Page 2 - SAFETY; ELECTRIC SHOCK can kill.; WARNING; ARC WELDING can be hazardous.
i SAFETY i WIRE-MATIC 250 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 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 followi...
Page 3 - ii
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...
Page 4 - iii
iii SAFETY iii WIRE-MATIC 250 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 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 create...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv WIRE-MATIC 250 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les p...
Page 6 - NOTES
NOTES WIRE-MATIC 250 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 7 - TABLE OF CONTENTS; RETURN TO MAIN INDEX
v Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . ...
Page 9 - INSTALLATION
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION WIRE-MATIC 250 INSTALLATION SECTION ........................................ Section A Technical Specifications ...................................................A-1Safety Precautions .................
Page 10 - RATED OUTPUT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC WIRE-MATIC 250 Duty Cycle Amps Volts at Rated Amps 100% 145 amps 26 60% 200 amps 28 35% 250 amps 26 Current Range Maximu...
Page 11 - SAFETY PRECAUTIONS; • Only qualified personnel should; SELECT PROPER LOCATION; INPUT CONNECTIONS; Reconnect Section of this manual for
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Read entire Installation Section before installingthe WIRE-MATIC 250 SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only ...
Page 12 - FUSE AND WIRE SIZES; Use proper wire sizes. See the; Technical; CAUTION
A-3 INSTALLATION 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 Technical Specifications page of this manual for the machinebeing used. The tripping action of delay type circuitbreakers decreases as the magnitude ...
Page 13 - Technical Specifications at the begin-; CONNECT SHIELDING GAS; Accessories Section of this manual.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC A-4 INSTALLATION WIRE-MATIC 250 A-4 For the 230/460/575V/ 60 HZ model which is notequipped with a plug, an input cord, o...
Page 14 - cylinder, insert the regulator; FIGURE A.4 - Input Air Supply Connections; RECONNECT PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC A-5 INSTALLATION WIRE-MATIC 250 A-5 7. Attach the flow regulator to the cylinder valve andtighten the union nut(s) secur...
Page 15 - INPUT LEAD IS CONNECTED.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC A-6 INSTALLATION WIRE-MATIC 250 A-6 FIGURE A.5 - Reconnect Diagram For 208/230/1/60 Machines. FIGURE A.6 - Reconnect Dia...
Page 16 - Fasten work cable using the bolt and nut provided.; OUTPUT POLARITY CONNECTION; b Be sure the nozzle insulator is fully screwed
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC CONNECT OUTPUT COMPONENTS INSTALL THE WORK CLAMP Attach the work clamp to the cable which extends fromthe front of the m...
Page 17 - WIRE SIZE CONVERSION PARTS; Lay the cable out straight.
A-8 INSTALLATION 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...
Page 19 - OPERATION
OPERATION WIRE-MATIC 250 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION SECTION ............................................ Section B Safety Instructions ............................................................B-1General Description...............
Page 20 - SAFETY INSTRUCTIONS; GENERAL DESCRIPTION; Keep your head out of fumes.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC B-1 OPERATION B-1 Read and understand this entire section before operat-ing your WIRE-MATIC 250. SAFETY INSTRUCTIONS ELE...
Page 21 - POWER SOURCE FEATURES:
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC POWER SOURCE FEATURES: 10 Ft. (3.0m) Input Power Cable - Includes plug andmating receptacle for 208/230V unit. Convenien...
Page 22 - WIRE FEEDER FEATURES:; MACHINE CAPABILITY; Duty Cycle
B-3 OPERATION B-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) d...
Page 23 - CONTROLS AND SETTINGS; Toggle switch to turn input; LINCOLN
B-4 OPERATION B-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 input power ON and OFF. Place the lever in the ONposition to tu...
Page 24 - USING THE WIRE DRIVE ROLL; Turn POWER SWITCH to OFF.; LOADING THE WIRE REEL
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC B-5 OPERATION B-5 WIRE-MATIC 250 USING THE WIRE DRIVE ROLL The drive roll provided with the WIRE-MATIC 250 hastwo groove...
Page 25 - FEEDING ELECTRODE; Changing the Run In; PROPER WIRE FEEDING
B-6 OPERATION B-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 depressing the retaining spring tab with thumb while pullingthe Readi-Reel cage from the molded adapter withboth hands. Do not remove ...
Page 26 - SETTING IDLE ROLL PRESSURE; Press the gun trigger for several seconds.; OPERATING STEPS; STARTING THE WELDER; ENTER FAST RUN-IN MODE; Close the gun trigger and turn the POWER
B-7 OPERATION B-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 ge...
Page 27 - MAKING A WELD; Turn the POWER SWITCH to ON.; Changing Run In Mode Section.; nate the possibility of the gas nozzle overheating.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC B-8 OPERATION B-8 WIRE-MATIC 250 NOTE: The unit will remember the run-in mode fromthe previous power down and return you...
Page 29 - ACCESSORIES; Replacement Magnum 250L Gun and
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ACCESSORIES WIRE-MATIC 250 ACCESSORIES SECTION ....................................... Section C Replacement Magnum 250L Gun and Cable Assembly ..........................................................C-1 K607-1...
