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SVM 119-A
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January 1996

WIRE-MATIC 255
View Safety Info

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
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VOLTS
increased by proper installation 16
18 20 22
24
WIRE SPEED

250 300 350

View Safety Info

200
... and thoughtful operation on 14 26
28 150
100
400
450
500

your part. DO NOT INSTALL, 50 550

600

OPERATE OR REPAIR THIS WIRE-MAT

IC 255
EQUIPMENT WITHOUT READ- 1 ON

ING THIS MANUAL AND THE 0

OFF

SAFETY PRECAUTIONS CON-

TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
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View Safety Info

SERVICE MANUAL
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View Safety Info

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
 i i
Return to Master TOC SAFETY
WARNING ARC WELDING can be hazardous.

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. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln 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.

ELECTRIC SHOCK can kill. ARC RAYS can burn.

1.a. The electrode and work (or ground) circuits 2.a. Use a shield with the proper filter and cover
are electrically “hot” when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot” parts with your bare the rays of the arc when welding or observing
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skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.

1.b. Insulate yourself from work and ground using dry insulation. 2.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.

In addition to the normal safety precautions, if welding 2.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
• Semiautomatic DC Constant Voltage (Wire) Welder. 3.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
1.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
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electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
1.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
1.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
1.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
3.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
1.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating
products.
1.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
3.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
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especially in confined areas, to insure breathing air is safe.

1.i. When working above floor level, use a safety belt to protect
3.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
1.j. Also see Items 4.c. and 6.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

3.e. Also see item 7b.

Apr. ‘93
WIRE-MATIC 255
 ii ii
Return to Master TOC SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
4.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 5.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.

4.b. Where compressed gases are to be used at the job site, 5.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 5.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
4.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can • A safe distance from arc welding or cutting operations and
cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
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4.d. Do not heat, cut or weld tanks, drums or containers until the 5.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 5.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 5.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
5.g. Read and follow the instructions on compressed gas
4.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
4.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a FOR ELECTRICALLY
welding area. powered equipment.
4.g. Connect the work cable to the work as close to the welding
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6.a. Turn off input power using the disconnect

area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
6.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
4.h. Also see item 7c.
6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Feb. ‘95
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WIRE-MATIC 255
 iii iii
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FOR ENGINE ELECTRIC AND MAG-
powered equipment. NETIC FIELDS
7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
may be dangerous
____________________________________________________
8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
7.b. Operate engines in open, well-ventilated current creates EMF fields around welding cables and
areas or vent the engine exhaust fumes welding machines
outdoors.
8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
____________________________________________________ before welding.

8.c. Exposure to EMF fields in welding may have other health

7.c. Do not add the fuel near an open flame effects which are now not known.
welding arc or when the engine is run-
ning. Stop the engine and allow it to cool 8d. All welders should use the following procedures in order to
before refueling to prevent spilled fuel minimize exposure to EMF fields from the welding circuit:
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from vaporizing on contact with hot

engine parts and igniting. Do not spill 8.d.1. Route the electrode and work cables together - Secure
fuel when filling tank. If fuel is spilled, them with tape when possible.
wipe it up and do not start engine until
fumes have been eliminated. 8.d.2. Never coil the electrode lead around your body.

____________________________________________________ 8.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
7.d. Keep all equipment safety guards, covers side, the work cable should also be on your right side.
and devices in position and in good repair.
Keep hands, hair, clothing and tools away 8.d.4. Connect the work cable to the workpiece as close as
from V-belts, gears, fans and all other possible to the area being welded.
moving parts when starting, operating or
repairing equipment. 8.d.5. Do not work next to welding power source.

____________________________________________________
Mar. ‘93
7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
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guards only when necessary and replace them when the

maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.

7.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

___________________________________________________

7.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
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hot.

WIRE-MATIC 255
 iv iv
Return to Master TOC SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 6. Eloigner les matériaux inflammables ou les recouvrir afin de
et les précautions de sûreté specifiques qui parraissent dans ce prévenir tout risque d’incendie dû aux étincelles.
manuel aussi bien que les précautions de sûreté générales suiv-
antes: 7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
Sûreté Pour Soudage A L’Arc échauffement et un risque d’incendie.
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible de
a. Les circuits à l’électrode et à la piéce sont sous tension la zone de travail qu’il est pratique de le faire. Si on place la
quand la machine à souder est en marche. Eviter toujours masse sur la charpente de la construction ou d’autres endroits
tout contact entre les parties sous tension et la peau nue éloignés de la zone de travail, on augmente le risque de voir
ou les vétements mouillés. Porter des gants secs et sans passer le courant de soudage par les chaines de levage,
trous pour isoler les mains. câbles de grue, ou autres circuits. Cela peut provoquer des
b. Faire trés attention de bien s’isoler de la masse quand on risques d’incendie ou d’echauffement des chaines et des
soude dans des endroits humides, ou sur un plancher met- câbles jusqu’à ce qu’ils se rompent.
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allique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande 9. Assurer une ventilation suffisante dans la zone de soudage.
partie du corps peut être en contact avec la masse. Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble de galvanisées plombées, ou cadmiées ou tout autre métal qui
soudage et la machine à souder en bon et sûr état defonc- produit des fumeés toxiques.
tionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le 10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir. d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
des porte-électrodes connectés à deux machines à soud- du solvant pour produire du phosgéne (gas fortement toxique)
er parce que la tension entre les deux pinces peut être le ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
courant pour soudage semi-automatique, ces precautions le code “Code for safety in welding and cutting” CSA Standard
pour le porte-électrode s’applicuent aussi au pistolet de W 117.2-1974.
soudage.
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2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
PRÉCAUTIONS DE SÛRETÉ POUR
du corps. LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc: REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
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3. Avant de faires des travaux à l’interieur de poste, la debranch-

4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93

WIRE-MATIC 255
 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES

WIRE-MATIC 255
v RETURN TO MAIN INDEX v

TABLE OF CONTENTS
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Select Proper Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Connect Output Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . .B-2
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Machine Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Using the Wire Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Operating Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C
Other Available Magnum 250L Gun and Cable Assembly . . . . . . . . . . . .C-1
Magnum Gun Connection Kit (Optional K466-6) . . . . . . . . . . . . . . . . . . .C-1
K672-1 Spool Gun Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Making a Weld with the Spool Gun Adapter and Spool Gun
(K672-1) Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Making a Weld with the Spool Gun Adapter (K672-1) Installed . . . . . . . .C-2
Timer Kit (K585-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3
Timer Kit Installation (Optional K585-1) . . . . . . . . . . . . . . . . . . . . . . . . . .C-3
Making Spot and Stitch Welds with Timer Kit Installed . . . . . . . . . . . . . . .C-4
Drive Roll Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
3/64” Aluminum Feeding Kit (K673-1) . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
K468 8” Spool Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
K363P Readi-Reel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
Dual Cylinder Mounting (K671-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Drive Rolls and Guide Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Cable Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Gun Tubes and Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Contact Tip and Gas Nozzle Installation . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Liner Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Liner Removal, Installation, and Trimming Instructions for Magnum 250L D-4
Gun Handle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
Accessories and Expendable Replacement Parts for
Magnum 250L Gun and Cable Assemblies . . . . . . . . . . . . . . . . . . . .D-6

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vi RETURN TO MAIN INDEX vi

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

How to use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-10
Oscilloscope Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-22
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-27

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-258

WIRE-MATIC 255
 INSTALLATION
TABLE OF CONTENTS
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- INSTALLATION SECTION -

INSTALLATION SECTION ........................................ Section A

Technical Specifications ...................................................A-1
Safety Precautions ...........................................................A-2
Select Proper Location.....................................................A-2
Stacking.......................................................................A-2
Tilting ...........................................................................A-2
Input Connections ............................................................A-2
Fuse and Wire Sizes ...................................................A-3
Input Power Connections and Ground Connections...A-3
Connect Shielding Gas................................................A-4
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Reconnect Procedure.......................................................A-5
Connect Output Components...........................................A-7
Install the Work Clamp ................................................A-7
Output Polarity Connection .........................................A-7
Gun Liner and Contact Tip Installation........................A-7
Wire Size Conversion Parts ........................................A-8
Gun and Cable Installation..........................................A-8
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WIRE-MATIC 255
 A-1 A-1
INSTALLATION
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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

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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
Input Voltage/ Fuse (Superlag) Type 750C wire in Type 750C Copper
Frequency or Breaker Size Copper conduit AWG Ground Wire in Conduit
(IEC Sizes)
Runs to Runs over
100ft. (30m.) 100ft. (30m.)
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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)
PHYSICAL DIMENSIONS
HEIGHT Width DEPTH WEIGHT
(W/GUN)

28.2” 18.8” 40.1” 220 lbs.

(719mm) (480mm) (1019mm) (100 Kg.)

OPERATING TEMPERATURE
STORAGE OPERATING
± 400C -200C to 400C
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WIRE-MATIC 255
 A-2 A-2
INSTALLATION
Read entire Installation Section before installing INPUT CONNECTIONS
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the WIRE-MATIC 255

SAFETY PRECAUTIONS WARNING

WARNING All input power must be electrically

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 is any ques-
working on the equipment. tion about whether your power supply is adequate
for the voltage, amperes, phase, and frequency
• Do not touch electrically hot parts. specified on the welder nameplate. Be sure the
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planned installation will meet the U.S. National

• Always connect the WIRE-MATIC 255 ground- Electrical Code and local code requirements. This
ing terminal to a good electrical earth ground welder may be operated from a single phase line
through the cable plug per the National or from one phase of a two or three phase line.
Electrical Code.
2. Models that have multiple input voltages specified
• Set the Wire-Matic 255 ON/OFF Power switch to on the nameplate (e.g., 208/230) are shipped con-
the OFF position when connecting power cord nected for the highest voltage. If the welder is to
to input power. be operated at a lower voltage, it must be recon-
____________________________________ nected according to the instructions on the inside
of the removable panel (Reconnect Access Door)
near the top left side of the Case Back Assembly.
SELECT PROPER LOCATION See the Reconnect Section of this manual for
details on reconnecting the machine to operate at
Place the WIRE-MATIC 255 where clean, cooling air different voltages.
can freely circulate in through the case back louvers
and out through the case front louvers. Dirt, dust, or 3. Be sure the voltage, phase, and frequency of the
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any foreign material that can be drawn into the input power is as specified on the machine rating
machine case back louvers should be kept at a mini- plate. See Figure A.1 for the location of the
mum. Not following these precautions can result in the machine's input cord entry, Reconnect Access
nuisance shutdown of the machine because of exces- Door, and Reconnect Panel, and Rear Nameplate.
sive operating temperatures.

STACKING
The WIRE-MATIC 255 cannot be stacked.

TILTING
The Wire-Matic 255 must be placed on a stable, level
surface so it will not topple over. Do not place the
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machine on an incline.

FIGURE A.1 - Case Back Assembly: Input Power

Cable Entry Connections.

WIRE-MATIC 255
 A-3 A-3
INSTALLATION
FUSE AND WIRE SIZES b. Fuse the two hot lines of the receptacle with
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super lag type fuses as shown in Figure A.2. A

Protect the input circuit with the super lag fuses or green wire in the input cord connects this ter-
delay type circuit breakers listed on the Technical minal to the frame of the welder. This ensures
Specifications page of this manual for the machine proper grounding of the welder frame when the
being used. The tripping action of delay type circuit welder plug is inserted into the receptacle.
breakers decreases as the magnitude of the current
increases. They are also called inverse time or ther- 4. Use proper wire sizes. See the Technical
mal/magnetic circuit breakers. Specification table for proper wire sizes. For
cable lengths over 100 feet, larger copper wires
DO NOT use fuses or circuit breakers with a lower amp should be used.
rating than recommended. This can result in "nui-
sance" tripping caused by inrush current even when
machine is not being used for welding at high output CAUTION
currents.

Use input and grounding wire sizes that meet local Connect to a system grounding wire. See the
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electrical codes or see the Technical Specifications United States National Electrical Code and local
page in this manual. codes for other details and means for proper
grounding.

INPUT POWER CONNECTIONS AND Connect to hot wires of a three-wire, single phase
system or to one phase of a two or three phase
GROUND CONNECTIONS system.
Have a qualified electrician connect the receptacle or
cable to the input power lines and the system ground
____________________________________
according to the U.S. National Electrical Code and any
applicable local codes.

1. Follow the Input Supply Connection Diagram on

the inside of the Reconnect Panel Access Door.

2. Use a single-phase line or one phase of a three-

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phase line.

For the 208V/230V/ 60 HZ model WIRE-MATIC 255

shipped with a 10 ft. input cord and plug connected to
the welder, mount the matching receptacle supplied
with the machine.

1. Mount the receptacle in a suitable location using

the screws provided.
FIGURE A.2. - Ground Connections.
2. Locate the receptacle within reach of the 10 ft.
input cord attached to the welder.

3. Mount the receptacle with the grounding terminal

at the top. This allows the power cable to hang
down without bending. See Figure A.2.
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a. The center terminal in the receptacle is for the

grounding connection.

WIRE-MATIC 255
 A-4 A-4
INSTALLATION
For the 230/460/575V/ 60 HZ model which is not
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equipped with a plug, an input cord, or a receptacle, WARNING

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 1/2" (13mm) of insulation from the input National Standard Z-49.1, “Safety
power supply leads. in Welding and Cutting” published by the American
Welding Society.
2. Connect the input power leads to terminals L1 and
L2 on the Reconnect Panel Assembly. ____________________________________
3. Torque the terminal screws to 16 in.-lbs. (1.8nm). 1. Set the gas cylinder on the rear platform of the
WIRE-MATIC 255.

2. Hook the chain in place to secure cylinder to rear

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of 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,

FIGURE A.3 - Input Power Connection For GREASE OR DAMAGE IS PRESENT! Inform your
230/460/575 Volt Models. gas supplier of this condition. Oil or grease in the pres-
ence of high pressure oxygen is explosive.

CONNECT SHIELDING GAS 5. Stand to one side away from the outlet and open
the cylinder valve for an instant to blow away any
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Customer must provide cylinder of appropriate type of dust or dirt which may have accumulated in the
shielding gas for gas metal arc welding for the process valve outlet.
being used. See Figure A.4 for the location of the com-
ponents used to connect the air supply cylinder. BE SURE TO KEEP YOUR FACE AWAY FROM THE
VALVE 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 an
authorized repair station clean the regulator or repair
any damage.
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WIRE-MATIC 255
 A-5 A-5
INSTALLATION
7. Attach the flow regulator to the cylinder valve and
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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 hose to the

WIRE-MATIC 255 rear fitting.

10. Tighten both the union nuts securely with a

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wrench.

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 stops FIGURE A.4 - Input Gas Supply Connections
moving, open the valve fully.

NEVER STAND DIRECTLY IN FRONT OF OR

BEHIND THE FLOW REGULATOR WHEN OPENING
RECONNECT PROCEDURE
THE CYLINDER VALVE. ALWAYS STAND TO ONE
Multiple voltage machines are shipped connected to
SIDE.
the highest input voltage listed on the machine's rating
plate. Before installing the machine, check that the
13. The flow regulator is adjustable. Adjust the flow
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Reconnect Panel in the Input Box Assembly is con-

regulator for the flow rate recommended for the
nected for the proper voltage.
procedure and process being used before making
the weld.
CAUTION

Failure to follow these instructions can cause

immediate failure of components within the
machine.
___________________________________

To reconnect a dual or triple voltage machine to a dif-

ferent voltage, change the position of the leads or links
on the Reconnect Panel based on the type of
machine. Follow The Input Supply Connection
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Diagram located on the inside of the Case Back

Reconnect 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.

