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WIRE-MATIC 255
VOLTS WIRE SPEED
RETURN TO MAIN INDEX
SVM 119-A
January 1996
WIRE-MATIC 255
For use with machines having Code Numbers: 10166,
10167.
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 20
18 22
300
16 24 250 350
200
14 26 400
150 450
... and thoughtful operation on 28
100 500
550
50
600
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
1
ON
EQUIPMENT WITHOUT
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i i SAFETY ARC WELDING can be hazardous. WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. 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 you purchase 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
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ii ii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 4.a. Remove fire hazards from the welding area. 5.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hoses
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iii iii SAFETY FOR ENGINE ELECTRIC AND MAG- powered equipment. NETIC FIELDS 7.a. Turn the engine off before troubleshooting and maintenance may be dangerous work unless the maintenance work requires it to be running. ____________________________________________________ 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and 7.b. Operate engines in open, well-ventilated welding machine
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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NOTES WIRE-MATIC 255 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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v v RETURN TO MAIN INDEX TABLE OF CONTENTS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Select Proper L
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vi vi RETURN TO MAIN INDEX TABLE OF CONTENTS (continued) Page Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E Power Supply Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5 SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6 Troubleshooting and Repair .
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INSTALLATION TABLE OF CONTENTS - INSTALLATION SECTION - INSTALLATION SECTION ........................................ Section A Technical Specifications ...................................................A-1 Safety Precautions ...........................................................A-2 Select Proper Location.....................................................A-2 Stacking.......................................................................A-2 Tilting ........................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Wire-Matic-255 INPUT - SINGLE PHASE/ 60 HERTZ ONLY Standard Voltage Input Current at Rated Output 208/230/1/60 53/49 Amps 230/460/575 50/25/20 Amps RATED OUTPUT Duty Cycle Amps Volts at Rated Amps 100% 145 amps 26 60% 200 amps 28 35% 250 amps 26 OUTPUT Current Range Maximum Open Circuit Voltage Wire Speed Range 30A - 250A 40V 50 - 600 IPM (1.27-15.2 m./minute) RECOMMENDED INPUT WIRE & FUSE SIZE 0 0 Input Voltage/ Fuse (Superlag) Type 75 C wire i
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A-2 A-2 INSTALLATION Read entire Installation Section before installing INPUT CONNECTIONS the WIRE-MATIC 255 WARNING SAFETY PRECAUTIONS All input power must be electrically WARNING disconnected before proceeding. ELECTRIC SHOCK can kill. • Only qualified personnel should install this machine. ____________________________________ • Turn the input power OFF at the dis- 1. Before starting the installation, check with the local connect switch or fuse box before power company to determine if there i
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A-3 A-3 INSTALLATION b. Fuse the two hot lines of the receptacle with FUSE AND WIRE SIZES super lag type fuses as shown in Figure A.2. A green wire in the input cord connects this ter- Protect the input circuit with the super lag fuses or minal to the frame of the welder. This ensures delay type circuit breakers listed on the Technical proper grounding of the welder frame when the Specifications page of this manual for the machine welder plug is inserted into the receptacle. being used. The t
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A-4 A-4 INSTALLATION For the 230/460/575V/ 60 HZ model which is not WARNING equipped with a plug, an input cord, or a receptacle, the input power supply leads must be connected Gas under pressure is explosive. directly to the Reconnect Panel as shown in Figure Always keep gas cylinders in an A.3. Refer to Technical Specifications at the begin- upright position and always keep ning of this chapter for proper wire sizes. chained to undercarriage or sta- tionary Y support. See American 1. Strip 1
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A-5 A-5 INSTALLATION 7. Attach the flow regulator to the cylinder valve and tighten the union nut(s) securely with a wrench. a. NOTE: If connecting the flow regulator to 100% CO2 cylinder, insert the regulator adapter between the regulator and cylinder valve. If adapter is equipped with a plastic washer, be sure it is seated properly to con- nect to the CO2 cylinder. 8. Connect one end of the inlet gas hose to the outlet fitting of the flow regulator. 9. Connect the other end of the inlet gas
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A-6 A-6 INSTALLATION ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHER OF THE TWO INPUT VOLTAGES LISTED ON THE NAMEPLATE. TO CHANGE VOLTAGE CONNECTION PROCEED AS FOLLOWS: 1. REMOVE THE OUTER STEEL HEX NUT FROM THE TERMINAL WHERE THE TRANSFORMER INPUT LEAD IS CONNECTED. 2. SHIFT THE TRANSFORMER INPUT LEAD TO THE TERMINAL THAT THE UNIT IS TO OPERATE ON AND FASTEN SECURELY WITH THE HEX NUT REMOVED IN STEP1. (MAKE CERTAIN THAT BRASS NUTS ARE TIGHT.) FIGURE A.5 - Reconnect Diagram
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A-7 A-7 INSTALLATION GUN LINER AND CONTACT TIP CONNECT OUTPUT COMPONENTS INSTALLATION INSTALL THE WORK CLAMP The Magnum 250L gun and cable provided with the WIRE-MATIC 255 is factory installed with a liner for a Attach the work clamp to the cable which extends from .035-.045” (0.9-1.2mm) diameter electrode and an the front of the machine using the following procedure: .035” (0.9mm) contact tip. 1. Insert the lug on the end of the work cable through 1. If a .045” diameter wire size is to be used,
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A-8 A-8 INSTALLATION 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 WARNING Turn the welder Power Switch OFF before chang- ing output connection. ____________________________________ 1. Lay the cable out straight. 2. Locate the knurled thumb screw on conductor block inside wire feed compartment. Unscrew it until the tip of the sc
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NOTES WIRE-MATIC 255 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
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OPERATION TABLE OF CONTENTS - OPERATION SECTION - OPERATION SECTION ............................................ Section B Safety Instructions............................................................B-1 General Description..........................................................B-1 Recommended Processes and Equipment......................B-2 Design Features and Advantages....................................B-2 Unit Features...............................................................B-2 Po
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B-1 B-1 OPERATION Read and understand this entire section before operat- CAUTION ing your WIRE-MATIC 255. When using a Wire-Matic 255 power source there SAFETY INSTRUCTIONS will be a small spark if the electrode contacts the work or ground within several seconds after WARNING releasing the trigger. ____________________________________ ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals GENERAL DESCRIPTION or internal wiring. The WIRE-MATIC 255 is a complete s
