Page 2 - WARNING; SAFETY; ELECTRIC SHOCK can kill.; ARC WELDING can be hazardous.
WARNING i SAFETY i WIRE-MATIC 255 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...
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 255 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 255 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 255 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 255 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 255 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 255 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 255 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-; ning of this chapter for proper wire sizes.; CONNECT SHIELDING GAS; Remove the cylinder cap.
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 255 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 Gas 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 255 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 1. ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHEST NAME- PLATED SINGLE PHASE INPUT VOLTAGE. TO CHANG...
Page 16 - CONNECT OUTPUT COMPONENTS; INSTALL THE WORK CLAMP; 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 255 A-8 WIRE SIZE CONVERSION PARTS The Wire-Matic 255 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 255 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 255. SAFETY INSTRUCTIONS ELE...
Page 21 - POWER SOURCE FEATURES:; Adjustable Flow Regulator - Accomodates CO; or
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: Wire Loading - Adjustable brake spindle mountsReadi-Reel® Adapter, included with WIRE-MATIC 255,or most any 2" (51mm) I.D. wire spool.Accommodating standard 12" (305mm) and 8"(203mm) diameter coils, the spindle’s adjustable brakeprovides appropriat...
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 255 USING THE WIRE DRIVE ROLL The drive roll provided with the WIRE-MATIC 255 hastwo groove...
Page 25 - FEEDING ELECTRODE; Changing the Run In Mode Section.; PROPER WIRE FEEDING
B-6 OPERATION B-6 To mount a 10 to 44 lb. (4.5 to 20 kg) spools: 8”(200mm) [Use K468 Adapter] and 12” (300mm)diameter: 1. Remove the locking collar and the Readi-ReelAdapter (if installed) on the 2 inch (51mm) diame-ter spindle. 2. If using an 8” (200mm) spool, place the K468Adapter on the spindle f...
Page 26 - SETTING IDLE ROLL PRESSURE; Press the gun trigger for several seconds.; OPERATING STEPS; STARTING THE WELDER; Turn power OFF on front panel of Wire-Matic 255.
B-7 OPERATION B-7 SETTING IDLE ROLL PRESSURE The idle roll pressure thumb 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 g...
Page 27 - MAKING A WELD; Turn the POWER SWITCH to ON.; Changing Run In; To stop welding, release the gun trigger and then
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 255 NOTE: Arc starting characteristics may be affectedwhen using the fast run-in mode since...
Page 29 - ACCESSORIES; Other Available 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 255 ACCESSORIES SECTION ....................................... Section C Other Available Magnum 250L Gun and Cable Assembly ..........................................................C-1 Ma...
Page 30 - K672-1 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 The kit includes a spool gun adapter module assemblywith a single connecting plug, a rear gas inlet settingwith hose, a ...
Page 33 - TO MAKE SPOT PLUG WELDS:; Close trigger and hold it closed for length of seam.; DRIVE ROLL KITS; gun tube, liner and two contact tips; K363P READI-REEL ADAPTER; Aluminum Wire Sizes:
C-4 ACCESSORIES C-4 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 35 - MAINTENANCE
MAINTENANCE WIRE-MATIC 255 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 36 - 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 37 - FAN MOTORS; SCR RECTIFIER; CHOKE
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 D-2 MAINTENANCE D-2 Figure D.1 - Component Locations. WIRE-MATIC 255 FAN MOTORS CONTROL PC BOARD MAIN TRANSFORMER SCR RE...
Page 38 - 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 40 - 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.; CLOCKWISE
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 43 - 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 255 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 44 - INPUT LINE VOLTAGE AND MAIN TRANSFORMER
E-1 THEORY OF OPERATION E-1 WIRE-MATIC 255 INPUT LINE VOLTAGE AND MAIN TRANSFORMER The desired single phase input power is connected tothe WIRE-MATIC 255 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 45 - SCR; OUTPUT RECTIFICATION AND FEEDBACK
E-2 THEORY OF OPERATION E-2 WIRE-MATIC 255 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 46 - CONSTANT VOLTAGE OUTPUT
E-3 THEORY OF OPERATION E-3 WIRE-MATIC 255 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 47 - WIRE DRIVE MOTOR AND FEEDBACK
E-4 THEORY OF OPERATION E-4 WIRE-MATIC 255 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 48 - 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 255 THERMAL PROTECTION A thermostat protects the machine from excessiveoperating ...
Page 49 - 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 255 A silicon controlled rectifier (SCR) is a three terminaldevice used to contro...
Page 51 - 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 255 TROUBLESHOOTING & REPAIR SECTION ........................................................................ Section FHow to use Troubleshooting Guide ...................
Page 52 - 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 255 This Troubleshooting Guide is provided tohelp you locate and repair ...
Page 53 - 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 255 _______________________________ CAUTION: Sometimes machine failures ...
Page 54 - 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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throu...
Page 55 - 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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throu...
Page 57 - 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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throu...
Page 58 - 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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throu...
Page 59 - 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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throu...
Page 60 - 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 255 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throu...
Page 61 - 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 255 TEST DESCRIPTION This test will determine if the correct voltages ...
Page 62 - MAIN TRANSFORMER 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-11 TROUBLESHOOTING & REPAIR F-11 WIRE-MATIC 255 MAIN TRANSFORMER TEST TEST PROCEDURE The ON/OFF POWER SWITCH will ...
Page 63 - 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 255 MAIN TRANSFORMER TEST (CONTINUED) Board.a. Turn the machine OFF be...
Page 65 - 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 255 STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED) TEST PROCEDURE 1. D...
Page 66 - 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 255 STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED) NOTE: DO NOT DISASS...
Page 67 - 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 255 ACTIVE SCR RECTIFIER ASSEMBLY TEST TEST DESCRIPTION The Active SCR...
Page 69 - 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 71 - TEST PROCEDURE; 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 255 TEST PROCEDURE NOTE: POLARITY MUST BE OBSERVED FOR THESE TESTS. Te...
Page 72 - 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 255 4. Test for 2 - 25 VDC between leadplug location 12J5 #539(B) (pos...
Page 73 - 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 255 This is a typical DC output voltage wave-form generated from a pro...
Page 74 - 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 255 This is a typical DC output voltage wave-form generated from a pro...
Page 75 - 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 255 This is NOT a typical DC output voltagewaveform. One output SCR is...
Page 76 - 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 255 This is NOT the typical DC output voltagewaveform. The output capa...
Page 77 - 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 255 This is a typical SCR gate pulse voltagewaveform. The machine was ...
Page 78 - 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 79 - 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 255 4. Carefully remove the P.C. Boardfrom the mounting standoffs. See...
Page 81 - 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 255 PROCEDURE 1. Disconnect main input power to themachine. 2. Remove ...
Page 83 - 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 255 PROCEDURE 1. Disconnect lead #208 andTransformer Lead X1 from the ...
Page 89 - 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 255 PROCEDURE See Figure F.16 for fan motor and fanremoval components....
Page 90 - 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 255 FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED) 7. Remove th...
Page 91 - 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 255 INPUT IDLE AMPS AND WATTS WIRE SPEED RANGE OPEN CIRCUIT VOLTAGE RE...
Page 95 - 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 255 Wiring Diagram (208/230) Code 10166 G E N E R A L I N F O R M A T I O N C O L O R...