WIRE-MATIC 255
 A-6 A-6
INSTALLATION
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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.)
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FIGURE A.5 - Reconnect Diagram For 208/230/1/60 Machines.

1. ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHEST NAME-
PLATED SINGLE PHASE INPUT VOLTAGE. TO CHANGE CONNECTIONS FOR A DIFFERENT INPUT
VOLTAGE, RECONNECT BOTH COPPER JUMPERS PER DIAGRAM BELOW. ALWAYS CONNECT
JUMPERS BETWEEN OUTER STEEL NUT AND INNER BRASS NUT ON TERMINAL STUDS.
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2. CONNECT THE INPUT POWER TO THE INPUT TERMINAL BLOCK, L1 AND L2 AT THE UPPER COR-
NER OF THE PANEL. TORQUE TO 16 IN-LBS.
3. CONNECT A GROUNDING LEAD TO THE GROUND STUD ( ) ON THE MACHINE NEAR THE TER-
MINAL BLOCK.
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FIGURE A.6 - Reconnect Diagram For 230/460/575/1/60 Machine.

WIRE-MATIC 255
 A-7 A-7
INSTALLATION
CONNECT OUTPUT COMPONENTS GUN LINER AND CONTACT TIP
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INSTALLATION
INSTALL THE WORK CLAMP
The Magnum 250L gun and cable provided with the
Attach the work clamp to the cable which extends from WIRE-MATIC 255 is factory installed with a liner for a
the front of the machine using the following procedure: .035-.045” (0.9-1.2mm) diameter electrode and an
.035” (0.9mm) contact tip.
1. Insert the lug on the end of the work cable through
the strain relief hole in the work clamp handle. See 1. If a .045” diameter wire size is to be used, install
Figure A.7. the .045” contact tip (also provided).

2. Slide the work cable through the hole up to the bolt 2. For other wire sizes, use the following procedure
and nut. for contact tip and gas nozzle installation. See
Figure A.8.
3. Fasten work cable using the bolt and nut provided.
a. Choose the correct size contact tip for the
electrode being used (wire size is stenciled on
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the side of the contact tip) and screw it snugly

into the gas diffuser.

b Be sure the nozzle insulator is fully screwed

onto the gun tube and does not block the gas
holes 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 selected
based on the welding application.

d. Adjust the gas nozzle for the GMAW process

FIGURE A.7 - Installing The Work Clamp. to be used.
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For the short-circuiting transfer process, the contact tip

OUTPUT POLARITY CONNECTION end should be flush to extended to .12" (3.2mm). See
Figure A.8.

WARNING For the spray transfer process, the contact tip should
be flush to recessed .12" (3.2mm). See Figure A.8.
Turn the welder Power Switch OFF before chang-
ing output connection.

____________________________________

The welder is shipped from the factory connected for

electrode positive (+) polarity. This is the normal polar-
ity for GMA welding.

If negative (-) polarity is required, interchange the con-

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nection of the electrode and work cables at the output

terminals located in the wire drive compartment near
the front panel. The electrode cable, which is attached
to the wire drive, is to be connected to the negative (-) FIGURE A.8 - Contact Tip and Electrode
labeled output terminal. The work cable which is Connections.
attached to the work clamp is to be connected to the
positive (+) labeled output terminal.

WIRE-MATIC 255
 A-8 A-8
INSTALLATION
WIRE SIZE CONVERSION PARTS
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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.
____________________________________
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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 screw no longer protrudes into
gun opening as seen from front of machine.

3. Insert the brass connector on the end of the gun

cable into conductor block through opening in the
front panel. Make sure the connector is fully insert-
ed and tighten thumb screw.

4. Connect the gun trigger connector from the gun

and cable to the mating receptacle on the front
panel. Make sure that the keyways are aligned,
insert and tighten retaining ring.
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NOTE: If a gun and cable other than the Magnum

250L is used, it must conform to connector specifica-
tions and the gun trigger switch must be capable of
switching 5 milliamps at 15 volts DC -resistive.

CAUTION
The gun trigger switch connected to the gun trig-
ger control cable must be a normally open,
momentary switch. The terminals of the switch
must be insulated from the Welding circuit.
Improper operation of or damage to the WIRE-
MATIC 255 might result if this switch is common to
an electrical circuit other than the WIRE-MATIC 255
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trigger circuit.
____________________________________

WIRE-MATIC 255
 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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WIRE-MATIC 255
 OPERATION
TABLE OF CONTENTS
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- 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
Power Source Features...............................................B-2
Wire Feeder Features .................................................B-3
Machine Capability ...........................................................B-3
Limitations ........................................................................B-3
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Controls and Settings.......................................................B-4

Using the Wire Drive Roll.................................................B-5
Procedure for Changing Drive Roll .............................B-5
Loading the Wire Reel.................................................B-5
Feeding Electrode .......................................................B-6
Proper Wire Feeding ...................................................B-6
Setting Idle Roll Pressure............................................B-7
Operating Steps ...............................................................B-7
Starting the Welder......................................................B-7
Changing Run-In Mode ...............................................B-7
Enter Slow Run-In Mode.........................................B-7
Enter Fast Run-In Mode .........................................B-7
Making a Weld.............................................................B-8
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WIRE-MATIC 255
 B-1 B-1
OPERATION
Read and understand this entire section before operat-
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ing your WIRE-MATIC 255. CAUTION

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
or internal wiring. GENERAL DESCRIPTION

• Insulate yourself from the work The WIRE-MATIC 255 is a complete semiautomatic
and ground. constant voltage DC arc welding machine built to meet
NEMA specifications. It combines a constant voltage
• Always wear dry insulating power source, a constant speed wire feeder, and a
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gloves. microcomputer-based controller to form a reliable high-

performance welding system.
____________________________________
Simple controls, consisting of continuous full range cal-
FUMES AND GASES ibrated voltage control and wire feed speed control,
can be dangerous. provide versatility with ease of use.

• Keep your head out of fumes.

• Use ventilation or exhaust to

remove fumes from breathing
zone.
____________________________________
WELDING, CUTTING and
GOUGING SPARKS
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can cause fire or explosion

• Keep flammable material away.

• Do not weld, cut or gouge on

containers that have held
combustibles.

____________________________________

ARC RAYS
can burn.

• Wear eye, ear and body

protection.
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____________________________________
Only qualified personnel should operate this equip-
ment. Observe all safety information throughout this
manual.

WIRE-MATIC 255
 B-2 B-2
OPERATION
RECOMMENDED PROCESSES AND POWER SOURCE FEATURES:
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EQUIPMENT 10 Ft. (3.0m) Input Power Cable - Includes plug and

mating receptacle for 208/230V unit. Convenient rear
The WIRE-MATIC 255 is recommended for GMA weld- reconnect panel allows easy access for 208V re-con-
ing processes using 10 to 44 lb. (4.5 to 20 kg) 2" nection.
(51mm) I.D. spools or Readi-Reel coils (with optional
adapter) of: Power Switch - Front panel toggle switch turns input
power on and off.
.025" through .045" (0.6-1.2mm) solid steel.
.035" (0.9mm) stainless steel. Pilot Light - Indicates when power is applied to
3/64" (1.2mm) aluminum. machine.
.045" (1.2mm) Outershield.
.035" (0.9mm) and .045" (1.2mm) Innershield self- Thermostatically-Controlled Fans - Cools trans-
shielding electrodes. former and other components only when required. The
fan motors stays off when used intermittently or at low
The WIRE-MATIC 255 is factory equipped to feed current procedures, reducing the amount of dust and
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.035" (0.9mm) and .045" (1.2mm) electrodes. It dirt drawn into the machine. This also reduces power
includes a 12 ft. (3.6m) GMAW gun and cable assem- consumption.
bly equipped for these wire sizes with a duty cycle rat-
ing of 200A, 60% or 250A, 35%. Using GMAW Electronic Overload Protection - Protects machine
processes requires use of the optional gas regulator from short circuit or high current overloading.
and a supply of shielding gas.
Power Source Line Voltage Regulation - Precise
DESIGN FEATURES AND SCR phase control circuit holds the voltage setting at a
ADVANTAGES constant level to maintain weld quality even when the
input voltage fluctuates +/- 10%.
UNIT FEATURES: Solid State Contactor -Output is turned on and off by
SCR's instead of a mechanical contactor providing
Continuous Voltage and Wire Speed Control - extra long life in highly repetitive welding applications.
Large, easy to use control knobs provide continuous
full-range calibrated control of both wire speed and Output Terminals - Easily accessible in wire drive
voltage. A "ready-reference Procedure Chart” is pro-
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compartment for quick cable connection and polarity

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vided on the inside of the wire drive section door giving reversal.
suggested settings for popular welding processes and
plate thickness. Wire speed control has fine resolution Work Cable - 10 ft. (3.0m) long with work clamp.
calibrated dial for repeatable and precise setting.

Undercarriage for Hand Mobility - Heavy duty 10"

(254mm) wheels and 4" (102mm) casters are factory
installed. The handle can be used for storing the weld-
ing gun and work cable.

Adjustable Flow Regulator - Accomodates CO2 or

argon blend gas. Includes a cylinder pressure gauge
and a dual seal flow gauge.

Gas cylinder Platform - Factory installed on the

undercarriage, it permits platform mounting and sup-
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port of a single gas cylinder. It is not necessary to

completely lift the gas cylinder when placing it on the
platform.

Easy Accessibility - The door on the wire feeder

enclosure protects wire and wire drive from dirt, dust,
and damage.

WIRE-MATIC 255
 B-3 B-3
OPERATION
WIRE FEEDER FEATURES: MACHINE CAPABILITY
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Wire Loading - Adjustable brake spindle mounts The WIRE-MATIC 255 is rated on the following duty
Readi-Reel® Adapter, included with WIRE-MATIC 255, cycles based on a 10-minute time period (i.e., for 60%
or most any 2" (51mm) I.D. wire spool. duty cycle, it is 6 minutes on and 4 minutes off).
Accommodating standard 12" (305mm) and 8"
(203mm) diameter coils, the spindle’s adjustable brake Duty Cycle Amps. Volts
provides appropriate dereeling drag to prevent wire
reel overrun and loop-offs. 100% 145 26

Tachometer Controlled Wire Drive - Precision con- 60% 200 28

trol of permanent magnet motor provides proper wire
feed acceleration and speed accuracy, independent of 35% 250 26
fluctuations in line voltage and wire loading. This gives
reliable arc starting and weld consistency.

Selectable Run-In Start-Up - A user selectable fea-

LIMITATIONS
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ture allows the wire feeder to feed wire directly at the

selected speed, (factory selected), or when the trigger
is pulled the wire feeder feeds wire at slow speed The WIRE-MATIC 255 may not operate satisfactorily if
regardless of the set wire feed speed until welding cur- powered with a portable or in-plant generating system.
rent is drawn or 2 seconds has expired. This feature
enhances starting and makes setting stick out a snap
The 2 second limit permits high speed loading of the
gun and cable.

Solid State Overload Protection - No circuit breaker

to reset. Simply pull the trigger to resume welding
once the overload condition has been cleared.

Unique Drive Roll and Guide Tube Design -

Precisely aligned guide tubes and drive rolls provide
long life. The design also permits quick reload by sim-
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ply starting wire into ingoing guide tube. Adjustable

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tension setting minimizes 'birdnesting', eliminates

milling through the wire, and gives positive feeding.
The double groove, reversible drive roll included with
the WIRE-MATIC 255 allows use of .030" (0.8mm)
through .045" (1.2mm) diameter wire. Drive roll kits for
other sizes and types of wire are also available.

Quick-Connect Welding Gun - Gun connector has

integrated 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 cable

assembly, rated 200 amps 60% duty, or 250 amps 35%
duty, is provided with the WIRE-MATIC 255. A liner,
diffuser and contact tips for .035" (0.9mm) and .045"
(1.2mm) electrodes are included.
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WIRE-MATIC 255
 B-4 B-4
OPERATION
CONTROLS AND SETTINGS
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All operator controls are located on the Front

Panel/Nameplate of the machine. See Figure B.1 for
the location of each control.

3
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4
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VOLTS WIRE SPEED

2
LINCOLN
ELECTRIC WIRE-MATIC 255
WARNING 1 ON

0 OFF
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POWER

Figure B.1 - Operator Controls.

1. POWER SWITCH: Toggle switch to turn input inches per minute (1.2 to 15.2 m/min). The control
power ON and OFF. Place the lever in the ON can be preset on the dial to the setting specified on
position to turn the WIRE-MATIC 255 ON. the Procedure Decal on the inside of the wire com-
partment door. Wire speed is not affected when
2. PILOT LIGHT: The red LED pilot light located next changes are made in the voltage control.
to the POWER SWITCH is lit when the power is
ON. NOTE: When the trigger is pulled, the wire feeder
feeds wire at low speed regardless of the wire feed
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3. VOLTAGE CONTROL POTENTIOMETER KNOB: speed set on the control until the welding arc starts or
Provide continuous adjustment of power source 2 seconds has elapsed. This feature enhances start-
output voltage over the rated 12 to 28 volt range. ing and makes it easier to set the stickout. The 2 sec-
Voltage can be adjusted while welding. ond limit permits high speed loading of the gun and
cable.
4. WIRE SPEED CONTROL POTENTIOMETER
KNOB: Controls the wire speed from 50 to 600

WIRE-MATIC 255
 B-5 B-5
OPERATION
USING THE WIRE DRIVE ROLL
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MOULDED ADAPTER
The drive roll provided with the WIRE-MATIC 255 has
two grooves, one for.030-.035" (0.8-0.9mm) solid steel RETAINING SPRING
electrode, and the other for .045" (1.2mm) solid steel
electrode. The welder is shipped with the drive roll WIRE DEREELING
installed in the .030-.035" (0.8-0.9mm) position as indi- DIRECTION
cated by the stenciling on the exposed side of the drive
roll. If .045" (1.2mm) electrode is to be used or one of
2" (51 mm)
the optional drive rolls is required, then the drive roll
O.D. SPINDLE
must be reversed or changed per the following instruc- LOCKING COLLAR
tions. This information also appears on the Procedure
BRAKE TENSION
Decal on the door inside the wire compartment. ADJUSTING SCREW

READI-REEL
PROCEDURE FOR CHANGING DRIVE
INSIDE CAGE WIRES
ROLL
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Different wire sizes may require changing the drive roll. FIGURE B.2 - Wire Reel Loading.
The applicable wire sizes are stamped on the drive roll.
Dual groove rolls must be installed so the side with the 4. Set one of the Readi-Reel inside cage wires on the
proper wire size stamp faces out. slot in the retaining spring tab.
1. Turn POWER SWITCH to OFF. 5. Lower the Readi-Reel to depress the retaining
spring and align the other inside cage wires with
2. Release the pressure on the idle roll by swinging the grooves in the molded adapter.
the pressure arm off the idle roll arm.
6. Slide the cage all the way onto the adapter until the
3. Remove the wire from the drive system. retaining spring "pops" up fully.
4. Remove the thumb screw from the drive roll.
WARNING
5. Turn the drive roll over or change to another roll as
required.
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Check to be sure the retaining spring has fully

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returned to the locking position and has securely

6. Replace the thumb screw. locked the Readi-reel cage in place. Retaining
spring must rest on the cage not the welding elec-
7. Check that the gun liner and contact tip are prop- trode.
erly sized for wire being used.
____________________________________
LOADING THE WIRE REEL NOTE: The retaining spring side of the Adapter should
be facing the center (inner) panel of the WIRE-MATIC
To mount a 22-30 lb. (10-14 kg) Readi-Reel package 255.
using the Readi-Reel adapter provided:
7. To remove the Readi-Reel from Adapter, depress
1. Remove the locking collar from the 2” (51mm) O.D. retaining spring tab with thumb while pulling the
spindle and mount the K363P Adapter so the spin- Readi-Reel cage from the molded adapter with
dle pin engages the hole provided in the Adapter. both hands. Do not remove Adapter from spindle.
Replace and tighten the locking collar.
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2. Rotate the spindle and adapter so the retaining

spring is at the 12 o'clock position.

