
J9J10
4
SCI TESTPLUG
260262261263265264266267
}123456789
10
123456
}}
*
*
PLUG
J10
J2
J1
254252253255251256
OPTIONAL TIMERBOARD
1 2 3 4 5 6 7 8
260
262
261
263
265
264
}J14
*
251
256
253
254
255
R4
R3 WIRE SPEED
ARC VOLTAGE
+
-
P2
JUMPER
T1
N.E.
N.C.
N.C. THERMOSTATS MOUNTED ON CHOKE COIL
N.D. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET
N.E. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.N.C.
N.D.
SPI TEST252
266
267
325
324
2
1
2
204
POWER-ONINDICATOR
P.M.GEARBOXMOTOR/
GUNTRIGGER
R.F. FILTER
203 207 N.B.
541
515B
555
206B
539B
B
U
R
W
W
B
2-5-93
L9078
TOSPOOL GUN
OPTION
G-3R
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
C
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
G-4ELECTRICAL DIAGRAMS
WIRE-MATIC 250
Wiring Diagram (208/230) Code 9800
GENERAL INFORMATION
COLOR CODE:
B - BLACKW - WHITE
THERMOSTAT
202
204A
203
204
208G1
X2
X1
G2209
SCR 1250V470A
SCR HEATSINKASBLY
SCR 2250V470A
C1 C2 C3 C4
+ + + +
POWER TRANSFORMER
L1
L2
GND
TO SINGLE PHASESUPPLY LINE
TO GROUND PER
CODE
207
206
OUTPUTCHOKE
NOTESN.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
CURRENT AND DUTY CYCLE OF IMMEDIATE ANDFUTURE APPLICATIONS.
N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
D1300V85A
* INDICATES CONNECTOR CAVITY NO.
ELECTRICAL SYMBOLS PER E1537
OFF AND REVERSE LEAD CONNECTIONS AT CABLECONDUCTOR STRAP AND WORK STUD.
NATIONAL ELECTRICAL
C1 THRU C430,000 MFD50V
320
THERMOSTATS3 S4
"POSITIVE". TO CHANGE POLARITY, TURN THE UNIT
.
R - REDU - BLUE
X3
X4
X5
X6
X7
15 OHMS100 WR
1
1-
31-9
2
L8
82
8
12345678
1 2 3 4 5 6 7 8
SP - 250
1 2 3 4 5 6 7 8
555
GASSOLENOID
**
*
(J4)
CONTROL BOARD
1 2 3 4
* 1234
*(J7)(J8)
515
541A
495
542
543
(J11)
(J12)
123
*
1 2 3 4 5 6
*
(J9)
209
208
204A
204
207206
GNDG1
G2
320
1
2345
6789
101112
(J3)
*
515
541A
495
542
543
541B321
539B322
123456789
10111213141516
*
123456789
1011121314
*(J5)
(J6)
324
206S
205
325A
324A
206A
206B515B325
539541
325A
SPOOL GUNMODULE
67845910
324B
325B
325A
324A
206A
TACH
P.M.
TOWORK
N.A.
207206 N.B.
R.F. FILTER
1
3
2
4
5
6
539
541
555
539
555
541
515B
206B
515B
206B
GND
202
203
325A
(COMPONENT SIDE OF P.C. BOARD)
1 4
5 8
1J4
J71 2
3 4
1 3
4 6
CAVITY NUMBERING SEQUENCE
J31
6 10
5
J12
J8
J5 J6
6
7 12
1 7 1 8
9 168 14
205
206S
+-
SHUNT
R.F. CHOKE AS'BLY.
328
S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TOPOWER TRANSFORMER.
J2J1
J11J14
J9J10
4
SCI TESTPLUG
260262261263265264266267
}123456789
10
123456
}}
*
*
PLUG
J10
J2
J1
254252253255251256
OPTIONAL TIMERBOARD
1 2 3 4 5 6 7 8
260
262
261
263
265
264
}J14
*
251
256
253
254
255
R4
R3 WIRE SPEED
ARC VOLTAGE
+
-
ABCDEF
541B539B322321325B324B
GND
(J13)
OPTIONAL SPOOL OR PULL GUNRECEPTACLE
N.C. THERMOSTATS MOUNTED ON CHOKE COIL
N.D. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET
N.E. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.N.C.