Page 30 - K607-1 SPOOL GUN ADAPTER KIT; LENGTH
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC C-1 ACCESSORIES C-1 * Included with the K578-1. K607-1 SPOOL GUN ADAPTER KIT The K607-1 Spool Gun Adapter Kit provides &...
Page 31 - Locate the panel receptacle lead harness included
C-2 ACCESSORIES C-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 ...
Page 32 - Fasten the panel receptacle to the case with the
C-3 ACCESSORIES C-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 the three #6-32 x 3/8" self tapping screws provid...
Page 33 - SPOOL GUN PREPARATION
C-4 ACCESSORIES C-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 (re...
Page 36 - TO MAKE SPOT PLUG WELDS:; Close trigger and hold it closed for length of seam.; DRIVE ROLL KITS; Aluminum Wire Sizes:
C-7 ACCESSORIES C-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 pu...
Page 37 - MAINTENANCE
MAINTENANCE WIRE-MATIC 250 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC MAINTENANCE SECTION ...................................... Section D Safety Precautions ...........................................................D-1Routine and Periodic Maintenance .....
Page 38 - Perform the following daily:
D-1 MAINTENANCE D-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. _________...
Page 40 - DRIVE ROLLS AND GUIDE TUBES; Remove the contact tip from the gun.; GUN TUBES AND NOZZLES; Replace worn contact tips as required.
D-3 MAINTENANCE D-3 DRIVE ROLLS AND GUIDE TUBES After every coil of wire, inspect the wire drive mecha-nism. Clean it as necessary by blowing with low pres-sure compressed air. Do not use solvents for cleaningthe idle roll because it may wash the lubricant out ofthe bearing. All drive rolls are stam...
Page 42 - 2 Remove any burrs from the end of the liner.; GUN HANDLE DISASSEMBLY; To open up the handle:; Pull the collar off the gun handle.
D-5 MAINTENANCE D-5 12 Remove any burrs from the end of the liner. 13. Screw the gas diffuser onto the end of the gun tube and tighten. NOTE: Be sure the gas diffuser is correct for the linerbeing used. (See table and diffuser stencil.) 14. Slightly tighten the set screw in the side of the gas diffu...
Page 45 - THEORY OF OPERATION; NOTE: Unshaded areas of Block Logic
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC THEORY OF OPERATION WIRE-MATIC 250 Figure E.1 -Block Logic Diagram NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion THEORY OF OPERATION SECTION ...................... Section E Power Supp...
Page 46 - INPUT LINE VOLTAGE AND MAIN TRANSFORMER
E-1 THEORY OF OPERATION E-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 ...
Page 47 - SCR; OUTPUT RECTIFICATION AND FEEDBACK
E-2 THEORY OF OPERATION E-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 t...
Page 48 - CONSTANT VOLTAGE OUTPUT
E-3 THEORY OF OPERATION E-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 ...
Page 49 - WIRE DRIVE MOTOR AND FEEDBACK
E-4 THEORY OF OPERATION E-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 t...
Page 50 - THERMAL PROTECTION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC E-5 THEORY OF OPERATION E-5 WIRE-MATIC 250 THERMAL PROTECTION A thermostat protects the machine from excessiveoperating ...
Page 51 - SCR OPERATION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC E-6 THEORY OF OPERATION E-6 WIRE-MATIC 250 A silicon controlled rectifier (SCR) is a three terminaldevice used to contro...
Page 53 - TROUBLESHOOTING & REPAIR; Replacement Procedures
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR WIRE-MATIC 250 TROUBLESHOOTING & REPAIR SECTION ........................................................................ Section FHow to use Troubleshooting Guide ...................
Page 54 - HOW TO USE TROUBLESHOOTING GUIDE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-1 TROUBLESHOOTING & REPAIR F-1 WIRE-MATIC 250 This Troubleshooting Guide is provided tohelp you locate and repair ...
Page 55 - PC BOARD TROUBLESHOOTING PROCEDURES
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-2 TROUBLESHOOTING & REPAIR F-2 WIRE-MATIC 250 _______________________________ CAUTION: Sometimes machine failures ...
Page 56 - OUTPUT PROBLEMS; Perform; Main Transformer
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-3 TROUBLESHOOTING & REPAIR F-3 WIRE-MATIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throu...
Page 57 - Perform the
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-4 TROUBLESHOOTING & REPAIR F-4 WIRE-MATIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throu...
Page 59 - FUNCTION PROBLEMS; SCR Rectifier
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-6 TROUBLESHOOTING & REPAIR F-6 WIRE-MATIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throu...
Page 60 - WIRE FEEDING PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-7 TROUBLESHOOTING & REPAIR F-7 WIRE-MATIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throu...
Page 61 - WELDING PROBLEMS; Check for rusty or dirty wire.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-8 TROUBLESHOOTING & REPAIR F-8 WIRE-MATIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throu...