3. Position the Readi-Reel so that it will rotate in a

clockwise direction when wire is dereeled from the
top of the coil. See Figure B.2.

WIRE-MATIC 255
 B-6 B-6
OPERATION
To mount a 10 to 44 lb. (4.5 to 20 kg) spools: 8” 5. Press the gun trigger and push the electrode into
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(200mm) [Use K468 Adapter] and 12” (300mm) the drive roll.
diameter:
a. If the electrode fails to thread itself into the out-
1. Remove the locking collar and the Readi-Reel going guide tube of the wire drive
Adapter (if installed) on the 2 inch (51mm) diame-
ter spindle. • open the quick release idle roll arm

2. If using an 8” (200mm) spool, place the K468 • thread the electrode manually
Adapter on the spindle first. The hole in the
Adapter arm is to engage the pin on the spindle. • re-close the arm.

3. Place the spool on the spindle, making certain the 6. Inch the electrode through the gun.
brake driving pin enters one of the holes in the
back side of the spool. Be certain the wire comes NOTE: If using the low speed starting feature, the wire
off the reel in a clockwise direction when dereeled will feed at low speed for 2 seconds while inching, then
from the top of the coil. come up to the set speed. To change run-in mode, see
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the Changing the Run In Mode Section.

4. Replace and tighten the locking collar for several
seconds.
PROPER WIRE FEEDING

FEEDING ELECTRODE Wire feeding problems can be avoided by observing

the following gun handling procedures:

WARNING • Do not kink or pull cable around sharp corners.

When inching, the electrode and drive mechanism • Keep the electrode cable as straight as possible
are electrically hot to work and ground. The elec- when welding or loading electrode through cable.
trode remains hot several seconds after the gun
trigger is released. • Do not allow dolly wheels or trucks to run over
cables.
____________________________________
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• Keep cable clean by following maintenance

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NOTE: Check that the proper drive rolls and gun parts instructions.
for the wire size and type are being used.
• Use only clean, rust-free electrode. The Lincoln
1. Turn the Readi-Reel or spool until the free end of electrodes have proper surface lubrication.
the electrode is accessible.
• Replace contact tip when the arc starts to become
2. Tightly holding the electrode, cut off the bent end unstable or the contact tip end is fused or
and straighten the first six inches. deformed.

a. If the electrode is not properly straightened, it

may not feed properly into the outgoing guide
tube or welding gun causing a "birdnest.")

3. Cut off the first inch.

4. Push the wire through the ingoing guide tube.

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WIRE-MATIC 255
 B-7 B-7
OPERATION
SETTING IDLE ROLL PRESSURE NOTE: When the POWER SWITCH is ON, the fan
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motor is thermostatically controlled to provide cooling

The idle roll pressure thumb screw is set at the factory for the transformer and other components only when
backed out 2-1/2 turns from full pressure. This is an the machine needs cooling. When the machine does
approximate setting. The optimum idle roll pressure not require fan cooling the fan does not run, such as
varies with type of wire, wire diameter, surface condi- when first turned on, when welding at low current, or at
tions, lubrication, and hardness. As a general rule, low duty cycle procedures.
hard wires may require greater pressure, and soft, or
aluminum wire, may require less pressure than the fac-
tory setting. The optimum idle roll setting can be deter- CHANGING RUN-IN MODE
mined as follows:

1. Push the end of gun against a solid object that is FAST OR SLOW RUN-IN MODE
electrically isolated from the welder output. SELECTION
2. Press the gun trigger for several seconds. The WIRE-MATIC 255 is factory set for fast run-in
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mode where the wire feed will accelerate directly to the

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a. If the wire "birdnests", jams, or breaks at the preset wire feed speed when the gun trigger is closed.
drive roll, the idle roll pressure is too great.
Back the thumb screw out 1/2 turn, run new Slow run-in mode may also be selected, where it will
wire through gun, and repeat steps 1 and 2. initially feed wire at 50 IPM until output current is
sensed or for 2.0 seconds, whichever occurs first.
b. If the drive roll slips, loosen the thumb screw After which it will accelerate to the preset wire feed
on the conductor block and pull the gun cable speed.
forward about 6" (15 cm). There should be a
slight waviness in the exposed wire. If there is
no waviness, the pressure is too low. Tighten
INSTRUCTIONS TO ENTER SLOW RUN-IN
the thumb screw 1/4 turn, reinstall the gun MODE
cable, and repeat steps 1 and 2.
1. Turn power OFF on front panel of Wire-Matic 255.

2. Turn the wire feed speed dial to minimum, fully

OPERATING STEPS counterclockwise.
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3. With the gun trigger closed, turn the power ON at

WARNING the front panel of the Wire-Matic 255.
Before operating the machine, be sure you have all 4. The gas solenoid will actuate two times to signal
the materials needed to perform the work. Be sure that the unit has entered the slow run-in mode (the
you are familiar with and have taken all possible gun trigger need only be closed until the first gas
safety precautions before starting the work. It is solenoid actuation is heard).
important that you follow these operating steps
each time you use the machine.
INSTRUCTIONS TO ENTER FAST RUN-IN
___________________________________
MODE
STARTING THE WELDER 1. Turn power OFF on front panel of Wire-Matic 255.
1. Turn the POWER switch to ON. This illuminates 2. Turn the wire feed speed dial to maximum, fully
the red LED pilot light. clockwise.
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2. Select the correct voltage and wire speed for the 3. With the gun trigger closed, turn the power ON at
welding process required. the front panel of the Wire-Matic 255.
3. Operate the gun trigger for welder output and to 4. The gas solenoid will actuate four times to signal
energize the wire feeder motor. that the unit has entered the fast run-in mode (the
gun trigger need only be closed until the first gas
solenoid actuation is heard).

WIRE-MATIC 255
 B-8 B-8
OPERATION
NOTE: Arc starting characteristics may be affected NOTE: When using Innershield electrode, the gas
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when using the fast run-in mode since optimum start- nozzle may be removed from the insulation on the end
ing processes are being overriden. of the gun. This will give improved visibility and elimi-
nate the possibility of the gas nozzle overheating.
When the trigger is closed at power up, no output
power or wire feed will be available until the trigger is 7. Connect the work cable to metal to be welded.
opened and reclosed, regardless of wire feed speed Work clamp (if used) must make good electrical
dial setting. contact to the work. The work must be grounded.

It is not necessary to repeat either of the above proce-

dures each time the unit is powered up. The unit will WARNING
remember the run-in mode from the previous power
down and return you to that same state upon your next When using an open arc process, it is necessary to
power up. Thus, you need only perform one of the use correct eye, head and body protection.
above procedures when you want to change the run-in
mode. ____________________________________
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8. Position electrode over joint. End of electrode may

MAKING A WELD be lightly touching the work.

1. Check that the electrode polarity is correct for the 9. Lower welding helmet, close gun trigger, and begin
process being used. welding. Hold the gun so the contact tip to work
distance is about 3/8 inch (10mm) or 3/4" (20mm)
2. Turn the POWER SWITCH to ON. for Outershield.

3. Set desired arc voltage and wire speed for the 10. To stop welding, release the gun trigger and then
electrode wire, material type and thickness, and pull the gun away from the work after the arc goes
gas (for GMAW) being used. out.

NOTE: Use the Application Chart on the door inside 11. When no more welding is to be done, close the
the wire compartment as a quick reference for some valve on gas cylinder (if used), momentarily oper-
common welding procedures. ate gun trigger to release gas pressure.
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NOTE: If Timer Kit is installed, see the Accessories 12. Turn POWER SWITCH to OFF.
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Section of this manual to select the desired mode and

for additional welding information Spot and Stitch
modes.

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: If set to slow run-in, when the trigger is pulled

the wire feeder feeds wire at low speed regardless of
the set wire feed speed until the welding arc starts or 2
seconds has elapsed. This feature enhances starting
and makes it easier to set the stickout. The 2 second
limit permits high speed loading of the gun and cable.
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To change run-in mode, refer to Changing Run In

Mode Section.

6. If welding gas is to be used, turn on the gas supply

and set the required flow rate (typically 25-35 CFH;
12-16 Liters/min).

WIRE-MATIC 255
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES

WIRE-MATIC 255
 ACCESSORIES
TABLE OF CONTENTS
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- ACCESSORIES SECTION -

ACCESSORIES SECTION ....................................... Section C

Other Available Magnum 250L Gun and
Cable Assembly ..........................................................C-1
Magnum Gun Connection Kit (Optional K466-6) .............C-1
K672-1 Spool Gun Adapter Kit.........................................C-1
Making a Weld with the Spool Gun Adapter and
Spool Gun (K672-1) Installed......................................C-1
Making a Weld with the Spool Gun Adapter (K672-1)
Installed .......................................................................C-2
Timer Kit (K585-1)............................................................C-3
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Timer Kit Installation (Optional K585-1) ...........................C-3

Making Spot and Stitch Welds with Timer Kit Installed ...C-4
Drive Roll Kits ..................................................................C-4
3/64” Aluminum Feeding Kit (K673-1)..............................C-4
K468 8” Spool Adapter.....................................................C-4
K363P Readi-Reel Adapter ..............................................C-4
Dual Cylinder Mounting (K671-1).....................................C-5
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WIRE-MATIC 255
 C-1 C-1
ACCESSORIES
OPTIONS/ACCESSORIES The kit includes a spool gun adapter module assembly
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with a single connecting plug, a rear gas inlet setting

with hose, a gun and cable holders and mounting
OTHER AVAILABLE MAGNUM 250L hardware with installation and operating instructions.
GUN AND CABLE ASSEMBLY (L9696)

The following GMAW gun and cable assemblies are

available for use with the WIRE-MATIC 255. Each is CAUTION
rated 200 amps 60% duty cycle or 250 amps 35% duty
cycle. The gun and cable assemblies are equipped The spool gun module is intended for use with
with the integrated connector, twist-lock trigger con- Lincoln Electric® Magnum™ Spool Guns only. Use
nector, and includes a liner, diffuser, and contact tips with other units may cause damage to the equip-
for the wire sizes specified: ment. For Spool Gun operation, refer to the
instruction manual provided with the Magnum™
Spool Gun.
LENGTH PART NO. WIRE SIZE
____________________________________
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10' (3.0 m) K533-1

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12' (3.6 m) K533-2* .035-.045”

15’ (4.5 m) K533-3 (0.9-1.2mm)
MAKING A WELD WITH THE SPOOL
10' (3.0 m) K533-4 GUN ADAPTER AND SPOOL GUN
12' (3.6 m) K533-5 .025-.030”
15’ (4.5 m) K533-6 (0.6-0.8mm) (K672-1) INSTALLED

* Included with the K578-1. The toggle switch on the front of the spool gun adapter
box permits quick transfer between the use of the
Wire-Matic 255 with its feeder gun and the connected
spool gun for same polarity electrodes.
MAGNUM GUN CONNECTION KIT
(Optional K466-6)
Using the optional K466-6 Magnum Connection kit for
the Wire-Matic permits use of standard Magnum 200,
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300 or 400 gun and cable assemblies.

K672-1 SPOOL GUN ADAPTER KIT

WARNING
Remove all input power to the Wire-Matic 255
before proceeding.

____________________________________

The K672-1 Spool Gun Adapter Kit provides recessed

panel “up front" direct connection of the K487 Spool
Gun (with remote speed control), or the K469 Spool
Gun (requiring K518 Connection Adapter) with the SP-
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255, SP255-I and Wire-Matic 255 wire feed welder

machines.

It also provides single switch transfer between the

machine's use with its feeder gun or the spool gun for
same polarity welding with different wire and gas
processes.

WIRE-MATIC 255
 C-2 C-2
ACCESSORIES
MAKING A WELD WITH THE SPOOL NOTE: The WIRE-MATIC 255 speed calibrated dial
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markings are not accurate when used for setting the

GUN ADAPTER (K672-1) INSTALLED Spool Gun speed.

CAUTION 4. The following procedure settings can be used as

initial settings for making test welds to determine
final settings:
In either transfer switch position, closing the gun
trigger will cause the electrode of both guns to be Wire Diameter WFS Setting Arc Voltage
electrically "HOT." Be sure unused gun is posi- In. (mm) Wire-Matic 255 Setting
tioned so the electrode or the tip will not contact
metal case or other metal common to the work. A .030” (.8mm) 270 15 V
gun holder is provided with the K672-1 kit for this .035” (.9mm) 250 16 V
purpose. 3/64” (1.2mm) 210 21 V

____________________________________ 5. To return to normal WIRE-MATIC 255 welding, set

the transfer switch to FEEDER position and reset
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1. The transfer switch in FEEDER position: feeder gun weld procedure settings.

a. Disables spool gun trigger, wire feed, and gas

output.

b. Closing the feeder gun trigger starts feeder

gun welding and makes both electrodes elec-
trically "HOT."

2. Transfer switch in SPOOL position:

a. Disables feeder gun wire feed and gas output.

However, closing feeder gun trigger will make
both electrodes electrically “HOT” and activate
spool gun gas output.

b. Closing spool gun trigger starts spool gun

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welding and makes both electrodes electrical-

ly "HOT".

3. Operation with Wire-Matic 255:

a. Turn the Wire-Matic input power ON, and the

transfer switch is to be in the SPOOL position.

b. Adjusting the voltage control will increase or

decrease your welding Voltage.

c. Adjusting the wire speed control will increase

or decrease the spool gun wire feed speed.
This represents the set speed for the K469
spool gun and the maximum set speed for the
K487 Spool Gun with the remote control in gun
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handle at maximum.

The remote control turned to minimum will give

approximately 50% of the maximum set WFS.

WIRE-MATIC 255
 C-3 C-3
ACCESSORIES
TIMER KIT (K585-1) TIMER KIT INSTALLATION
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(OPTIONAL K585-1)
The Timer Kit provides selectable 4-step trigger inter-
lock, spot and stitch functions, and manual adjustment
of burnback time. This kit installs easily using only a WARNING
screwdriver. It replaces the blank upper panel on Case Remove all input power to the WIRE-MATIC 255
Front. It offers the following mode selections: before proceeding.
• The Normal Welding mode provides welding
power only while gun trigger is pressed.
____________________________________

• The 4-Step Trigger mode eliminates the need to 1. Verify that the following items have been included
hold gun trigger while welding. It operates in 4 in the kit:
steps:
a. Timer Board and Panel Assembly.
1. Close trigger and establish welding arc.
b. Two sheet metal screws.
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2. Release trigger and continue welding.

c. Wiring harness.
3. Re-close trigger near end of weld.
2. Turn the POWER SWITCH to OFF.
4. Release trigger again to stop welding.
3. Disconnect AC input power to the machine.
• The Spot Weld mode allows a single timed weld
cycle each time the gun trigger is held closed. 4. Remove the Cover Plate Assembly from the front
Duration is set with SPOT/STITCH ON TIME knob. of the machine by removing the two screws which
fasten it using a screwdriver, a 5/16" (8mm) nut dri-
• The Stitch Weld mode allows repeated timed weld ver, or other suitable tool.
cycles while gun trigger is held closed. Weld on-
time is set with SPOT/STITCH ON TIME knob, and 5. Reach through the exposed panel opening and
weld off time is set with STITCH OFF TIME knob. attach the rectangular 8-pin plug connector on the
Timer Kit wiring harness to the available mating
The BURNBACK TIME knob is used to manually set receptacle connector on the upper left corner of
the Control Board inside the machine.
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arc power delay at the end of any above selected weld

mode to prevent wire sticking in the weld. With the
Timer Kit not installed, a preselected delay is automat- a. Be sure that the latch on the connector is
ically set by the machine. aligned with that on the Control Board and
insert it until the latch engages.

b. Check that the remaining connector on the

opposite end of the wiring harness is firmly
attached to the mating connector on the PC
Board on the Timer Kit panel, and that the
latch is engaged.