N.D.
SPI TEST252
266
267
325
324
2
1
2GUNTRIGGER
204
POWER-ONINDICATOR
H1
T1
L1 L2
H1
LINESWITCH
S1
H1
H4H4
H3
H5H2P2
L1
GND. RECONNECT PANEL
P2T1
FANMOTORS
T2P1 P2
S2THERMOSTAT
N.C.
L2
R22.5K10W
G
N.E.
5
1 3
4 2
H4
H5
H2
H2 21/32 31/32 61/64 1/2 63/64 ð
H3
H1
(SHOWN CONNECTEDFOR 230 VOLT.)
MOTOR/GEARBOX
541
515B
555
539
206B
WR
U
BB
G-4R
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
C
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
G-5ELECTRICAL DIAGRAMS
WIRE-MATIC 250
Wiring Diagram (208/230) Code 9799
GENERAL INFORMATION
COLOR CODE:
B - BLACKW - WHITE
THERMOSTAT
202
204A
203
204
208G1
X2
X1
G2209
SCR 1250V470A
SCR HEATSINKASBLY
SCR 2250V470A
C1 C2 C3 C4
+ + + +
POWER TRANSFORMERH3
H2
H1
L1 L2
H1
LINESWITCH
S1
H2 H3L1
GND. RECONNECT PANEL
L1
L2
GND
TO SINGLE PHASESUPPLY LINE
TO GROUND PER
CODE
P2T1
FANMOTORS
T2P1 P2
S2THERMOSTAT
207
206
OUTPUTCHOKE
NOTESN.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
CURRENT AND DUTY CYCLE OF IMMEDIATE ANDFUTURE APPLICATIONS.
N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
D1300V85A
* INDICATES CONNECTOR CAVITY NO.
ELECTRICAL SYMBOLS PER E1537
OFF AND REVERSE LEAD CONNECTIONS AT CABLECONDUCTOR STRAP AND WORK STUD.
NATIONAL ELECTRICAL
H4
LOW V.
L2
HIGH V.
C1 THRU C430,000 MFD50V
H1
H2
H3
H1
H4
320
THERMOSTATS3 S4
R2
"POSITIVE". TO CHANGE POLARITY, TURN THE UNIT
.
R - REDU - BLUE
2.5K10W
GX3
X4
X5
X6
X7
15 OHMS100 WR
1
1-
31-9
2
8651
L
12345678
1 2 3 4 5 6 7 8
SP - 250
1 2 3 4 5 6 7 8
555
GASSOLENOID
**
*
(J4)
CONTROL BOARD
1 2 3 4
* 1234
*(J7)(J8)
515
541A
495
542
543
(J11)
(J12)
123
*
1 2 3 4 5 6
*
(J9)
209
208
204A
204
207206
GNDG1
G2
320
1
2345
6789
101112
(J3)
*
515
541A
495
542
543
541B321
539B322
123456789
10111213141516
*
123456789
1011121314
*(J5)
(J6)
324
206S
205
325A
324A
206A
206B515B325
539541
325A
SPOOL GUNMODULE
67845910
324B
325B
325A
324A
206A
TACH
TOWORK
N.A.
1
3
2
4
5
6
539
541
555
539
555
541
515B
206B
515B
206B
GND
202
203
325A
(COMPONENT SIDE OF P.C. BOARD)
1 4
5 8
1J4
J71 2
3 4
1 3
4 6
CAVITY NUMBERING SEQUENCE
J31
6 10
5
J12
J8
J5 J6
6
7 12
1 7 1 8
9 168 14205
206S
+-
SHUNT
R.F. CHOKE AS'BLY.
