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SVM144-B
July, 2006
POWER MIG 255
For use with machines having Code Number : 10563, 10583,10986, 10990
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you a
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits 4.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 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. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section A-1 Section A-1 TABLE OF CONTENTS - INSTALLATION SECTION - Installation ..............................................................................................................Section A Technical Specifications...............................................................................................A-2 Safety Precautions .......................................................................................................A-3 Uncrating the POWER MIG 255........................
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS – POWER MIG 255 INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current @ 200 Amp Rated Output Input Current @ 250 Amp Rated Output 208/230/60 Hz 41/37 Amps 50/46 230/460/575/60 Hz 41/20/16 Amps 50/24/19 RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 40% 250 Amps 26 Volts 60% 200 Amps 28 Volts 100% 145 Amps 26 Volts OUTPUT Welding Current Range Maximum Open Circuit Voltage Welding Voltage Range (Continuous) 30 – 300 Amps 40 Volts 10-
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A-3 A-3 INSTALLATION Read entire installation section before starting INPUT POWER, GROUNDING AND installation. CONNECTION DIAGRAMS SAFETY PRECAUTIONS WARNING WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as ELECTRIC SHOCK can kill. output terminals or internal wiring. • Only qualified personnel should perform this • All input power must be electrically discon- installation. nected before proceeding. • Only personnel that have read and under- -----------------------
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A-4 A-4 INSTALLATION FIGURE A.1 — DUAL VOLTAGE MACHINE INPUT CONNECTIONS. 3. The 208/230 volt 60 Hz model POWER MIG is 4. Using the instructions in Figure A.3, have a qual- shipped with a 10 ft. input cable and plug con- ified electrician connect the receptacle or cable to nected to the welder. A matching receptacle is the input power lines and the system ground per supplied with the machine. Mount the receptacle the U.S. National Electrical Code and any applic- in a suitable location using t
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A-5 A-5 INSTALLATION FIGURE A.2 — TRIPLE VOLTAGE MACHINE INPUT CONNECTIONS. FIGURE A.3 — RECEPTACLE DIAGRAM. OUTPUT POLARITY CONNECTIONS CONNECT TO A SYSTEM The welder, as shipped from the factory, is connected GROUNDING WIRE. SEE for electrode positive (+) polarity. This is the normal THE UNITED STATES NATIONAL ELECTRICAL polarity for GMA welding. CODE AND/OR LOCAL CODES FOR OTHER If negative (–) polarity is required, interchange the con- DETAILS AND MEANS FOR PROPER GROUNDING. nection of the
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A-6 A-6 INSTALLATION GUN AND CABLE INSTALLATION WARNING The Magnum 250L gun and cable provided with the CYLINDER may explode if POWER MIG 255 is factory installed with a liner for damaged. 0.035-0.045 in. (0.9-1.2 mm) electrode and an 0.035 • Gas under pressure is explosive. Always keep in. (0.9 mm) contact tip. Install the 0.045 tip (also pro- gas cylinders in an upright position and always keep chained to undercarriage or stationary vided) if this wire size is being used. support. See America
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Section B-1 Section B-1 TABLE OF CONTENTS - OPERATION SECTION - Operation ................................................................................................................Section B Product Description......................................................................................................B-3 Recommended Processes and Equipment..................................................................B-3 Welding Capability........................................................
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B-2 B-2 OPERATION Read entire Operation section before operating the POWER MIG 255. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone. WELDING SPARKS can cause fire or explosion. • Keep flammable material away. • Do not weld on clo
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B-3 B-3 OPERATION PRODUCT DESCRIPTION RECOMMENDED PROCESSES AND EQUIPMENT The POWER MIG™ 255 is a complete semiautomatic constant voltage DC arc welding machine built to meet The POWER MIG 255 is recommended for GMA NEMA specifications. It combines a constant voltage welding processes using 10 to 44 lb (4.5 to 20 kg) ® power source and a constant speed wire feeder with a 2 in. (51 mm) I.D. spools or Readi-Reel coils (with microcomputer-based controller to form a reliable high- optional adapter)
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B-4 B-4 OPERATION DESCRIPTION OF CONTROLS WIRE DRIVE ROLL Power ON/OFF Switch — Place the lever in the “ON” The drive rolls installed with the POWER MIG each position to energize the POWER MIG 255. When the have two grooves, both for 0.030-0.0035 in. power is on, the red LED display lights illuminate. (0.8-0.9 mm) solid steel electrode. Drive roll size is indi- cated by the stencilling on the exposed side of the drive Voltage Control — This is a continuous control that roll. If feeding problems
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B-5 B-5 OPERATION 2 IN. O.D. PROCEDURE FOR CHANGING ADAPTER SPINDLE RETAINING DRIVE AND IDLE ROLL SETS SPRING 1. Turn off the power source. 2. Release the pressure on the idle roll by swinging BRAKE the adjustable pressure arm down toward the HOLDING PIN back of the machine. Lift the cast idle roll assem- RETAINING COLLAR GROOVES bly and allow it to sit in an upright position. 3. Remove the outside wire guide retaining plate by loosening the two large knurled screws. READI-REEL INSIDE CAGE RELEA
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B-6 B-6 OPERATION 2. If the wire “birdnests”, jams, or breaks at the drive TO START THE WELDER roll, the idle roll pressure is too great. Back the adjustment knob out 1/2 turn, run new wire Turn the Power Switch switch to ON. This lights the red through gun, and repeat above steps. LED display lights. With the desired voltage and wire speed selected, operate the gun trigger for welder out- 3. If the only result was drive roll slippage, loosen the put and to energize the wire feed motor. adjustme
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B-7 B-7 OPERATION NOTE: Arc starting characteristics may be effected 5. If welding gas is to be used, turn on the gas sup- when using the fast run-in mode since optimum start- ply and set the required flow rate (typically 25-35 ing processes are being overridden. CFH; 12-16 liters/min). On the initial trigger closure at power up, no output 6. When using innershield electrode, the gas nozzle power or wire feed will be available until the trigger is may be removed from the insulation on the end of
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B-8 B-8 OPERATION 5. Use only clean, rust-free electrode. The Lincoln WIRE FEED OVERLOAD electrodes have proper surface lubrication. PROTECTION 6. Replace contact tip when the arc starts to become The POWER MIG has solid state overload protection unstable or the contact tip end is fused or of the wire drive motor. If the motor becomes deformed. overloaded, the protection circuitry turns off the wire feed speed and gas solenoid. Check for proper size 7. Keep wire reel spindle brake tension to mi