6. Align the Timer Kit panel so you can carefully insert

the printed circuit board and wiring harness
through the opening in the front panel.

a. Make sure the wiring harness is not pinched

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between panels or between printed circuit

board and front panel.

7. Fasten the Timer Kit assembly with either the two

supplied screws or with the original screws to com-
plete the installation.

WIRE-MATIC 255
 C-4 C-4
ACCESSORIES
MAKING SPOT AND STITCH WELDS 3. Set the procedure for the metal thickness to be
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welded.
WITH TIMER KIT INSTALLED
4. Close trigger and hold it closed for length of seam.
TO MAKE SPOT PLUG WELDS:
a. Hold gun in one place during ON time and
The SPOT WELD MODE is used to make spot plug move gun just beyond edge of molten metal
welds when continuous welds are not needed or to during OFF time.
hold thin sheet metal together prior to stitch welding or
continuous welding. NOTE: For smoothest welds on thinner metal, point
gun slightly toward the direction of travel.
Plug welds are made by using a punch to make a 3/16"
(5mm) diameter hole in the top sheet and arc welding
through the hole into the back sheet. DRIVE ROLL KITS
1. Punch 3/16" (5mm) holes in the top sheet. The following drive rolls and Magnum 250L gun and
cable parts are available to feed different sizes and
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2. Set the SPOT/STITCH ON-TIME control to types of electrodes.

approximately 1.2 seconds.
Steel Wire Sizes: Part Number
3. Set the procedure for the metal thickness to be .025 - .035" (0.6-0.9mm) KP674-035S
welded. .030 - .045" (0.8-1.2mm) KP674-045S
.045" Cored (1.2mm) KP674-045C
4. Install spot weld nozzle (if available) on gun and
press it against the top sheet so the top and bot- Aluminum Wire Sizes:
tom sheets are tight together. 3/64" (1.2mm) KP674-3/64A

5. Close trigger and hold it closed until the arc goes

out.

a. If a spot weld nozzle is not used, smoother 3/64” (1.2mm) ALUMINUM FEEDING
welds will result by moving the welding wire in KIT (K673-1)
a small circle during the weld.
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Provides gun and wire drive conversion parts to weld

TO MAKE A STITCH WELD: with 3/64” (1.2mm) aluminum wire. 5356 alloy alu-
minum wire is recommended for best push feeding
The STITCH WELD MODE is used to weld thin mater- performance.
ial when warpage and burn through are a problem.
Proper adjustment of the Spot/Stitch On-Time, Stitch Kit includes drive roll and incoming guide tube for the
Off-Time, and arc travel speed permits welding thin wire drive, and 450 gun tube, liner and two contact tips
sheet metal with small welds, minimum distortion, and for the gun, along with S21529 installation instructions.
no burnthrough.

1. The SPOT/STITCH ON-TIME KNOB sets welding K468 8” SPOOL ADAPTER

time.
The K468 Spool Adapter permits the use of 8” Spools
a. Start with a dial setting of 0.5 seconds. Raise on the Wire-Matic 255 spindle.
setting to increase penetration and weld size.
Lower setting to reduce burnthrough and dis-
tortion.
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K363P READI-REEL ADAPTER

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2. The STITCH OFF-TIME KNOB sets off time

between welds. The K363P Readi-Reel Adapter mounts to the 2” spin-
dle. It is needed to mount the 22-20 lb. Readi-Reels.
a. Start with a dial setting of 0.5 seconds. Raise
setting to reduce burnthrough. Lower setting
to make weld flatter and smoother.

WIRE-MATIC 255
 C-5 C-5
ACCESSORIES
DUAL CYLINDER MOUNTING KIT
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(K671-1)
Permits stable side-by-side mounting of two full size
(9” dia. x 5’ high) gas cylinders with “no lift” loading.
Simple installation with installation kick stand and easy
instructions provided (L9687). Includes upper and
lower cylinder supports, wheel axles and mounting
hardware.
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WIRE-MATIC 255
 MAINTENANCE
TABLE OF CONTENTS
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- MAINTENANCE SECTION -

MAINTENANCE SECTION ...................................... Section D

Safety Precautions ...........................................................D-1
Routine and Periodic Maintenance ..................................D-1
Component Locations ......................................................D-2
Drive Rolls and Guide Tubes ...........................................D-3
Cable Cleaning.................................................................D-3
Gun Tubes and Nozzles...................................................D-3
Contact Tip and Gas Nozzle Installation..........................D-3
Liner Removal and Replacement.....................................D-4
Liner Removal, Installation, and Trimming Instructions
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for Magnum 250L ........................................................D-4

Gun Handle Disassembly ................................................D-5
Accessories and Expendable Replacement Parts for
Magnum 250L Gun and Cable Assemblies .....................D-6
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WIRE-MATIC 255
 D-1 D-1
MAINTENANCE
SAFETY PRECAUTIONS
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WARNING
• Have a qualified electrician do the maintenance
and troubleshooting work.

• Disconnect the input power off using the dis-

connect switch at the main input supply before
working inside machine.

• Unplug the power cable if it is connected to a

receptacle.
____________________________________

Read the Safety Precautions in the front of this manu-

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al before working on this machine.

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ROUTINE AND PERIODIC

MAINTENANCE
1. Disconnect input AC power supply lines to the
machine before performing periodic maintenance,
tightening, cleaning, or replacing parts. See
Figure D.1.

Perform the following daily:

1. Check that no combustible materials are in the

welding or cutting area or around the machine.
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2. Remove any debris, dust, dirt, or materials that

could block the air flow to the machine.

3. Inspect the electrode cables for any slits, punc-

tures in the cable jacket, or any condition that
would affect the proper operation of the machine.

Perform Periodically:

Clean the inside of the machine with low pressure air

stream. 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.
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Fan Motor Assembly.

Control Printed Circuit Board.

NOTE: The fan motor has sealed bearings which

require no maintenance.

WIRE-MATIC 255
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MAIN TRANSFORMER
BOARD
CONTROL PC

WIRE-MATIC 255
MAINTENANCE

CHOKE
BRIDGE

Figure D.1 - Component Locations.

SCR RECTIFIER
FAN MOTORS
D-2
 D-3 D-3
MAINTENANCE
DRIVE ROLLS AND GUIDE TUBES CONTACT TIP AND GAS NOZZLE
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INSTALLATION
After every coil of wire, inspect the wire drive mecha-
nism. Clean it as necessary by blowing with low pres- 1. Choose the correct size contact tip for the elec-
sure compressed air. Do not use solvents for cleaning trode being used (wire size is stenciled on the side
the idle roll because it may wash the lubricant out of of the contact tip) and screw it snugly into the gas
the bearing. All drive rolls are stamped with the wire diffuser.
sizes they will feed. If a wire size other than that
stamped on the roll is used, the drive roll must be a. Be sure the nozzle insulator is fully screwed
changed. onto the gun tube and does not block the gas
holes in the diffuser.

CABLE CLEANING 2. Slip or screw the appropriate gas nozzle onto the
nozzle insulator.
Clean the cable liner after using approximately 300
pounds (136 kg) of electrode. Note: Either a standard .50" (12.7mm) or optional .62"
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(15.9mm) I.D. slip-on gas nozzle may be used and

1. Remove the cable from the wire feeder and lay it should be selected based on the welding application.
out straight on the floor.
3. Adjust the gas nozzle as appropriate for the
2. Remove the contact tip from the gun. GMAW process to be used.

3. With an air hose at the gas diffuser end, use low a. Typically, the contact tip end should be flush to
pressure to gently blow out the cable liner. extended .12" (3.2mm) for the short-circuiting
transfer process and recessed .12" (3.2mm)
for spray transfer.
CAUTION

Excessive pressure at the start may cause the dirt

to form a plug.

____________________________________
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4. Flex the cable over its entire length and again blow
out the cable.

5. Repeat this procedure until no more dirt comes

out.

GUN TUBES AND NOZZLES

1. Replace worn contact tips as required.

2. Remove spatter from the inside of the gas nozzle

and tip every 10 minutes of arc time or as required.
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WIRE-MATIC 255
 D-4 D-4
MAINTENANCE
LINER REMOVAL AND
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REPLACEMENT
NOTE: When you change wire size, a replacement
gas diffuser is required. Use the table below to select
the proper diffuser so the liner is held securely in place.

Diameter of Replacement Liner Size Stenciled on Fixed Nozzle Gas Adjustable Nozzle
Electrodes Used Part Number End of Liner Diffuser Part No. Gas Diffuser Part
Bushing (and Stencil) No. (and Stencil)

.025-.030" Steel M16087-2 .030 (0.8mm) S19418-3 S19418-2

(0.6-0.8mm)

.035-.045" Steel M16087-1 .045 (1.2mm) S19418-3 S19418-1

(0.9-1.2mm)
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3/64" Aluminum M17714-1 3/64” (1.2mm) S19418-3 S19418-1

(1.2mm)

LINER REMOVAL, INSTALLATION, 8. Fully seat the liner bushing into the connector.

AND TRIMMING INSTRUCTIONS 9. Tighten the setscrew on the brass cable connector.
FOR MAGNUM 250L
NOTE: Do not install the gas diffuser onto the end of
NOTE: The variation in cable lengths prevents the the gun tube at this time.
interchange ability of liners between guns. Once a liner
has been cut for a particular gun, it should not be 10. Straighten the cable with the gas nozzle and noz-
installed in another gun unless it can meet the liner cut zle insulator removed from the gun tube.
off length requirement. Liners are shipped with the
jacket of the liner extended the proper amount. 11. Trim the liner to the length shown in FIGURE D.2.
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1. Remove the gas nozzle and nozzle insulator.

SET SCREW BRASS CABLE CONNECTOR
2. Locate the set screw in the gas diffuser which is
used to hold the old liner in place.
1-1/4" (1.25)
3. Loosen the set screw with a 5/64" (2.0mm) Allen (31.8MM)
wrench. LINER TRIM
LENGTH

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 liner
GAS DIFFUSER
out of the cable.
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NOZZLE INSULATOR
7. Insert a new untrimmed liner into the connector
end of the cable. GAS NOZZLE

a. Check the liner bushing stencil to make sure it

is the appropriate one for the wire size being FIGURE D.2 - Liner maintenance.
used.

WIRE-MATIC 255
 D-5 D-5
MAINTENANCE
12 Remove any burrs from the end of the liner.
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13. Screw the gas diffuser onto the end of the gun tube
and tighten.

NOTE: Be sure the gas diffuser is correct for the liner

being used. (See table and diffuser stencil.)
COUNTER-
14. Slightly tighten the set screw in the side of the gas CLOCKWISE
diffuser against the cable liner using 5/64" (2.0mm)
Allen wrench.

CAUTION
This screw should only be gently tightened. Over
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tightening will split or collapse the liner and cause

poor wire feeding.

____________________________________
FIGURE D.3 - Gun Handle disassembly.
GUN HANDLE DISASSEMBLY
The internal parts of the gun handle may be inspected
or serviced if necessary.

The gun handle consists of two halves that are held

together with a collar on each end.

To open up the handle:

1. Turn the collars approximately 60 degrees coun-

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terclockwise (the same direction as removing a

right 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 the

gun handle against a corner, place a screwdriver
against the tab on the collar and give the screwdriver a
sharp blow to turn the collar past an internal locking rib.
See Figure D.3.
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WIRE-MATIC 255
 D-6 D-6
MAINTENANCE
ACCESSORIES AND EXPENDABLE
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REPLACEMENT PARTS FOR

MAGNUM 250L GUN AND CABLE
ASSEMBLIES

DESCRIPTION PART NO. ENGLISH SIZE METRIC SIZE

Cable Liner M16087-2 .025- .030" 0.6 - 0.8 mm
For 15' (4.5m) or Shorter Cable M16087-1 .035- .045" 0.9 - 1.2 mm
M17714-1* 3/64" (Alum. Wire) 1.2 mm (Alum. Wire)

Contact Tips S19391-6 .025" 0.6 mm

Standard Duty S19391-7 .030" 0.8 mm
S19391-1** .035" 0.9 mm
S19391-2** .045" 1.2 mm
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Heavy Duty S19392-1 .035" 0.9 mm

S19292-2 .045" 1.2 mm

S19393-5 .025" 0.6 mm

Tapered S19393-6 .030" 0.8 mm
S19393-1 .035" 0.9 mm
S19393-2 .045" 1.2 mm

Tab (For Aluminum) S18697-46* 3/64” (Alum. wire) 1.2 mm

Gas Nozzles
Fixed (Flush) M16081-1 3/8” 9.5 mm
M16081-2** 1/2” 12.1 mm
M16081-3 5/8” 15.9 mm

(Recessed) M16080-1 3/8” 9.5 mm

M16080-2 5/8” 15.9 mm
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M16080-3 5/8” 15.9 mm

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(Requires: Gas Diffuser Assembly.) S19418-3 .025-.045” 0.6-1.2 mm

Adjustable Slip-On M16093-2 1/2” 12.7 mm

M16093-1 5/8” 15.9 mm

(Requires: Nozzle Insulator Assembly.) S19417-1

(Requires: Gas Diffuser Assembly) S19416-2 0.25 - .030" 0.6-0.8 mm

S19416-2 0.35 - .045" 0.9-1.2mm
Gasless Nozzle (for Innershield®) M16938***

Gun Tube Assembly

Standard (60 Degrees) S18920**
45 Degrees S19890*

* Included with K673-1 3/64” (1.2 mm) Aluminum

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Feeding Kit. 5356 alloy aluminum wire recom-

mended to alleviate potential soft wire feeding
problems with push-type wire feeding.

** Included with Wire-Matic 255.

*** Requires S19428-1 Gas Diffuser Assembly.

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 NOTES

WIRE-MATIC 255
 THEORY OF OPERATION
TABLE OF CONTENTS
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- THEORY OF OPERATION SECTION -

THEORY OF OPERATION SECTION ...................... Section E

Power Supply Operation .................................................E-1
Input Line Voltage and Main Transformer ...................E-1
Output Rectification and Feedback Control ................E-2
Constant Voltage Output .............................................E-3
Wire Drive Motor and Feedback .................................E-4
Thermal Protection ...........................................................E-5
SCR Operation .................................................................E-6
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WIRE GAS
SPEED SOLENOID

WIRE
DRIVE
ARC MOTOR
VOLTAGE

CONTROL BOARD

TACH
G
A
T
E GUN TRIGGER AND THUMB SWITCH
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
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A
L

RECONNECT
POSITIVE
TERMINAL

C CHOKE
A F
P E
A E
C D
SCR I B
RECTIFIER T A
O C
R K
FAN S NEGATIVE
MOTORS TERMINAL

SHUNT

Figure E.1 -Block Logic Diagram

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

WIRE-MATIC 255
 E-1 E-1
THEORY OF OPERATION
INPUT LINE VOLTAGE AND MAIN TRANSFORMER
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WIRE GAS
SPEED SOLENOID
WIRE
DRIVE
ARC MOTOR
VOLTAGE

CONTROL BOARD

TACH
G
A
T
E GUN TRIGGER AND THUMB SWITCH
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
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L
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RECONNECT
POSITIVE
TERMINAL

C CHOKE
A F
P E
A E
C D
SCR I B
RECTIFIER T A
O C
R K
FAN S NEGATIVE
MOTORS TERMINAL

SHUNT

Figure E.2 - Input Line Voltage and Main Transformer.

