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AUTO ARC 255 Owner's Manual

Arc welding power source and wire feeder m-25 gun
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Auto Arc 255
And M-25 Gun
For Warranty Claims And Technical Support, Contact:
Milweld Inc., National Distributor
P.O. Box 338, Hortonville, WI 54944-0338
Tel 920-779-0916 Fax 920-779-0924
OM-157 066V
November 2000
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
R

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Summary of Contents for AUTO ARC 255

  • Page 1 Auto Arc 255 And M-25 Gun For Warranty Claims And Technical Support, Contact: Milweld Inc., National Distributor P.O. Box 338, Hortonville, WI 54944-0338 Tel 920-779-0916 Fax 920-779-0924 OM-157 066V November 2000 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description...

  • Page 3: Table Of Contents

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage 1-2. Arc Welding Hazards 1-3. Additional Symbols For Installation, Operation, And Maintenance 1-4. Principal Safety Standards WARNING 1-5. EMF Information SECTION 2 – INSTALLATION This product, when used 2-1.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.
  • Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’...

  • Page 9: Section 2 - Installation

    SECTION 2 – INSTALLATION 2-1. Specifications Rated Welding Amperage Range Output 200 A @ 28 Volts DC, 60% Duty Cycle 40 – 250 250 A @ 28 Volts DC, 40% Duty Cycle Wire Type And Diameter Solid Steel / Flux Cored/ Stainless Steel Aluminum .030 –...

  • Page 10: Welding Power Source Duty Cycle And Overheating

    2-3. Welding Power Source Duty Cycle And Overheating 6 Minutes Welding Overheating 2-4. Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. Do not weld at rated load longer than shown below. Using gasless flux cored wire reduces gun duty cycle.

  • Page 11: Installing Work Clamp

    2-5. Installing Work Clamp 2-6. Installing Gas Supply Tools Needed: Tools Needed: Work Cable Boot Slide boot onto work cable. Route cable out front panel opening from inside. Negative (–) Output Terminal Connect cable to terminal and cover connection with boot. Hardware Work Clamp Route cable through clamp handle...

  • Page 12: Installing Welding Gun

    2-7. Installing Welding Gun 2-8. Installing Wire Spool And Adjusting Hub Tension When a slight force is needed to turn spool, tension is set. Tools Needed: 15/16 in OM-157 066 Page 8 Use compression spring with 8 in (200 mm) spools. Drive Assembly Gun Securing Knob Gun End...

  • Page 13: Setting Gun Polarity

    2-9. Setting Gun Polarity Tools Needed: 3/4, 11/16 in 2-10. Positioning Jumper Links 200 VOLTS 230 VOLTS Tools Needed: 3/8 in 230 VOLTS 460 VOLTS 575 VOLTS S-156 140 S-153 980 Polarity Changeover Label Always read and follow manufac- ture’s recommended polarity. Ref.

  • Page 14: Electrical Service Guide

    2-11. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1999 National Electrical Code (NEC) 1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.

  • Page 15: Threading Welding Wire

    2-13. Threading Welding Wire Open pressure assembly. Tighten Close and tighten pressure assembly, and let go of wire. Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle. 6 in (150 mm) Pull and hold wire; cut off end. Use pressure indicator scale to set a desired drive roll pressure.

  • Page 16: Section 3 - Operation

    SECTION 3 – OPERATION 3-1. Front Panel Controls OM-157 066 Page 12 Controls For Standard Units Wire Speed Control The scale around the control is percent, not wire feed speed. Voltage Switch Use control and Voltage Range Selector (see Section 3-2) to set arc voltage.

  • Page 17: Center Baffle Controls

    3-2. Center Baffle Controls PRESS TO RESET DO NOT SWITCH UNDER LOAD WIRE VOLTAGE MODE RANGE HIGH FULL Wire Mode Switch For better control of wire speed use the Low position when wire speed is between 90 and 670 ipm. Use the Full position when wire speed is between 150 ipm and 1030 ipm.

  • Page 18: Weld Parameter Chart

    3-3. Weld Parameter Chart OM-157 066 Page 14...
  • Page 19 Ref. 200 062 OM-157 066 Page 15...