328
S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TOPOWER TRANSFORMER.
J2J1
J11J14
J9J10
4
SCI TESTPLUG
260262261263265264266267
}123456789
10
123456
}}
*
*
PLUG
J10
J2
J1
254252253255251256
OPTIONAL TIMERBOARD
1 2 3 4 5 6 7 8
260
262
261
263
265
264
}J14
*
251
256
253
254
255
R4
R3 WIRE SPEED
ARC VOLTAGE
+
-
ABCDEF
541B539B322321325B324B
GND
(J13)
OPTIONAL SPOOL OR PULL GUNRECEPTACLE
P2
JUMPER
T1
N.E.
N.C.
N.C. THERMOSTATS MOUNTED ON CHOKE COIL
N.D. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET
N.E. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.N.C.
N.D.
SPI TEST252
266
267
325
324
2
1
2
204
POWER-ONINDICATOR
P.M.GEARBOXMOTOR/
GUNTRIGGER
R.F. FILTER
203 207 N.B.
541
515B
555
206B
539B
B
U
R
W
W
B
G-5R
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
C
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
G-6ELECTRICAL DIAGRAMS
WIRE-MATIC 250
Control PC Board (G2332) Schematic
J37
204G1
H11C
4O
CI2
215
64
562
R173
10K
R163
562
R167
562
R174
40V
600m
AQ
40
40V
600m
AQ
41
J36
X114
1312
50V
0.1C113
+5 V
74H
C37
3
X5
20 10
10K
R176
D
204
X18
910
+15
V
X17
65
562
R168
Vss
Vdd
MC
68H
C11
X6
126
681
R172
2.21
K
R166
G2
B
H11C
4O
CI3
215
64
J35
2.21
K
R177
T1 A
UX.
C
681
R171
X3
14 7
-10
V
50V
0.1C116
50V
0.1C114
74H
C16
5
X8
16 8
204A
202
54H
C13
2A X
1
3
10
J10
8
7
1
5
J2
4
1
6
J1 J4
53
4
203
NONESCALE
T1
SUP'S'D'G.
RESI
STO
RS =
Ohm
s (1
/4W
UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D)
THER
M. L
D. C
ONN.
XA
WIREMATIC 250 CONTROL
G2330
SCHEMATIC
NO.
XM5386
SHT.
J9
41
1
J8J7
2
J3
8 16
1
J5
71
J6
149
8
6
712
1
+5 V
100
R20
3
D110
J2
1
J2
6
J2
9
J2
4
J2
7
J2
5
J2
8
J2
10
J2
3
+15
V+5
V
J2
2
D113
4.75
K
R209
4.75
K
R210
D112
10K
R24
D111
100
R20
4
J7
1
+5 V 54
1A
+5 V
+5 V
541A
+5 V
10K
R25
J7
2
J7
3
D99
TIME
20
10/O
E
2D
5Q 6Q
0D
7Q4Q3Q2Q1Q0Q
Vcc
GN
D
/LE
6D4D 5D1D 3D 7D
74H
C37
3
X5
17
4
12 9 6 5
11
16 12
7
1813
1938
15
14
BURNBACK
2.21
K
R191
511
R189
D98
44.2
K
R188
J12
J14
C118
J16
44.2
K
R190
263
511
R187
C119
D101
SPI INTERFACE
+5 V
+5 V
+5 V
262
264
SCI INTERFACE 206A PU
LL G
UN
STITCHSTITCH
C334.