INPUT LINE VOLTAGE AND MAIN

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TRANSFORMER
The desired single phase input power is connected to
the WIRE-MATIC 255 through a line switch located on
the front panel.

A reconnect panel allows the user to configure the

machine for the desired input voltage. This AC input
voltage is applied to the primary of the main trans-
former and to the thermostatically controlled fan
motors. The transformer changes the high voltage, low
current 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 drive
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and gas solenoid operation. The weld power windings

connect to the Control Board as well as to the main
SCR Rectifier.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

WIRE-MATIC 255
 E-2 E-2
THEORY OF OPERATION
OUTPUT RECTIFICATION AND FEEDBACK
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WIRE GAS
SPEED SOLENOID
WIRE
DRIVE
ARC MOTOR
VOLTAGE

CONTROL BOARD

TACH
G
A
T
E GUN TRIGGER AND THUMB SWITCH
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
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L
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RECONNECT
POSITIVE
TERMINAL

C CHOKE
A F
P E
A E
C D
SCR I B
RECTIFIER T A
O C
R K
FAN S NEGATIVE
MOTORS TERMINAL

SHUNT

Figure E.3 - Output Rectification and Feedback.

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OUTPUT RECTIFICATION AND

FEEDBACK CONTROL
The AC output from the main transformer secondary
weld winding is rectified and controlled through the
SCR rectifier assembly. Output voltage and current
are sensed at the shunt and output terminals and are
fed back to the control board. The control board com-
pares the commands of the ARC Voltage Control
potentiometer with the feedback signals. The appro-
priate gate firing pulses are generated by the control
board and applied to the SCR rectifier assembly. The
control board controls the firing of the SCRs, thus con-
trolling the output of the machine. See SCR
Operation. The control board also powers and com-
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mands the gas solenoid and the wire drive motor.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

WIRE-MATIC 255
 E-3 E-3
THEORY OF OPERATION
CONSTANT VOLTAGE OUTPUT
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WIRE GAS
SPEED SOLENOID
WIRE
DRIVE
ARC MOTOR
VOLTAGE

CONTROL BOARD

TACH
G
A
T
E GUN TRIGGER AND THUMB SWITCH
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
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L
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RECONNECT
POSITIVE
TERMINAL

C CHOKE
A F
P E
A E
C D
SCR I B
RECTIFIER T A
O C
R K
FAN S NEGATIVE
MOTORS TERMINAL

SHUNT

Figure E.4 - Constant Voltage Output.

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CONSTANT VOLTAGE OUTPUT

The controlled DC output from the SCR rectifier
assembly is filtered by the capacitor bank resulting is a
constant voltage DC output. Since the output choke is
in series with the positive leg of the rectifier and also in
series with the gun and welding load, a filtered con-
stant voltage output is applied to the output terminals
of the machine.
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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

WIRE-MATIC 255
 E-4 E-4
THEORY OF OPERATION
WIRE DRIVE MOTOR AND FEEDBACK
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WIRE GAS
SPEED SOLENOID
WIRE
DRIVE
ARC MOTOR
VOLTAGE

CONTROL BOARD

TACH
G
A
T
E GUN TRIGGER AND THUMB SWITCH
LINE MAIN
TRANSFORMER S
SWITCH I
G FEEDBACK
N
A
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L
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RECONNECT
POSITIVE
TERMINAL

C CHOKE
A F
P E
A E
C D
SCR I B
RECTIFIER T A
O C
R K
FAN S NEGATIVE
MOTORS TERMINAL

SHUNT

Figure E.5 - Wire Drive Motor and Feedback.

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WIRE DRIVE MOTOR AND

FEEDBACK
The wire drive motor is controlled by the control board.
A motor speed feedback signal is generated at the
motor tach and sent to the control board. The control
board compares this feedback signal with the com-
mands set forth by the Wire Speed Control poten-
tiometer and sends the appropriate armature voltage
to the wire drive motor. The drive motor speed is thus
controlled which in turn regulates the electrode wire
feed speed through the gun.
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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

WIRE-MATIC 255
 E-5 E-5
THEORY OF OPERATION
THERMAL PROTECTION
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THERMAL PROTECTION
A thermostat protects the machine from excessive
operating temperatures. Excessive operating temper-
atures may be caused by a lack of cooling air or oper-
ating the machine beyond the duty cycle and output
rating. There are three thermostats within the WIRE-
MATIC 255 machine. One of the thermostats, located
on the output choke, energizes the cooling fan motors
when required. The other choke thermostat "opens"
the trigger circuit, preventing machine weld output and
wire feed, if excessive operating temperatures are
detected. The third thermostat insures that the fan
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motors are operating when required.

The thermostats are self-resetting once the machine

cools sufficiently. If the thermostat shutdown is caused
by excessive output or duty cycle and the fans are
operating normally, the power switch may be left on
and the reset should occur within a 15 minute period.
If the fans are not turning or the air intake louvers are
obstructed, then the input power must be removed and
the fan problem or air obstruction be corrected.
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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

WIRE-MATIC 255
 E-6 E-6
THEORY OF OPERATION
SCR OPERATION
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INPUT

CATHODE
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OUTPUT
NOTE: AS THE GATE
PULSE IS APPLIED
ANODE LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.

GATE

Figure E.6 - SCR Operation

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A silicon controlled rectifier (SCR) is a three terminal An SCR is fired by a short burst of current into the gate.
device used to control rather large currents to a load. This gate pulse must be more positive than the cath-
An SCR acts very much like a switch. When a gate sig- ode voltage. Since there is a standard PN junction
nal is applied to the SCR it is turned ON and there is between gate and cathode, the voltage between these
current flow from anode to cathode. In the ON state the terminals must be slightly greater than 0.6V. Once the
SCR acts like a closed switch. When the SCR is turned SCR has fired it is not necessary to continue the flow
OFF there is no current flow from anode to cathode of gate current. As long as current continues to flow
thus the device acts like an open switch. As the name from anode to cathode the SCR will remain on. When
suggests, the SCR is a rectifier, so it passes current the anode to cathode current drops below a minimum
only during positive half cycles of the AC supply. The value, called holding current, the SCR will shut off. This
positive half cycle is the portion of the sine wave in normally occurs as the AC supply voltage passes
which the anode of the SCR is more positive than the through zero into the negative portion of the sine wave.
cathode. If the SCR is turned on early in the positive half cycle,
the conduction time is longer resulting in greater SCR
When an AC supply voltage is applied to the SCR, the output. If the gate firing occurs later in the cycle the
device spends a certain portion of the AC cycle time in conduction time is less resulting in lower SCR output.
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the off state and the remainder of the time in the on

state. The amount of time spent in the ON state is con-
trolled by the gate.

WIRE-MATIC 255
 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
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WIRE-MATIC 255
 TROUBLESHOOTING & REPAIR
TABLE OF CONTENTS
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- TROUBLESHOOTING & REPAIR SECTION -

TROUBLESHOOTING & REPAIR SECTION ........................................................................ Section F

How to use Troubleshooting Guide ....................................................................................................F-1
PC Board Troubleshooting Procedures..............................................................................................F-2
Troubleshooting Guide .......................................................................................................................F-3
Test Procedures
Main Transformer Test................................................................................................................F-10
Static SCR Rectifier Bridge Test.................................................................................................F-13
Active SCR Rectifier Assembly Test ...........................................................................................F-16
Wire Drive Motor and Tachometer Feedback Test .....................................................................F-19
Oscilloscope Waveforms ..................................................................................................................F-22
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Normal Open Circuit Voltage Waveform ....................................................................................F-22

Typical Output Voltage Waveform - Machine Loaded ................................................................F-23
Abnormal Output Voltage Waveform - Machine Loaded One Output SCR Not Functioning .....F-24
Abnormal Open Circuit Voltage Output Capacitor Bank Not Functioning ..................................F-25
Typical SCR Gate Voltage Waveform ........................................................................................F-26
Replacement Procedures
Control PC Board Removal and Replacement...........................................................................F-27
Wire Drive Assembly Removal and Replacement......................................................................F-29
SCR Output Rectifier Removal and Replacement .....................................................................F-31
Capacitor Bank Removal and Replacement ..............................................................................F-33
Main Transformer Removal and Replacement...........................................................................F-35
Fan Motor and Fan Removal and Replacement ........................................................................F-37
Retest After Repair .....................................................................................................................F-40
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WIRE-MATIC 255
 F-1 F-1
TROUBLESHOOTING & REPAIR
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HOW TO USE TROUBLESHOOTING GUIDE

WARNING
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 and
machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this
manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to Step 3. RECOMMENDED COURSE OF
help you locate and repair possible machine ACTION
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malfunctions. Simply follow the three-step

procedure listed below. The last column labeled “Recommended
Course of Action” lists the most likely com-
Step 1. LOCATE PROBLEM (SYMPTOM). ponents that may have failed in your
Look under the column labeled “PROBLEM machine. It also specifies the appropriate
(SYMPTOMS)”. This column describes pos- test procedure to verify that the subject com-
sible symptoms that the machine may exhib- ponent is either good or bad. If there are a
it. Find the listing that best describes the number of possible components, check the
symptom that the machine is exhibiting. components in the order listed to eliminate
Symptoms are grouped into the following one possibility at a time until you locate the
categories: output problems, function prob- cause of your problem.
lems, wire feeding problems, and welding
problems. All of the referenced test procedures
referred to in the Troubleshooting Guide are
Step 2. PERFORM EXTERNAL TESTS. described in detail at the end of this chapter.
The second column labeled “POSSIBLE Refer to the Troubleshooting and Repair
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AREAS OF MISADJUSTMENT(S)” lists the Table of Contents to locate each specific

obvious external possibilities that may con- Test Procedure. All of the specified test
tribute to the machine symptom. Perform points, components, terminal strips, etc. can
these tests/checks in the order listed. In be found on the referenced electrical wiring
general, these tests can be conducted with- diagrams and schematics. Refer to the
out removing the case wrap-around cover. Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/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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WIRE-MATIC 255
 F-2 F-2
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
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- Remove the P.C. Board from the static-

WARNING shielding bag and place it directly into the
equipment. Don’t set the P.C. Board on or
ELECTRIC SHOCK can kill. near paper, plastic or cloth which could have a
static charge. If the P.C. Board can’t be
Have an electrician install
installed immediately, put it back in the static-
and service this equipment.
shielding bag.
Turn the input power OFF at
the fuse box before work-
- If the P.C. Board uses protective shorting
ing on equipment. Do not
jumpers, don’t remove them until installation is
touch electrically hot parts.
complete.
_______________________________
CAUTION: Sometimes machine failures - If you return a P.C. Board to The Lincoln
appear to be due to PC board failures. These Electric Company for credit, it must be in the
problems can sometimes be traced to poor static-shielding bag. This will prevent further
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electrical connections. To avoid problems

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damage and allow proper failure analysis.

when troubleshooting and replacing PC
boards, please use the following procedure: 4. Test the machine to determine if the failure
symptom has been corrected by the
1. Determine to the best of your technical abil- replacement PC board.
ity that the PC board is the most likely com-
ponent causing the failure symptom. NOTE: It is desirable to have a spare (known
good) PC board available for PC board trou-
2. Check for loose connections at the PC bleshooting.
board to assure that the PC board is proper-
ly connected. NOTE: Allow the machine to heat up so that
all electrical components can reach their oper-
3. If the problem persists, replace the suspect ating temperature.
PC board using standard practices to avoid
static electrical damage and electrical 5. Remove the replacement PC board and
shock. Read the warning inside the static substitute it with the original PC board to
resistant bag and perform the following pro- recreate the original problem.
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cedures:
a. If the original problem does not reappear
P.C. Board can be dam- by substituting the original board, then
aged by static electricity. the PC board was not the problem.
Continue to look for bad connections in
- Remove your body’s static the control wiring harness, junction
ATTENTION charge before opening the blocks, and terminal strips.
Static-Sensitive static-shielding bag. Wear
Devices an anti-static wrist strap. For b. If the original problem is recreated by the
Handle only at safety, use a 1 Meg ohm substitution of the original board, then
Static-Safe resistive cord connected to the PC board was the problem. Reinstall
Workstations a grounded part of the the replacement PC board and test the
equipment frame. machine.
Reusable
Container - If you don’t have a wrist 6. Always indicate that this procedure was fol-
Do Not Destroy strap, touch an unpainted, lowed when warranty reports are to be sub-
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grounded, part of the equip- mitted.

ment frame. Keep touching the frame to pre-
vent static build-up. Be sure not to touch any NOTE: Following this procedure and writing
electrically live parts at the same time. on the warranty report, “INSTALLED AND
SWITCHED PC BOARDS TO VERIFY PROB-
- Tools which come in contact with the P.C. LEM,” will help avoid denial of legitimate PC
Board must be either conductive, anti-static or board warranty claims.
static-dissipative.

WIRE-MATIC 255
 F-3 F-3
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
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PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION

OUTPUT PROBLEMS
Major Physical or Electrical Damage 1. Contact your local Lincoln 1. Contact The Lincoln Electric
is Evident Electric Authorized Field Service Dept. (216) 383-2531 or
Service Facility. 1-800-833-9353 (WELD)

Machine is dead- No Open Circuit 1. Make certain that the input 1. Check input power switch (S1).
Voltage output and No Wire Feed power switch is in the "ON" posi- It may be faulty.
when gun trigger is pulled. tion.
2. Check for lose or broken wires
2. Check the input voltage at the at the reconnect panel.
machine. Input voltage must
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match the rating plate and the 3. Perform Main Transformer

reconnect panel. Test.

3. Blown or missing fuses in the 4. Check the thermostats and

input line. associated leads for loose or
broken connections. See wiring
4. The thermostats may be open diagram.
due to machine overheating. If
machine operates normally after 5. The control board may be faulty.
a cooling off period then check Replace.
for proper fan operation and
ventilation. Make certain that
the machine's duty cycle is not
being exceeded.

5. Check the trigger circuit. Leads

#324 to #325 should have conti-
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nuity (zero ohms) when the gun

trigger is pulled. If not then the
gun may be faulty - replace.
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CAUTION
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
WIRE-MATIC 255
 F-4 F-4
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
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PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION

OUTPUT PROBLEMS
No Open Circuit Voltage output but 1. Check the input voltage at the 1. Check for loose or broken con-
wire feeds normally when gun trig- machine. Input voltage must nections at the output terminals,
ger is pulled. match the rating plate and the the choke, the capacitor bank
reconnect panel. and all heavy current carrying
leads.
2. The gun may be faulty. Check
or replace. 2. Make sure that the transformer
secondary leads are securely
connected to the SCR Rectifier
Assembly.
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3. Perform the SCR Rectifier

Assembly Test.

4. The control board may be faulty

- Replace.

Wire feeds but welding output is low 1. Make sure that the proper wire 1. Check for loose or faulty con-
causing wire to "stub". Welds are and procedures are being used. nections of the heavy current
"cold". Machine cannot obtain full carrying leads.
rated output of 200 amps at 28 volts. 2. Check gun and work cable for
loose or faulty connections. 2. The output capacitor bank may
be faulty. Check for loose con-
nections at the capacitors. Also
check for leaky capacitors.
Replace if necessary.
WARNING: The liquid elec-
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trolyte in these capacitors is

toxic. Avoid contact with any
portion of your body.

3. Perform the SCR Rectifier

Assembly Test.

4. Perform the Main Transformer

Test.