Page 62 - The arc striking is poor.; Output Rectifier
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-9 TROUBLESHOOTING & REPAIR F-9 WIRE-MATIC 250 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throu...
Page 63 - TEST DESCRIPTION; This test will determine if the correct voltages are being:; MATERIALS NEEDED
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-10 TROUBLESHOOTING & REPAIR F-10 WIRE-MATIC 250 TEST DESCRIPTION This test will determine if the correct voltages ...
Page 64 - TEST PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-11 TROUBLESHOOTING & REPAIR F-11 WIRE-MATIC 250 MAIN TRANSFORMER TEST (CONTINUED) TEST PROCEDURE The ON/OFF POWER ...
Page 65 - Test for correct nameplate input volt-
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-12 TROUBLESHOOTING & REPAIR F-12 WIRE-MATIC 250 MAIN TRANSFORMER TEST (CONTINUED) a. Turn the machine OFF betweene...
Page 67 - STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED)
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-14 TROUBLESHOOTING & REPAIR F-14 WIRE-MATIC 250 STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED) TEST PROCEDURE 1. D...
Page 68 - Reconnect leads X2 and X3.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-15 TROUBLESHOOTING & REPAIR F-15 WIRE-MATIC 250 STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED) NOTE: DO NOT DISASS...
Page 69 - ACTIVE SCR RECTIFIER ASSEMBLY TEST
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-16 TROUBLESHOOTING & REPAIR F-16 WIRE-MATIC 250 ACTIVE SCR RECTIFIER ASSEMBLY TEST TEST DESCRIPTION The Active SCR...
Page 71 - ACTIVE SCR RECTIFIER ASSEMBLY TEST (CONTINUED)
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ACTIVE SCR RECTIFIER ASSEMBLY TEST (CONTINUED) 7. Connect the Tester to the SCR 1 asshown in Figure F.7. a. Connect Test...
Page 73 - MUST; WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (CONTINUED)
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-20 TROUBLESHOOTING & REPAIR F-20 WIRE-MATIC 250 TEST PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. Te...
Page 74 - Pull the gun trigger.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-21 TROUBLESHOOTING & REPAIR F-21 WIRE-MATIC 250 4. Test for 2 - 25 VDC between lead#539 (positive) (8J5) and lead ...
Page 75 - SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-22 TROUBLESHOOTING & REPAIR F-22 WIRE-MATIC 250 This is a typical DC output voltage wave-form generated from a pro...
Page 76 - TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-23 TROUBLESHOOTING & REPAIR F-23 WIRE-MATIC 250 This is a typical DC output voltage wave-form generated from a pro...
Page 77 - ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-24 TROUBLESHOOTING & REPAIR F-24 WIRE-MATIC 250 This is NOT a typical DC output voltagewaveform. One output SCR is...
Page 78 - ABNORMAL OPEN CIRCUIT VOLTAGE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-25 TROUBLESHOOTING & REPAIR F-25 WIRE-MATIC 250 This is NOT the typical DC output voltagewaveform. The output capa...
Page 79 - TYPICAL SCR GATE VOLTAGE WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-26 TROUBLESHOOTING & REPAIR F-26 WIRE-MATIC 250 This is a typical SCR gate pulse voltagewaveform. The machine was ...
Page 80 - CONTROL PC BOARD REMOVAL AND REPLACEMENT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Printed Circuit Boards can be damaged by static electricity. Follow static handlingguidelines detailed in “PC Board Trou...
Page 81 - Lift the Control Board straight up; CONTROL PC BOARD REMOVAL AND REPLACEMENT (CONTINUED)
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-28 TROUBLESHOOTING & REPAIR F-28 WIRE-MATIC 250 4. Remove the eight Phillips Headmounting screws using a PhillipsH...
Page 83 - PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-30 TROUBLESHOOTING & REPAIR F-30 WIRE-MATIC 250 PROCEDURE 1. Disconnect main input power to themachine. 2. Remove ...
Page 85 - Cut any necessary cable ties.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-32 TROUBLESHOOTING & REPAIR F-32 WIRE-MATIC 250 PROCEDURE 1. Disconnect lead #208 andTransformer Lead X1 from the ...
Page 91 - Remove the Case Back screws.; FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED)
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-38 TROUBLESHOOTING & REPAIR F-38 WIRE-MATIC 250 PROCEDURE See Figure F.16 for fan motor and fanremoval components....
Page 92 - Remove the fan motor.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-39 TROUBLESHOOTING & REPAIR F-39 WIRE-MATIC 250 FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED) 7. Remove th...
Page 93 - INPUT IDLE AMPS AND WATTS; Maximum Idle Watts
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC F-40 TROUBLESHOOTING & REPAIR F-40 WIRE-MATIC 250 INPUT IDLE AMPS AND WATTS WIRE SPEED RANGE OPEN CIRCUIT VOLTAGE RE...
Page 97 - ELECTRICAL DIAGRAMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ELECTRICAL DIAGRAMS G-2 WIRE-MATIC 250 Wiring Diagram (230/460/575) Code 10004 G E N E R A L I N F O R M A T I O N C O L...
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