75K
R71
6.81
K
R77
14
28
D5
A7
D1 D2
A1
GN
D
Vpp
A13
A14
A8
A5 OE
CE
A4A3D
4
A2 A6
A12
A10
D7
A9 A11
D6
A0
D0
D3
Vcc
27C
256
X4
1716
1
13
227
12
20 2710
18
9
11 2321
26325
2
24
5
15
6
19
8 4
.33m
H
L6
1N40
07D1
4
TO O
PTIO
NAL
100
R20
5
1N40
07D1
3
TRIG
GER
325A
324A
100
R20
261
4.7
35V
C21
P8J8
4
1W16V
DZ2
D34
475K
R67
1.00
K
R62
40V
600m
AQ
12
5.62
K
R68
1.00
K
R63
1W15V
DZ1
1.00
K
R60
1.00
K
R64
100
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600m
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V
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D109
CN
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6
5
18.2
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7
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5
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44.2
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R198
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18.2
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8
44.2
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D106
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254
251
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44.2
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4.75
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6
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52 1.50
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100
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+5 V
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ON 3 PLACE DECIMALS IS + .OO2
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SUBJECT
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FRAM
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ON
NEC
TIO
N
POW
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UPP
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OU
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LY
Ch'ge.Sht.No.
LAB
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VOLT
AGE
NET
GEN
ERAL
INFO
RM
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N
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TH G
RO
UN
D C
ON
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TIO
N
B -
CO
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ON
CO
NN
ECTI
ON
NO
TES
: A CO
MM
ON C
ODE
NUM
BER.
555
-
205
ON 2 PLACE DECIMALS IS + .O2
UNLESS OTHERWISE SPECIFIED TOLERANCEON HOLES SIZES PER E-2056
206B
A
TAC
H33
2
R82
THE LINCOLN ELECTRIC CO.
ELEC
TRIC
AL S
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PER
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537
RED
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CLEVELAND, OHIO U.S.A.TYPEEQUIP.
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0
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7/2/
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A/D
A/D
A/D
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X6
21 43454932 3022 24 23 28194733
7
25 29
8
17 5218
513127
353653910 63841 374 429 401213 1114
20
48 50 16
2 3
15444634
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4.0M
Hz
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2W10
M
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67
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R18
22p
100V
C31
SPOT/4T/OPTIONSPOT/
SWITCHCONT
SENSE SWITCHSTITCHBOARD
TIMEOFF-
ON-TIME
D100
6.81
K
R109
C40
4.75
K
R91D
50
J4
1
J4
5
J4
7
X36
54
33.2
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6
5.62
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4
4.75
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22p
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3
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4
J13
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J92
D80
X11
14
98
TO OPTION BOARD MATERIAL TOLERANCE ("t") TO AGREEWITH PUBLISHED STANDARDS
ON ALL ANGLES IS + .5 OF A DEGREE
FILE
: G23
30_2
CA
THIS
DIA
GRAM
MAY
NOT
SHO
W T
HE E
XACT
COM
PONE
NTS
OR C
IRCU
ITRY
OF
CONT
ROLS
HAV
ING
CIRC
UIT
BOAR
D M
AY C
HANG
E W
ITHO
UT A
FFEC
TING
THE
INTE
RCHA
NGEA
BILI
TY O
F A
COM
PLET
E BO
ARD.
N.A.
SIN
CE C
OMPO
NENT
S OR
CIR
CUIT
RY O
N A
PRIN
TED
C62
V
VINPU
TC
C
EEN
C
OUT
INPU
T
NULL
4
NULL
7
OP27
X22
2
8
36 5
151
1
R127
LAST
NO
. USE
D
19L-
DIO
DES
= 1A
, 400
V (U
NLES
S O
THER
WIS
E SP
ECIF
IED)
CAPS
. = u
fd (.
022/
50V
UNLE
SS O
THER
WIS
E SP
ECIFI
ED)
51.1
K
R131
CHK.
204A
202
CT. A
UX.
T1
DATEMJH
118
D-C-
R-21
2
125
DR. 2/16/93
T1
1-31-922-5-937-2-93E3-25-94E
G-6R
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
CR
etur
n to
Sec
tion
TO
C
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are notavailable from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may resultin danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to S
ectio
n T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
Ret
urn
to M
aste
r T
OC
G-7ELECTRICAL DIAGRAMS
WIRE-MATIC 250
Control PC Board (G2332) Layout
G-7
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are notavailable from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may resultin danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
WM
250
CO
NTR
OL
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