5. The control board may be faulty.

Replace.
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CAUTION
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

WIRE-MATIC 255
 F-5 F-5
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
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PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION

OUTPUT PROBLEMS
The output voltage and wire feed is 1. Remove the gun. If the problem 1. Check the machine's internal
present continuously or pulsing is resolved the gun trigger circuit trigger leads for grounds or
when gun trigger is NOT activated. is faulty. Repair or replace. shorts. See Wiring Diagram.

2. If the problem is not resolved 2. The control board may be faulty.

then contact your Local Lincoln Replace.
Electric Authorized Field
Service Facility.
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CAUTION
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

WIRE-MATIC 255
 F-6 F-6
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
Return to Section TOC
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PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION

FUNCTION PROBLEMS
No control of arc voltage. Wire feed- 1. The Arc Voltage Control poten- 1. The Arc Voltage Control poten-
ing is normal. tiometer may be dirty. Rotate tiometer may be faulty. Check or
several times and check if prob- replace. See Wiring Diagram.
lem is resolved.
2. Perform the SCR Rectifier
Assembly Test.

3. The control board may be faulty.

Replace.
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There is no gas flow when gun trig- 1. Check gas source and hoses for 1. Check the gas solenoid by dis-
ger is pulled. Wire feeds and weld leaks or kinks. connecting it from the control
voltage is present. board (Plug J8) and applying a
2. If Spool Gun adaptor is not 12 VDC external supply to the
installed make certain jumper gas solenoid. If the solenoid
plug is installed in plug J20. See does NOT activate then it may
Wiring Diagram. be faulty. Replace.

2. The control broad may be faulty.

Replace.

The machine stops feeding wire 1. Check for mechanical restric- 1. Check the motor armature cur-
while welding. tions in the wire feeding path. rent. Normal armature current is
The gun may be clogged. 1.75 amps maximum. If the
motor armature current is normal
the control board may be faulty.
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Replace.

2. If the motor armature current is

high (2 to 2.5 amps) and there
are NO restrictions in the wire
feeding path then the motor or
gear box may be defective.
Replace.
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CAUTION
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

WIRE-MATIC 255
 F-7 F-7
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
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PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION

WIRE FEEDING PROBLEMS

No control of wire feed speed. 1. The wire feed speed control 1. The Wire Speed Control poten-
Other machine functions are nor- may be dirty. Rotate several tiometer may be faulty. Check
mal. times and check if problem is or replace. See Wiring
resolved. Diagram.

2. Perform the Wire Drive Motor

and Tach Feedback test.

3. The control board may be faulty.

Replace.
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1. If the drive rolls are turning then

There is no wire feed when gun trig- check for a mechanical restric- 1. Perform the Wire Drive Motor
ger is pulled. Normal open circuit tion in the wire feed path. and Tach Feedback Test.
voltage is present.
2. The gun liner may be clogged. 2. The Wire Feed Control poten-
Check or Replace. tiometer may be faulty. Check
or replace. See Wiring
3. If the drive rolls are NOT turning Diagram.
when the gun trigger is pulled
then contact your local Lincoln 3. The control board may be faulty.
Electric Authorized Field Replace.
Service Facility.
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CAUTION
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

WIRE-MATIC 255
 F-8 F-8
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
Return to Section TOC
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PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION

WELDING PROBLEMS
The arc is unstable and or "hunting". 1. Check for worn or melted con- 1. Check for loose connections at
tact tip. the output terminals, the choke,
the capacitor bank and all heavy
2. Check for loose or faulty con- current carrying leads.
nections on the work and elec-
trode cables. 2. Make sure that the transformer
secondary leads are securely
3. Make sure electrode polarity is connected to the SCR Rectifier
correct or welding process Assembly.
being used.
3. The output capacitor bank may
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4. Check for rusty or dirty wire. be faulty. Check for loose con-
nections at the capacitors. Also
5. Make sure machine settings check for leaky capacitors.
and gas are correct for process Replace if necessary.
being used. WARNING: The liquid elec-
trolyte in these capacitors is
toxic. Avoid contact with any
portion of your body.

4. The control board may be faulty.

Replace

Weld bead is narrow or ropy. May 1. Make sure the weld procedure 1. The output capacitor bank may
have porosity with electrode stub- and electrode polarity is correct be faulty. Check for loose con-
bing into plate. for the process being used. nections at the capacitors. Also
check for leaky capacitors.
2. Make sure shielding gas is cor- Replace if necessary.
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rect and flow is proper. WARNING: The liquid elec-

trolyte in these capacitors is
3. Make sure the weld joint is not toxic. Avoid contact with any
"contaminated". portion of your body.

2. The control board may be faulty.

Replace.

The contact tip seizes in the gas dif- 1. The tip being over heated due to
fuser. excessive current and/or high
duty cycle welding.

2. A light application of high tem-

perature antisieze lubricant
(such as Lincoln E2607
Graphite Grease) may be
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applied to the contact tip

threads.

CAUTION
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

WIRE-MATIC 255
 F-9 F-9
TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual
Return to Section TOC
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PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENTS(S) COURSE OF ACTION

WELDING PROBLEMS
The welding arc is variable and slug- 1. Check the welding cable con- 1. Perform the Output Rectifier
gish. nections for loose or faulty con- Bridge Test.
nections.
2. The control board may be faulty.
2. Make sure the wire feed speed, Replace.
voltage, and shielding gas are
correct for the process being
used.

The arc striking is poor. 1. Check the welding cable con- 1. The control board may be faulty.
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nections for loose or faulty con- Replace.

nections.

2. Make sure the wire feed speed,

voltage, and shielding gas are
correct for the process being
used.
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Return to Section TOC
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CAUTION
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

WIRE-MATIC 255
 F-10 F-10
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER TEST
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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 to
the technician or the machine operator and will invalidate your factory warranty. For
your 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 perform
Return to Section TOC
Return to Master TOC

the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

TEST DESCRIPTION
This test will determine if the correct voltages are being:

a. Applied to the primary windings of the Main Transformer.

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b. Induced on the secondary and auxiliary windings of the main transformer.

MATERIALS NEEDED
5/16" Nut Driver.
Volt-Ohm Meter.
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WIRE-MATIC 255
 F-11 F-11
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER TEST
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TEST PROCEDURE

WARNING
The ON/OFF POWER SWITCH will be
"hot" during these tests.
__________________________

NOTE: Secondary voltages will vary

proportionably with the primary input
voltage.

1. Disconnect the main input power

supply to the machine.
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2. Remove the Case Top and Side

Panels with a 5/16" nut driver.

3. Locate Plug J3 and Plug J6 on the

G2803 Control PC Board.

NOTE: The location of Plugs may vary

depending on the machine code.

#202
(1J3)
J3
WM-255 CONTROL

#204A (2J3)
#203
G2803

(3J3)
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#206
J9 (4J6)
#209
(7J6)

J6

J4 #208
(16J6)
J5
J1 J10
J7

J2
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FIGURE F.1 - G2803 Control PC

Board Main Transformer Test Points.

WIRE-MATIC 255
 F-12 F-12
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER TEST (CONTINUED)
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4. Locate the following leads on Plug Board.

J3: a. Turn the machine OFF between
G2803: each test.
LEAD PLUG b. Carefully insert the meter
LOCATION probes into the back of each
Molex Plug pin cavity to perform
#202 1J3 the test.
#203 3J3 G2803:
#204 A 2J3
5. Connect main input power to the FROM TO EXPECTED
machine. LEAD LEAD VOLTAGE

6. Turn the Wire-Matic 255 ON/OFF #208 #209 60 VAC

POWER SWITCH to ON. (16J6) (7J6)
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7. Make the following voltage tests at #208 #206 30 VAC

Plug J3. (16J6) (4J6)

a. Turn the machine OFF between #209 #206 30 VAC

each test. (7J6) (4J6)

b. Carefully insert the meter c. If any of the voltages tested are

probes into the back of each incorrect, check for loose or bro-
Molex Plug pin cavity to perform ken leads between the test
the test. points and the main transformer.
G2803:
d. If ALL the voltages tested are
FROM TO EXPECTED
incorrect or missing, go to Step
LEAD LEAD VOLTAGE
12.
#202 #203 30 VAC 12. Test for correct nameplate input volt-
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(1J3) (3J3) age between the H1 lead at the

ON/OFF POWER SWITCH to H2 or
#202 #204 A 15 VAC H3 (H5 if connected for 575 VAC) at
(1J3) (2J3) the reconnect panel. Voltage tested
will vary depending on Input Voltage
Connection. See wiring diagram for
#203 #204 A 15 VAC test point locations.
(3J3) (2J3)
a. If the voltage test is incorrect,
8. Turn OFF the machine
- check for loose or broken
9. Locate the following leads on Plug leads between the reconnect
J6 on the G2803 Control PC Board. panel and the ON/OFF POWER
G2803: SWITCH.
LEAD PLUG
- test the ON/OFF POWER
LOCATION
SWITCH for proper operation.
#206 4J6
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#208 16J6 b. If the correct nameplate voltage

#209 7J6 is being applied to the main
transformer and one or more of
10. Turn ON the machine. the secondary voltages are
missing or are incorrect, the
11. Make the following voltage tests at main transformer may be faulty.
Plug J6 on the G2803 Control PC Replace.

WIRE-MATIC 255
 F-13 F-13
TROUBLESHOOTING & REPAIR
STATIC SCR RECTIFIER ASSEMBLY TEST
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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 to
the technician or the machine operator and will invalidate your factory warranty. For
your 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 perform
Return to Section TOC
Return to Master TOC

the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

TEST DESCRIPTION
This test is used to quickly determine if an SCR or diode is shorted or "leaky." See the
Machine Waveform Section in this manual for normal and abnormal output waveforms.
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MATERIALS NEEDED
Analog Ohmmeter (Multimeter).
Wire-Matic 255 wiring diagrams (See Electrical Diagrams Section of this Manual).
5/16" Nut Driver.
1/2" Open end or socket wrench.
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WIRE-MATIC 255
 F-14 F-14
TROUBLESHOOTING & REPAIR
STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED)
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TEST PROCEDURE
1. Disconnect main AC input power to
the machine.

2. Disconnect Plugs J3 and J6 from

the G2803 Control Board. This
electrically isolates the SCR bridge
assembly. See Figure F.2.

J3
LEADS
WM-255 CONTROL

X2 AND X3
G2803
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NEGATIVE
J9
CAPACITOR
J6
BANK
BUSS BAR
J4

J5
J1 J10
J7 FIGURE F.3 - Location of Leads X2
J2
and X3.

5. Separate leads X2 and X3 from the

negative capacitor bank buss bar.
FIGURE F.2 - Remove Plugs J3 and J6 Be sure there is no electrical con-
to Perform Static SCR Rectifier tact. See Figure F.3.
Assembly Test.
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3. Verify that the capacitors have com-

pletely discharged with an Analog
Volt-Ohm meter.

4. Disconnect leads X2 and X3 from

the negative capacitor bank using a
1/2" open end wrench. See Figure
F.3.
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WIRE-MATIC 255
 F-15 F-15
TROUBLESHOOTING & REPAIR
STATIC SCR RECTIFIER ASSEMBLY TEST (CONTINUED)
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NOTE: DO NOT DISASSEMBLE THE

SCR RECTIFIER HEAT SINK ASSEM-
BLY.

6. Test for high or infinite resistance

from the anode to the cathode of
SCR 1. See Figure F.4. Use an
analog ohmmeter (Multimeter).
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FIGURE F.4 - SCR 1 Test Points.

7. Test for high or infinite resistance

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from the cathode to the anode of

SCR 1 by reversing the meter leads.
See Figure F.4.

a. If a high or infinite resistance is

indicated for both tests 6 and 7,
the SCR 1 is not “shorted”.

b. If a low resistance is indicated in

either tests 6 or 7, the SCR is
faulty. Replace SCR Assembly.

8. Repeat Steps #7 to test SCR 2.

9. Reconnect leads X2 and X3.

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10. Reconnect Plugs J3 and J6.

11. If this test did not identify the prob-

lem or to further test the SCR, go to
the Active SCR Test.

WIRE-MATIC 255
 F-16 F-16
TROUBLESHOOTING & REPAIR
ACTIVE SCR RECTIFIER ASSEMBLY TEST
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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 to
the technician or the machine operator and will invalidate your factory warranty. For
your 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 perform
Return to Section TOC
Return to Master TOC

the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

TEST DESCRIPTION
The Active SCR Test will determine if the device is able to be gated ON and conduct current
from anode to cathode.
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MATERIALS NEEDED
An SCR Tester as specified in this procedure.
Wire-Matic 255 wiring diagrams (See Electrical Diagrams Section of this Manual).
SCR Heat Sink Assembly Drawings.
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WIRE-MATIC 255
 F-17 F-17
TROUBLESHOOTING & REPAIR
ACTIVE SCR RECTIFIER ASSEMBLY TEST (CONTINUED)
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TEST PROCEDURE
1. Disconnect main AC input power to
the machine.

2. Disconnect Molex Plugs J3 and J6

from the G2803 Control Board.
See Figure F.5.
LEADS
X2 AND X3
J3
WM-255 CONTROL

NEGATIVE
G2803

CAPACITOR
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J9 BANK
J6
BUSS BAR
J4
FIGURE F.6 - Location of Leads X2
J5 and X3.
J1 J10
J7

J2
5. Separate leads X2 and X3 from the
negative capacitor bank buss bar.
Be sure there is no electrical con-
tact. See Figure F.6.
FIGURE F.5 - Control Board Molex
Plug Locations for G2803 PC Control NOTE: DO NOT DISASSEMBLE THE
Board. SCR RECTIFIER HEAT SINK ASSEM-
BLY.
3. Verify that the capacitors have com-
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pletely discharged with an Analog

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6. Construct the circuit shown in Figure

Volt-Ohm meter. F.7. One 6-volt lantern battery can
be used. R1 and R2 resistor values
4. Disconnect leads X2 and X3 from are ±10%. Set voltmeter scale low,
the negative capacitor bank using a at approximately 0-5 volts or 5-10
1/2" open end wrench. volts.
See Figure F. 6.
a. Test the voltage level of the bat-
tery. Short leads (A) and (C).
Close switch SW-1. Battery
voltage should be 4.5 volts or
higher. If lower, replace the bat-
tery.
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WIRE-MATIC 255
 F-18 F-18
TROUBLESHOOTING & REPAIR
ACTIVE SCR RECTIFIER ASSEMBLY TEST (CONTINUED)
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7. Connect the Tester to the SCR 1 as 10. Close or keep closed switch SW-1.
shown in Figure F.7.
11. Close switch SW-2 for 2 seconds
a. Connect Tester lead (A) to the and release and read meter.
anode.
a. If the voltage is 3 - 6 volts while
b. Connect Tester lead (C) to the the switch is closed and after
cathode. the switch is open, the SCR is
functioning.
c. Connect Tester lead (G) to the
gate. b. If the voltages is 3-6 volts only
when the switch is closed or
there is no voltage when the
switch is closed, the SCR is
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defective.

NOTE: Be sure battery is functioning

properly. A low battery can affect the
results of the test. Repeat Battery Test
Procedure in Step 6 if needed.

12. Open switch SW-1.

13. Reconnect the Tester leads. See

Figure F.7.

a. Connect Tester lead (A) to the

cathode.

b. Connect Tester lead (C) to the

anode.
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c. Disconnect Test lead (G) from

the gate.

14. Close switch SW-1.

15. Read meter for zero voltage.

a. If the voltage is zero, the SCR is

functioning.

b. If the voltage is higher than

FIGURE F.7 - SCR Tester Circuit and zero, the SCR is shorted.
SCR connections.

