Lincoln Electric PM 255 manual

RED-D-ARC PM 255 Red-D-Ar c Spec-Built W elding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on Y ou This welder 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[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can b urn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your ski[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits [...]

PM 255 Thank You for selecting a QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instru[...]

vi vi MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions...................................[...]

vii vii MASTER T ABLE OF CONTENTS FOR ALL SECTIONS (cont.) Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 General Maintenance .........................[...]

A-1 A-1 INST ALLA TION 75°C Copper Wire 75°C Copper Wire Input Ampere in Conduit in Conduit Input Voltage/ Fuse or Breaker Rating On AWG (IEC) Sizes AWG (IEC) Sizes (For lengths (For lengths Frequency (Hz) Size (Super Lag) Nameplate up to 100 ft.) exceeding 100 ft.) 230/60 60 46 10 (6 mm 2 ) 8 (10 mm 2 ) 460/60 30 24 14 (2.5 mm 2 ) 12 (4 mm 2 ) 5[...]

A-2 A-2 INST ALLA TION INPUT PO WER, GR OUNDING AND CONNECTION DIA GRAMS 1. Before starting the installation, check with the local power company if there is any question about whether your power supply is adequate for the volt- age, amperes, phase, and frequency specified on the welder nameplate. Also be sure the planned installation will meet the [...]

A-3 A-3 INST ALLA TION 4. Using the instructions in Figure A.3, have a quali- fied electrician connect the receptacle or cable to the input power lines and the system ground per the U.S. National Electrical Code and any applica- ble local codes. See “Technical Specifications” at the beginning of this chapter for proper wire sizes. For long runs[...]

A-4 A-4 INST ALLA TION FIGURE A.3 — Receptacle Diagram CONNECT TO A SYSTEM GROUNDING WIRE. SEE THE UNITED STATES NATIONAL ELECTRICAL CODE AND/OR LOCAL CODES FOR OTHER DETAILS AND MEANS FOR PROPER GROUND- ING. CONNECT TO HOT WIRES OF A THREE- WIRE, SINGLE PHASE SYSTEM OR TO ONE PHASE OF A TWO OR THREE PHASE SYSTEM. OUTPUT POLARITY CONNECTIONS The [...]

GUN AND CABLE INST ALLA TION The Magnum 250L gun and cable provided with the PM 255 is factory installed with a liner for .035-.045" (0.9-1.2 mm) electrode and an .035" (0.9 mm) contact tip. Install the .045 tip (also provided) if this wire size is being used. Turn the welder power switch off before installing gun and cable. 1. Lay the ca[...]

B-1 B-1 OPERA TION Read entire Operation section before operating the PM 255. 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 [...]

B-2 B-2 OPERA TION PR ODUCT DESCRIPTION The PM 255 is a complete semiautomatic constant voltage DC arc welding machine built to meet NEMA specifications. It combines a constant voltage power source and a constant speed wire feeder with a micro- computer-based controller to form a reliable high-per- formance welding system. A simple control scheme, [...]

B-3 B-3 OPERA TION PR OCEDURE FOR CHANGING DRIVE AND IDLE R OLL SETS 1. Turn off the power source. 2. Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the back of the machine. Lift the cast idle roll assembly and allow it to sit in an upright position.. 3. Remove the outside wire guide retaining plate by loo[...]

B-4 B-4 OPERA TION FEEDING WIRE ELECTR ODE When triggering, the electrode and drive mecha- nism are electrically “hot” relative to work and ground and remain “hot” several seconds after the gun trigger is released. NOTE: Check that drive rolls, guide plates and gun parts are proper for the wire size and type being used. Refer to Table C.1 i[...]

B-5 B-5 OPERA TION It is not necessary to repeat either of the above proce- dures each time the unit is powered up. The unit will remember the run-in mode from the previous power down and return you to that same state upon your next power up. Thus, you need only perform one of the above procedures when you want to change the run-in mode. MAKING A W[...]

B-6 B-6 OPERA TION F AN CONTR OL The fan is designed to come on automatically when a weld arc is established. The fan will stay on for a mini- mum of 6 minutes after the weld arc is terminated. The fan will also stay on when the machine ’ s welding and feeding are disabled during thermostatic over temperature protection. (See Welding Thermal Over[...]