  • Page 20: Section 4 - Maintenance & Troubleshooting

    SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Replace Damaged Or Unreadable Labels Blow Out Or Vacuum Inside 4-2. Circuit Breaker CB1 OM-157 066 Page 16 Y Disconnect power before maintaining. 3 Months Repair Or Replace Cracked Cables And Cords 6 Months Remove drive roll and...

  • Page 21: Fuses F1 And F2

    4-3. Fuses F1 And F2 4-4. Changing Drive Roll And Wire Inlet Guide Tools Needed: 5/64 in 7/16 in 4-5. Replacing Gun Contact Tip Tools Needed: Tools Needed: 3/8 in Y Turn Off unit, and disconnect input power. Fuse F1 (See Parts List For Rating) F1 protects the 115 volts ac winding of transformer T1.

  • Page 22: Cleaning Or Replacing Gun Liner

    4-6. Cleaning Or Replacing Gun Liner 3/8 in Lay gun cable out straight before installing new liner. OM-157 066 Page 18 Y Disconnect gun first. Head tube Remove nozzle, contact tip, adapter, and wire outlet guide. Blow out gun casing. Tools Needed: 3/8 in Remove liner.

  • Page 23: Replacing Switch And/Or Head Tube

    4-7. Replacing Switch And/Or Head Tube Remove handle locking nut. Secure head tube in vice. Install existing shock washer onto new head tube. Hand-tighten head tube into connector cable. Tools Needed: 3/4 in Y Disconnect gun first. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important).

  • Page 24: Troubleshooting

    4-8. Troubleshooting Welding Trouble No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-12). Reset circuit breaker CB1 (see Section 4-2). Replace fuse F1 and/or F2 (see Section 4-3). Replace building line fuse or reset circuit breaker if open (see Section 2-12). Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Section 2-7 and/or 4-7).

  • Page 25: Section 5 - Electrical Diagram

    SECTION 5 – ELECTRICAL DIAGRAM SB-173 544-E Figure 5-1. Circuit Diagram For Welding Power Source OM-157 066 Page 21...
  • Page 26 Notes OM-157 066 Page 22...

  • Page 27: Section 6 - Parts List

    SECTION 6 – PARTS LIST Hardware is common and not available unless listed. Figure 6-2 – 2 Figure 6-6 - 20 Figure 6-5 – 19 Item Dia. Part Mkgs..... . . 146 168 .
  • Page 28 ..... . 187 255 ..... .
  • Page 29 28 (Fig. 6–3) Hardware is common and not available unless listed. ST-800 931-D Figure 6-2. Baffle, Center w/Components OM-157 066 Page 25...
  • Page 30 Item Dia. Part Mkgs. Figure 6-2. Baffle, Center w/Components (Fig 6-1 Item 2) ... . 058 427 RING, retaining spool ... . 085 980 NUT, stl hex full .625-11 .
  • Page 31 See Table 6-1 Drive Roll & Wire Guide Kits. Hardware is common and not available unless listed. Table 6-1. Drive Roll And Wire Guide Kits IMPORTANT: Base selection of drive rolls upon the following recommended usages: 1. V-Grooved rolls for hard wire. 2.
  • Page 32 Item Dia. Part Mkgs..... . . 602 009 ..... . 172 075 .
  • Page 33 Hardware is common and not available unless listed. Item Dia. Part Mkgs..... . . 116 996 ..... . 143 810 .
  • Page 34 Hardware is common and not available unless listed. Item Dia. Part Mkgs. Figure 6-5. Panel, Front w/Components (Fig 6-1 Item 19) ... . 148 956 HANDLE, switch ... . 097 924 KNOB, pointer 1.625 dia x .250 ID w/setscrew .
  • Page 35 Ref. 800 792-B Figure 6-6. Exploded View Of Gun OM-157 066 Page 31...
  • Page 36 ..O-RING, .187 ID x .103CS rbr ..196 255 SWITCH, trigger OPTIONAL To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
  • Page 37 Notes...
  • Page 38 Notes...
  • Page 39 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY – Subject to the terms and conditions below, warrants to its original retail purchaser that new equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is...

  • Page 40: Owner's Record

    Owner’s Record Please complete and retain with your personal records. Model Name Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Resources Available Always provide Model Name and Serial/Style Number. Contact your Distributor for: Contact the Delivering Carrier for: For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.

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