8. Close switch SW-1. 16. Perform the Active Test Procedure

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outlined in Steps 5-13 for SCR 2.

NOTE: Switch SW-2 should be open.
17. Replace all SCR assemblies that do
9. Read meter for zero voltage. not pass the above tests.

a. If the voltage reading is higher 18. Replace all Molex Plugs onto the
than zero, the SCR is shorted. Control Board and connect leads X2
and X3.
WIRE-MATIC 255
 F-19 F-19
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST
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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 to
the technician or the machine operator and will invalidate your factory warranty. For
your 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 perform
Return to Section TOC
Return to Master TOC

the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

TEST DESCRIPTION
This test will determine if the wire drive motor and voltage feedback circuit are functioning
properly.
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MATERIALS NEEDED
5/16" Nut Driver.
Volt-Ohmmeter.
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WIRE-MATIC 255
 F-20 F-20
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (CONTINUED)
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TEST PROCEDURE
NOTE: POLARITY MUST BE
OBSERVED FOR THESE TESTS.

Test for Correct Wire Drive Motor

Armature Voltage

1. Disconnect main input power to the

machine.

2. Remove the Case Top and Side

Panels using a 5/16" nut driver.
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3. Locate Plug J5 on the G2803

Control Board. See Figure F.8.

J3
WM-255 CONTROL
G2803

J9
J6
#541 (W)
(13J5)

#539 (B)
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J4 J5 (12J5)

J1 J10 J2 #555
J7
(1J5)
#206B
#515B (2J5)
(3J5)

FIGURE F.8 - Plug J5 Location on

G2803 PC Control Board.
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WIRE-MATIC 255
 F-21 F-21
TROUBLESHOOTING & REPAIR
WIRE DRIVE MOTOR AND TACHOMETER FEEDBACK TEST (CONTINUED)
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4. Test for 2 - 25 VDC between lead

plug location 12J5 #539(B) (posi- a. If the 15 VDC is present, check
tive) (12J5) and lead #541(W) the leads to the tach circuit.
(13J5) (negative) to determine if the
correct armature voltage is being b. If the leads are okay and 15
supplied. See Figure F.8. VDC is present, the correct volt-
age is being received from the
a. Insert probes in to the Molex pin Control Board. Go to Feedback
cavities. Test.

5. Pull the gun trigger. c. If the 15 VDC is not present and

the leads are okay, the Control
6. Read meter. Normal DC volts is Board may be faulty. Replace.
from 2 - 25 VDC. VDC varies
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depending on wire feed speed.

Test for Feedback Voltage to the
a. If voltage to the wire drive motor Control Board
armature is zero, check the
wires between Plug J5 and the 1. Test for 1.5 - 3.5 VDC between lead
wire drive motor. (Check J11, #555 (positive) (1J5) and lead
J12, and J15). See Wiring #206B (negative) (2J5) . See Figure
Diagram. F.8 for pin locations.

b. If the wires are okay and voltage a. Insert probes into Molex pin
to the drive motor armature is cavities.
zero, the Control Board may be
faulty. Replace. 2. Pull gun trigger.

c. If the correct DC armature volt- 3. Read meter for 1.5 - 3.5 VDC.
age is present at the wire drive
motor, the motor or motor brush- a. If the 1.5 - 3.5 VDC is present,
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es may be faulty. Test and/or the tach circuit is sending the

replace. correct feedback signal to the
Control Board.
d. If the motor is running at high
speed and the armature voltage NOTE: IF THE MOTOR IS NOT RUN-
is high and uncontrollable, pro- NING, THE FEEDBACK VOLTAGE MAY
ceed with the tachometer test. BE FROM 0 TO 5 VDC.

b. If the 1.5 - 3.5 VDC is not pre-

Test for Supply Voltage to sent or not correct, the Control
Tachometer Board is not receiving the prop-
er feedback voltage from the
1. Test for 15 VDC between lead tach circuit. Check the leads
#515B (positive) (3J5) and lead from the tach circuit to the
#206B (negative) (2J5) . See Figure Control Board for loose or bro-
F.8 for pin locations. ken connections.
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a. Insert probes into Molex pin c. If the leads are okay, the Control
cavities. Board may be faulty. Replace.

2. Pull gun trigger.

3. Read meter for 15 VDC.

WIRE-MATIC 255
 F-22 F-22
TROUBLESHOOTING & REPAIR
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NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

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SCOPE SETTINGS

This is a typical DC output voltage wave-

form generated from a properly operating Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
machine. Note that each vertical division
represents 20 volts and that each horizontal Horizontal Sweep . . . . . . . . . .2 ms/Div.
division represents 2 milliseconds in time.
Coupling . . . . . . . . . . . . . . . . . . . . .DC.
Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-) Trigger . . . . . . . . . . . . . . . . . . .Internal.
probe to work.
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WIRE-MATIC 255
 F-23 F-23
TROUBLESHOOTING & REPAIR
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TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

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MACHINE LOADED TO 250 AMPS AT 26 VDC

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SCOPE SETTINGS

This is a typical DC output voltage wave-

form generated from a properly operating Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
machine. Note that each vertical division
represents 20 volts and that each horizontal Horizontal Sweep . . . . . . . . . .5 ms/Div.
division represents 5 milliseconds in time.
The machine was loaded with a resistance Coupling . . . . . . . . . . . . . . . . . . . . .DC.
grid bank.
Trigger . . . . . . . . . . . . . . . . . . .Internal.
Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-)
probe to work.
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WIRE-MATIC 255
 F-24 F-24
TROUBLESHOOTING & REPAIR
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ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

ONE OUTPUT SCR NOT FUNCTIONING
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MACHINE LOADED TO 220 AMPS AT 22 VDC

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SCOPE SETTINGS

This is NOT a typical DC output voltage

waveform. One output SCR is not function- Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
ing. Note the increased ripple content. One
SCR gate was disconnected to simulate an Horizontal Sweep . . . . . . . . . .5 ms/Div.
open or non-functioning output SCR. Each
vertical division represents 20 volts and Coupling . . . . . . . . . . . . . . . . . . . . .DC.
each horizontal division represents 5 mil-
liseconds in time. The machine was loaded Trigger . . . . . . . . . . . . . . . . . . .Internal.
with a resistance grid bank.

Note: Scope probes connected at machine

output terminals: (+) probe to electrode, (-)
probe to work.
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WIRE-MATIC 255
 F-25 F-25
TROUBLESHOOTING & REPAIR
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ABNORMAL OPEN CIRCUIT VOLTAGE

OUTPUT CAPACITOR BANK NOT FUNCTIONING
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SCOPE SETTINGS

This is NOT the typical DC output voltage

waveform. The output capacitors are not Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.
functioning. Note the lack of “filtering” in the
output waveform. The output capacitor Horizontal Sweep . . . . . . . . . .5 ms/Div.
bank was disconnected. Each vertical divi-
sion represents 20 volts and each horizontal Coupling . . . . . . . . . . . . . . . . . . . . .DC.
division represents 5 milliseconds in time.
Trigger . . . . . . . . . . . . . . . . . . .Internal.
Note: Scope probes connected at machine
output terminals: (+) probe to electrode, (-)
probe to work.
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WIRE-MATIC 255
 F-26 F-26
TROUBLESHOOTING & REPAIR
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TYPICAL SCR GATE VOLTAGE WAVEFORM

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SCOPE SETTINGS

This is a typical SCR gate pulse voltage

waveform. The machine was in an open cir- Volts/Div . . . . . . . . . . . . . . . . . .2 V/Div.
cuit condition (no load) and operating prop-
erly. Note that each vertical division repre- Horizontal Sweep . . . . . . . . . .5 ms/Div.
sents 2 volts and each horizontal division
represents 5 milliseconds in time. Coupling . . . . . . . . . . . . . . . . . . . . .DC.

Note: Scope probes connected at Plug J3 Trigger . . . . . . . . . . . . . . . . . . .Internal.

on the control board. The (+) probe to lead
G2, and the (-) probe to lead 204.
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WIRE-MATIC 255
 F-27 F-27
TROUBLESHOOTING & REPAIR
CONTROL PC BOARD REMOVAL AND REPLACEMENT
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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 to
the technician or the machine operator and will invalidate your factory warranty. For
your 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 perform
Return to Section TOC
Return to Master TOC

the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

CAUTION

Printed Circuit Boards can be damaged by static electricity. Follow static handling
guidelines detailed in “PC Board Troubleshooting Procedures” at the beginning of
this chapter.
_______________________________________________________
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REMOVAL AND REPLACEMENT PROCEDURE

MATERIALS NEEDED

5/16" Nutdriver.
Phillips head screwdriver.
Static electricity grounding strap.
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WIRE-MATIC 255
 F-28 F-28
TROUBLESHOOTING & REPAIR
CONTROL PC BOARD REMOVAL AND REPLACEMENT (CONTINUED)
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REMOVAL AND REPLACE- 4. Carefully remove the P.C. Board

from the mounting standoffs. See
MENT PROCEDURE Figure F.10.

1. Disconnect main input power the

machine.

2. Remove the Case Top and Side

Panels using 5/16" nut driver.

3. Disconnect all wiring harness plugs

and Molex Plugs connected to the
Control Board. See Figure F.9.
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WM-255 CONTROL

J3
G2803

J9

J6

J4 J5
FIGURE F.10 - Control Board
J1 J7 J10 J2
Mounting Locations may vary
with different Code Machines.
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5. Lift the Control Board straight up

FIGURE F.9 - Wiring Harness and and out from the machine.
Molex Plug Locations.
6. When re-installing the Control
Board carefully secure Board to
mounting standoffs.
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WIRE-MATIC 255
 F-29 F-29
TROUBLESHOOTING & REPAIR
WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT
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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 to
the technician or the machine operator and will invalidate your factory warranty. For
your 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 perform
Return to Section TOC
Return to Master TOC

the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

MATERIALS NEEDED

Large slot head screwdriver.

5/16" Nut Driver.
Small slot head screwdriver.
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WIRE-MATIC 255
 F-30 F-30
TROUBLESHOOTING & REPAIR
WIRE DRIVE ASSEMBLY REMOVAL AND REPLACEMENT (CONTINUED)
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PROCEDURE
1. Disconnect main input power to the
machine.

2. Remove the Case Top and Side

Panels.

3. Using the 5/16” Nutdriver remove

the gear box top cover.

4. Remove the two sheet metal screws

located on the left rear side of the
gear box housing using a 5/16” nut-
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driver.

5. Remove the drive roll. See Figure

F.11.

a. Remove the thumb screw, drive

hub, and the spacer.

6. Remove the screw holding the gun

connector assembly to the Case
Front Panel. See Figure F.11.

7. Slide the entire wire drive assembly

carefully toward the Case Back and
approximately 2” (51 mm) away FIGURE F.11 - Wire Drive Assembly
from the center baffle to gain access Removal
to the drive motor and wiring.
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10. Disconnect molex plugs J15, J12,

a. The gas hose and gun connec- and J11. See wiring diagram.
tor leads will limit the travel dis-
tance. 11. Remove the drive roll assembly.

8. Disconnect the drive motor from the a. Remove the two screws mount-
drive roll assembly. ing the drive roll assembly to the
insulator board using a 5/16” nut
a. Remove the three large phillips driver.
head screws on the outboard
side of the drive roll assembly b. Loosen the set screw using a
face plate using a phillips head slot head screwdriver that holds
screw driver. the outgoing guide tube into the
drive roll assembly.
9. Separate the drive roll assembly
from the drive motor. c. Remove the drive assembly by
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sliding it off the out going guide

a. Grip the drive motor in one hand tube and towards the Case
and the drive assembly in the Back at the rear of the machine.
other hand.

b. Wiggle the drive motor and drive

assembly gently back and forth
until the two parts separate.

WIRE-MATIC 255
 F-31 F-31
TROUBLESHOOTING & REPAIR
SCR OUTPUT RECTIFIER REMOVAL & REPLACEMENT
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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 to
the technician or the machine operator and will invalidate your factory warranty. For
your 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 perform
Return to Section TOC
Return to Master TOC

the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

MATERIALS NEEDED
5/16" Nut driver.
1/2" Open end wrench.
1/2" Socket wrench, universal tool, and extension.
3/8" Open end wrench.
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Slot head screwdriver.

Wire cutters.
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WIRE-MATIC 255
 F-32 F-32
TROUBLESHOOTING & REPAIR
SCR OUTPUT RECTIFIER REMOVAL & REPLACEMENT (CONTINUED)
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PROCEDURE 4. Cut the SCR gate leads G1 and G2

(see wire markers and wiring dia-
1. Disconnect lead #208 and gram) using wire cutters.
Transformer Lead X1 from the heat
sink on the left side of the machine a. The easiest access to these
(facing the front) using a 1/2" socket leads is from the right side of the
wrench. See Figure F.12. machine.

a. Thin lead is always on the out- b. Cut any necessary cable ties.
board side of the connection.
5. Remove the four screws holding the
SCR Assembly to the floor of the
machine using a 5/16" nut driver.
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6. Pivot the SCR Assembly counter-

clockwise to provide access to the
right side heat sink.
See Figure F.14.

FIGURE F.12 - Heat Sink lead discon-

nection.

2. Disconnect lead #204 and heavy

lead from the middle heat sink with a
Return to Section TOC

1/2" socket wrench and 1/2" open

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end wrench. See Figure F.13.

3. Remove the diode lead from the FIGURE F.14 - Heat Sink Lead
negative capacitor band buss bar on Disconnection
the right side of the machine using a
slot head screwdriver and 3/8" open 7. Remove lead #209 and Transformer
end wrench. Lead X4 from the right side heat sink
using a 1/2" socket wrench and 1/2"
open end wrench.

8. Clear the leads and carefully

remove the SCR Rectifier Assembly.

NOTE: When installing the SCR

Rectifier Assembly, apply a thin coating
of Dow Corning #340 Compound to the
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electrical connections.

FIGURE F.13 - Heat Sink lead discon-

nection.

WIRE-MATIC 255
 F-33 F-33
TROUBLESHOOTING & REPAIR
CAPACITOR BANK REMOVAL AND REPLACEMENT
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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 to
the technician or the machine operator and will invalidate your factory warranty. For
your 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 perform
Return to Section TOC
Return to Master TOC

the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

WARNING
THE LIQUID ELECTRODE IN THE CAPACITORS IS TOXIC. DO NOT TOUCH THE CAPAC-
ITORS WITH ANY PART OF YOUR BODY.

_____________________________________________________________
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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.
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WIRE-MATIC 255
 F-34 F-34
TROUBLESHOOTING & REPAIR
CAPACITOR BANK REMOVAL AND REPLACEMENT (CONTINUED)
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PROCEDURE 6. Remove the #204 lead from the pos-

itive buss bar.
See Figure F.15 for location of Capacitor
7. Remove the shunt from the negative
Bank Removal and Replacement com-
capacitor bank buss bar using a 1/2"
ponents.
socket wrench with a universal tool
adapter.

a. Two people may be required to

remove the shunt. One person
may have to reach through from
the left side of the machine to
keep the bolt in position while
the other person loosens the
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nut.
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8. Remove the two screws holding the

capacitor bank to the floor of the
machine using a 5/16" nut driver.

9. Clear the leads and carefully

remove the capacitor bank assem-
bly from the machine.

FIGURE F.15 - Location of Capacitor

Bank Removal and Replacement
Components.
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1. Disconnect main input power to the

machine.

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 the
negative capacitor bank buss bar
using two 1/2" open end wrenches.

4. Remove the output choke lead and

the heavy lead extending from the
SCR Rectifier Assembly to the posi-
tive capacitor bank buss bar using a
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1/2" open end wrench.

5. Remove lead #206 and the D1

diode lead from the negative capac-
itor bank buss bar using a slot head
screwdriver and 3/8" open end
wrench.