C-1 C-1 A CCESSORIES DRIVE R OLL KITS Refer to Table C.1 for various drive roll kits that are available for the PM 255. All items in Bold are sup- plied standard with the POWER MIG. TABLE C.1 3/64" (1.2 mm) ALUMINUM FEEDING KIT (K1703-1) This kit helps push feeding aluminum through stan- dard machine feeder and gun. It provides gun and wire dr[...]

C-2 C-2 A CCESSORIES 4. Attach the rectangular 10-pin plug connector on the timer kit wiring harness to the mating receptacle connector located directly behind the removed cover panel. Be sure that the latch on the connec- tor is aligned with the one on the board and insert it until the latch engages. 5. Align the timer panel for installation and c[...]

C-3 C-3 A CCESSORIES SPOOL GUN AD APTER KIT (K1700-1) (Inc luded in the K1692-1) Remove all input power to the PM 255 before pro- ceeding. The Spool Gun Adapter Kit provides direct connection and use of the K1692-1 Spool Gun (with remote speed control) with the PM 255 wire feed welder. It also provides gun trigger switch transfer between the machin[...]

D-1 D-1 MAINTENANCE 3 . If using optional adjustable slip-on nozzles, see Table D.2 in this section. • Be sure the nozzle insulator is fully screwed onto the gun tube and does not block the gas holes in the diffuser. • Slip the appropriate gas nozzle onto the nozzle insulator. Either a standard .50" (12.7 mm) or optional .62" (15.9 mm[...]

Counterclockwise ➣ D-2 D-2 MAINTENANCE 7. Screw the gas diffuser onto the end of the gun tube and securely tighten. Be sure the gas diffuser is correct for the liner being used. (See table and dif- fuser stencil.) 8. Tighten the set screw in the side of the gas diffuser against the cable liner using a 5/64" (2.0 mm) Allen wrench. This screw [...]

D-3 D-3 MAINTENANCE English Metric Description Part No. Size Size CABLE LINER For 15' (4.5 m) or M16087-2 .025 – .030" 0.6 – 0.8 mm shorter Cable M16087-1 .035 – .045" 0.9 – 1.2 mm M17714-1 3/64" 1.2 mm (Alum. wire) (Alum. wire) CONTACT TIPS Standard Duty S19391-6 .025" 0.6 mm S19391-7 .030" 0.8 mm S19391-1 * .[...]

E-1 TR OUBLESHOO TING E-1 PM 255 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CA UTION This Troubleshooting Guide is provided to help you locate and repair possible machi[...]

E-2 E-2 TR OUBLESHOO TING PROBLEMS (SYMPT OMS) Major Physical or Electrical Damage is Evident There is no wire feed or open cir- cuit voltage when the gun trigger is pulled. The machine displays are lit indicating input power to the PM 255. Output voltage and wire feed is pre- sent when gun trigger is not pulled (not activated). Machine output is l[...]

E-3 E-3 TR OUBLESHOO TING PROBLEMS (SYMPT OMS) Poor arc striking with electrode sticking or blasting off. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Make sure settings for wire feed speed and voltage are correct for process being used. 2. The Run-In (Fast or Slow) speed may be wrong for process and technique being used. See Operation Section. 3. The gas[...]

E-4 E-4 TR OUBLESHOO TING PROBLEMS (SYMPT OMS) Gas does not flow when gun trigger is pulled. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Make sure gas supply is con- nected properly and turned “ on ” . 2. If the gas solenoid does actuate (click) when the gun trigger is pulled there may be a restriction in the gas supply line. 3. The gun cable assembl[...]

F-1 F-1 WIRING DIA GRAMS 1 209 555 B W 515 254 262 207 P .M. 208S J9 B T A C H D1 ASBLY 2-01A 11 1 28.4V 14.2V 14.2V 116.6V 515 206A SCI 541A 326 543 206B 353 GENERAL INFORMATION CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P .C. BOARD) 1 2 1 J7 1 16 J5 9 TO WORK CAVITY J13 WIRE FEED SPEED C1 THRU C3 31,000 MFD 50V 4 - U 515B 555 206B 206 204S 3 2 [...]

F-2 F-2 DIMENSION PRINT 3-00F M19231 PM 255[...]

NO TES PM 255[...]

NO TES PM 255[...]

NO TES PM 255[...]

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W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA [...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fume[...]

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