WIRE-MATIC 255
 F-35 F-35
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
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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 to
the technician or the machine operator and will invalidate your factory warranty. For
your 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 perform
Return to Section TOC
Return to Master TOC

the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

MATERIALS NEEDED
5/16" Nut Driver.
1/2" Open end wrench.
3/8" Open end wrench.
1/2" Socket wrench, extender, universal adapter.
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Wire cutters.
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WIRE-MATIC 255
 F-36 F-36
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER REMOVAL AND REPLACEMENT (CONTINUED)
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PROCEDURE 12. Disconnect the positive output lead

at the wire drive motor.
1. Disconnect main input power to the
machine. 13. Remove the strain relief grommet
through which the positive output
2. Remove the Case Top and Side lead passes through the horizontal
Panels. baffle of the machine.

3. Perform the Capacitor Bank 14. Pull down on the positive output
Removal Procedure. lead until it slides out the hole in the
baffle.
4. Remove lead X1 from the left side
SCR heat sink assembly using a 15. Carefully remove the main trans-
1/2" socket wrench, extender and former.
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universal adapter.
a. Be sure all leads are clear.
5. Remove lead X4 from the right side
heat 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 end
wrench.

7. Disconnect all leads from the

POWER SWITCH.

8. Remove the POWER SWITCH.

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9. Label and cut leads #202, #203,

#204A.

a. Cut lead #204A at a point just in

front of the transformer.

b. These leads must be re-spliced

during reassembly.

c. An alternative to cutting these

leads is to remove them from
Molex Plug J3 and pull them
free of any wire bundles.

10. Remove all cable ties, wire mounts,

- and any harness tape that could
get in the way during transformer
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removal using wire cutters and

screwdriver.

11. Remove the four screws mounting

the transformer to the floor of the
machine using a 5/16" nut driver.

WIRE-MATIC 255
 F-37 F-37
TROUBLESHOOTING & REPAIR
FAN MOTOR AND FAN REMOVAL AND REPLACEMENT
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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 to
the technician or the machine operator and will invalidate your factory warranty. For
your 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 perform
Return to Section TOC
Return to Master TOC

the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).

_____________________________________________________________

MATERIALS NEEDED
3/4" Open end wrench.
1/2" Socket wrench with extension.
Phillips head screwdriver.
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WIRE-MATIC 255
 F-38 F-38
TROUBLESHOOTING & REPAIR
FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED)
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PROCEDURE
See Figure F.16 for fan motor and fan
removal components.
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FIGURE F.16 - Fan Motor and Fan

Removal Components

1. Remove the Case Back screws. 5. Loosen the two screws holding the
reconnect panel in place and a slide
2. Remove the gas solenoid using a the reconnect panel from the frame.
3/4" open end wrench.
6. Remove the fan blade. Note fan
3. Using a 5/16” wrench, remove the 5 blade position on motor shaft for ref-
screws holding the fan motor mount- erence for replacing fan.
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ing bracket to the case back.

a. Pry the fan blade off the motor.
4. Tilt the Case Back away from the
machine and remove the screws b. Slide the fan blade off the motor
holding the Case Back to the floor of shaft.
the machine using a 1/2" socket
wrench with extension.

WIRE-MATIC 255
 F-39 F-39
TROUBLESHOOTING & REPAIR
FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED)
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7. Remove the fan motor.

a. Loosen and remove the two

screws from the motor mounting
bracket using a slot head screw
driver.

b. When the motor is free from the

mounting bracket, place it care-
fully on the bottom of the
machine.

c. Cut any necessary wire wraps

bundling the motor leads.
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d. Remove the leads from the fan

motor.

8. Install the replacement motor in the

reverse order of removal.

9. Install the fan blade. When

installing the fan blade, the blade is
flush with the end of the motor shaft.

a. Spin the fan to be sure it is free

to rotate.

10. Reassemble the remaining compo-

nents in reverse order of removal.
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WIRE-MATIC 255
 F-40 F-40
TROUBLESHOOTING & REPAIR
RETEST AFTER REPAIR
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INPUT IDLE AMPS AND WATTS

Input Volts/Hertz Maximum Idle Amps Maximum Idle Watts

230/60 6.4 375

OPEN CIRCUIT VOLTAGE

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10 to 40 VDC 35-40 VDC Strike Voltage

WIRE SPEED RANGE

50 - 600 IPM (1.27 - 15.2 m/minute)

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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 NOTES

WIRE-MATIC 255
 G-1 TABLE OF CONTENTS G-1
- ELECTRICAL DIAGRAMS SECTION -
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Electrical Diagram Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G

Wiring Diagram (208/230) Code 10166 . . . . . . . . . . . . . . . . . . . . . . . . . G-2

Wiring Diagram (230/460/575) Code 10167 . . . . . . . . . . . . . . . . . . . . . . G-3
Control PC Board (G2803) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . G-4
Control PC Board (G2803) Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
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WIRE-MATIC 255
 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES

WIRE-MATIC 255
 G-2 ELECTRICAL DIAGRAMS G-2

Wiring Diagram (208/230) Code 10166

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WIRE - MATIC 255 (208 / 230V)

GENERAL INFORMATION
1
OPTIONAL ELECTRICAL SYMBOLS PER E1537
TIMER 260 1 (J7)
* CONTROL BOARD (J8)
2

*
* 392
BOARD
* 3 COLOR CODE:
262 2
J16 (J4) 390
4
261 3 * B - BLACK
263 4 W - WHITE
J1 1 2 3 4 *
5 (J9)
R - RED
265
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 U - BLUE
264 6
266 7 SCI TEST * INDICATES CONNECTOR CAVITY NO.

541A
267 8

324A
325A

206A
515

495
PLUG

542

543
1 2 3 4 5 6

260

262

261
263

265

264

266
267
1 R.F.
2
CHOKE
3
AS'BLY
251 4
* **
5 1

WIRE SPEED 6
J2
1 555 2
202 1
J21

R3
204A 2 1
7 SPI TEST 2 206B 3
252 203 3 2
8 PLUG 3 515B 206 4
4 392B 3
9 4 325 207 5
G1 5 390A 4
10 5 GND 6
204 6

1
* 6 209 7
G2 7
(J3)
256 254 (J5) 324
7 8

*
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**
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252 2
* 8
8 9
J20
*
ARC VOLTAGE 9 GAS
R4
253 3 (J6)
J10 9 10
255 4 10 SOLENOID
253 10 205 11 SPOOL GUN ADAPTER
251 5 11 HARNESS
11 12
254 256 6 12
+ 12 B 206S 13 515 1
POWER-ON
13 W 325A 14 325A 2
INDICATOR
14 320 15 324A
- 3
255 208 16 206A 4
TO
541A 5 SPOOL GUN
495
OPTION
6
542 7
543 8
** 392 9
GND
** J15 390 10
J14 515B 1 515B
392B 11

390A 12
1 555 2 555 ** 13
2 B 3 B JUMPER USED WITHOUT
GUN 2 325 325 J11 14
SPOOL GUN OPTION
TRIGGER 3 206B 4 206B
B 1
1 324 4 324 5

W 6 W W 2

TO
WORK
N.A.
MOTOR/ R.F. R.F.
GEARBOX CHOKE CHOKE
P.M. W T R 515B
AS'BLY. AS'BLY.
A **
U 555 **
C J12
H B 206B J13 NOTES
B 1
206 207 1 N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
CURRENT AND DUTY CYCLE OF IMMEDIATE AND
B W 2
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325 2
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FUTURE APPLICATIONS.
320 328 325A 3
N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
N.C.
N.D. 324 4 "POSITIVE". TO CHANGE POLARITY, TURN THE UNIT
R.F. FILTER TO SINGLE PHASE
OFF AND REVERSE LEAD CONNECTIONS AT CABLE
THERMOSTAT THERMOSTAT SUPPLY LINE
N.B. S3 S4 L1 CONDUCTOR STRAP AND WORK STUD.

N.C. THERMOSTATS MOUNTED ON CHOKE COIL

S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO
L2 POWER TRANSFORMER.
X5
202
N.D. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET
H4 .
P2
X6 W N.E. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.
204A GND
H2 H3
TO GROUND PER
X7 208 L1
203 NATIONAL ELECTRICAL
LOW V. HIGH V.
X1 G1
JUMPER CODE
H1 H1 SCR 1 B
250V
470A
204
L2
L1 L2 X2 SCR HEATSINK
ASBLY
H2 GND. RECONNECT PANEL
H2 X3 SCR 2
250V G

*
*
470A
X4 CAVITY
H3 G2 N.C.
H1 H4
H3 209 CAVITY NUMBERING SEQUENCE NUMBERING SEQUENCE
SHUNT POWER TRANSFORMER D1 P2
300V
(COMPONENT SIDE OF P.C. BOARD) (NON-LEAD SIDE OF CONNECTOR)
T1 T2
T1 85A P1 P2
+
H1 -
2 1 2 1 3
FAN
LINE 206 S2 J13
J11
MOTORS J14 J15
SWITCH THERMOSTAT J12
J21
S1 205 1 3 4 4 6
15 OHMS
1 4 1 5 1 6
R1 100 W
C1 THRU C4 J1
206S C1 C2 C3 C4 R2 J3 1 7
30,000 MFD J4 J2
50V 204 2.5K J16
+ + + + J20
OUTPUT N.E. 10W 5 8 6 10 7 12
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CHOKE
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8 14

207
1 7 1 8

J5 J6

8 14 9 16

1 2 1 3
J7 J9
J8 J10

3 4 4 6
C-RW

L9690

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.

WIRE-MATIC 255
 G-3 ELECTRICAL DIAGRAMS G-3

Wiring Diagram (230/460/575) Code 10167

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WIRE - MATIC 255 (230 / 460 / 575V)

GENERAL INFORMATION
OPTIONAL 1

TIMER 260 1 (J7)* CONTROL BOARD 2 ELECTRICAL SYMBOLS PER E1537

(J8)

*
*
BOARD
* 3 392
262 2
J16 (J4) COLOR CODE:
4 390
261 3 *
263 4 B - BLACK
J1 1 2 3 4 * W - WHITE
265 5 (J9)
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 R - RED
264 6
U - BLUE
266 7 SCI TEST
* INDICATES CONNECTOR CAVITY NO.

541A
267 8

324A
325A

206A
515

495
PLUG

542

543
1 2 3 4 5 6

260

262

261
263

265

264

266
267
1 R.F.
2
** CHOKE
3
AS'BLY
251
J21
4 1
*
5 1 2
J2 202 1
6 1 555 2 392B 3
WIRE SPEED

R3
204A 2
7 2 206B 390A 4
SPI TEST 3
252 203 3
8 PLUG 3 515B 206 4
4
9 4 325 207 5 **
G1 5
10
J20
5 GND 6
204 6

1
* 6 209 7
G2 7
(J3) GAS
256 254 (J5) 324 SOLENOID
7 8

*
* SPOOL GUN ADAPTER
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252 2 8
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* 8 9 HARNESS
ARC VOLTAGE 9
R4 253 3
9 (J6)
J10 10
4 10 515 1
255
253 10 205 11
11 325A 2
251 5
11 12
12 324A 3

POWER-ON
+
254 256 6 12 B 206S 13 206A 4
TO
INDICATOR
13 W 325A 14 541A 5 SPOOL GUN
14 320 15 495
-
OPTION
6
255 208 16 542 7
543 8
392 9
390 10
392B 11
** 390A 12
GND
** J15 13
J14 14
JUMPER USED WITHOUT
515B 1 515B SPOOL GUN OPTION

1 555 2 555 **
2 325 2 325 B 3 B J11

GUN 3 206B 4 206B B 1

TRIGGER 324 324 5
1 4

W 6 W W 2

TO
WORK
N.A.
R.F. R.F.
W CHOKE
CHOKE
MOTOR/ T R
NOTES
515B
AS'BLY AS'BLY
GEARBOX P.M. A U 555
**
C J12 N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE
H B 206B 1
CURRENT AND DUTY CYCLE OF IMMEDIATE AND
B 1
325 2 FUTURE APPLICATIONS.
206 207 3 N.B. THIS DIAGRAM SHOWS THE "ELECTRODE" POLARITY
B W 2
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"POSITIVE". TO CHANGE POLARITY, TURN THE UNIT

324 4
OFF AND REVERSE LEAD CONNECTIONS AT CABLE
320 328 325A ** CONDUCTOR STRAP AND WORK STUD.
N.C.
N.D. TO SINGLE PHASE J13
N.C. THERMOSTATS MOUNTED ON CHOKE COIL
R.F. FILTER SUPPLY LINE
THERMOSTAT THERMOSTAT S2 MOUNTED CLOSEST TO FAN; S3 MOUNTED CLOSEST TO
N.B. L1
S3 S4 POWER TRANSFORMER.

N.D. THERMOSTAT S4 MOUNTED ON FAN SENSOR BRACKET

.
L2 N.E. RESISTOR R2 MOUNTED ON FAN SENSOR BRACKET.
X5
202
5
H5
X6
204A L1 L2 GND
TO GROUND PER
X7 208
T1 203 NATIONAL ELECTRICAL
X1 G1 4 2 H2
CODE
H1 SCR 1
P2 250V
470A
H2 204
1 3 H4
L1 L2 H5 X2 SCR HEATSINK
ASBLY H3
H3
X3 SCR 2 H1

*
*
250V
470A RECONNECT PANEL (SHOWN CONNECTED
CAVITY
GND.
X4
G2
FOR 230 VOLT.) CAVITY NUMBERING SEQUENCE NUMBERING SEQUENCE
H1 H4 G
H4 209 (COMPONENT SIDE OF P.C. BOARD) (NON-LEAD SIDE OF CONNECTOR)
SHUNT POWER TRANSFORMER D1
300V N.C.
+ 85A 2 1 2 1 3
H1 J13
- P2 J11
J14 J15
LINE 206 T1 T2 J12
P1 P2 J21
SWITCH 1 3 4 4 6
1 6
S1 205 FAN 1 4 1 5
15 OHMS S2 J1
MOTORS J3 1 7

R1
100 W J4 J2
THERMOSTAT
C1 THRU C4 J16
206S C1 C2 C3 C4
30,000 MFD J20
5 8 6 10 7 12
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50V 204
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+ + + +
OUTPUT 8 14

CHOKE R2
1 7 1 8
207 2.5K
N.E. 10W J5 J6

8 14 9 16

1 2 1 3
J7 J9
J8 J10

3 4 4 6
C-RW

L9691

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.

WIRE-MATIC 255
 G-4 ELECTRICAL DIAGRAMS G-4
Control PC Board (G2803) Schematic
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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 not
available 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 result
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. WIRE-MATIC 255
 G-5 ELECTRICAL DIAGRAMS G-5
Control PC Board (G2803) Layout
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2803 G
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WIREMATIC 255 CONTROL

G2803
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CAPACITORS = MFD/VOLTS
RESISTORS = OHMS

THIS SHEET CONTAINS PROPRIETARY INFORMATION 3-24-95A

EQUIP.
OWNED BY THE LINCOLN ELECTRIC CO. AND IS THE LINCOLN ELECTRIC CO. TYPE WM-255
NOT TO BE REPRODUCED, DISCLOSED OR USED CLEVELAND, OHIO U.S.A.
WITHOUT THE EXPRESS PERMISSION OF SUBJECT CONTROL P.C. BOARD ASSEMBLY
SCALE FULL

G 2803
SHT.
THE LINCOLN ELECTRIC CO. DR F.V. DATE 9-19-94 CHK FV REF. SUP'S'D'G NO.

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 not
available 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 result
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine. WIRE-MATIC 255