Lincoln Electric MAGNUM 250 Operator's Manual

Lincoln electric welder user manual

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250/350/450 AND 550
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
act and be careful.
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
MAGNUM PRO
K2651-[ ], K2652-[ ], K2653-[ ] and K2655-[ ]
Models
RETURN TO MAIN MENU
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
IM10009-B
September, 2010

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Summary of Contents for Lincoln Electric MAGNUM 250

  • Page 1 MAGNUM PRO 250/350/450 AND 550 Models 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...
  • Page 2: California Proposition 65 Warnings

    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 PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 3: Electric Shock Can Kill

    ELECTRIC ShOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 PRÉCAUTIONS 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.
  • Page 6 We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.
  • Page 7: Table Of Contents

    TABLE OF CONTENTS General Description ... Section A _______________________________________________________________________________________ Installation ... Section B Connector Kit Installation to Gun Cable ... B-1 K466-1 &-8 Installation ... B-1 K466-2 Installation ... B-1 K466-3 Installation ... B-1 K466-4 Installation ... B-1 K466-5 Installation ... B-2 K466-6, 7, 9 &...
  • Page 8 GENERAL DESCRIPTION GENERAL DESCRIPTION The MAGNUM® PRO 250, 350, 450 & 550 Amp and cable assemblies have been designed to meet specifi- cation for welding with steel electrode using the GMAW (gas metal arc welding) and gas-shielded FCAW (flux- cored arc welding) processes. Most models of MAGNUM®...
  • Page 9: General Description

    GENERAL DESCRIPTION MAGNUM® PRO 250 (250 amperes AT 100% DUTY CYCLE WITh CO 250 amperes AT 100% DUTY CYCLE WITh MIXED GAS) Description Product Cable Wire Size Number Length (m) in. (mm) K2651-1 10 ft. 035 (0.9) (3.1) 5/64 (2.0) K2651-2 15 ft.
  • Page 10 GENERAL DESCRIPTION MAGNUM® PRO 450 (450 amperes AT 100% DUTY CYCLE WITh CO 325 amperes AT 100% DUTY CYCLE WITh MIXED GAS) Description Product Cable Wire Size Number Length (m) in. (mm) K2653-1 10 ft. .035 (0.9) (3.1) 5/64 (2.0) K2653-2 15 ft.
  • Page 11: Installation

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING ELECTRIC ShOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. ------------------------------------------------------------------------ Only qualified personnel should install, use or service this equipment...
  • Page 12: K466-5 Installation

    b. Remove the molded gas plug fitting on the side of the feeder end handle and replace it with the barbed brass fit- ting provided in the kit. The included wrench will fit both the gas plug and barbed fitting. c.
  • Page 13: Liner Installation

    LINER INSTALLATION AND TRIMMING INSTRUCTIONS Installation of (KP44 and KP44N series liners) a. Lay the gun and cable straight on a flat surface. b. Make sure that the set screw in the connector end is backed out so as not to damage liner or liner bushing.
  • Page 14: Contact Tip And Gas Nozzle Installation

    CONTACT TIP AND GAS NOzzLE INSTALLATION a. Choose the correct size contact tip for the electrode being used (wire size is stenciled on the side of the contact tip) and screw it snugly into the gas diffuser. b. Slip the appropriate gas nozzle onto the diffuser. The proper nozzle should be selected based on the welding application.
  • Page 15: Connection To L-Tec Adapted Feeders

    CONNECTION TO L-TEC ADAPTED FEEDERS Gun and cable assemblies which were assembled with a K466-5 connection kit will connect easily to an L-Tec feeder equipped with an L-Tec feeder connector assembly. L-Tec feeders require this connector assem- bly (similar to a Tweco adapter) to connect with a gun and cable.
  • Page 16: Operation

    electroDes AnD equiPment The MAGNUM® PRO 250, 350, 450 & 550 Amp guns and cables have been designed for use with Lincoln L- 50 and L-56, solid steel wire electrodes for the GMAW process and Lincoln Outershield cored electrodes for the gas-shielded FCAW process.
  • Page 17: Maintenance

    removAl, instAllAtion AnD trimming instructions For mAgnum note: The variation in cable lengths prevents the interchangeability of liners. Once a liner has been cut for a particular gun, it should not be installed in anoth- er gun, unless it can meet the liner cut off length requirement.
  • Page 18 TRIM CORE TUBE FLUSH WITHIN ± .125 (3.18mm) I N S U L A T I O N O N T H E C O N T R O L W I R E S M U S T N O T B E C U T O R D A M A G E D . R E D O F C A B L E J A C K E T .
  • Page 19: Wire Feeder End Repair

    bly and connect the replacement control lead termi- nals. j. Position the cable boot and strain relief on the cable so it fits in cable handle cavity and lock the strain relief in place by pushing the two halves together. k.
  • Page 20 4.68 (119 mm) GAS PLUG OR FITTING FEEDER END CONNECTOR TAIL PIECE INCOMING CONNECTOR strands with the threaded end out. Assemble incom- ing connector to cable by forcing the steel tube of the connector into the inside diameter of the cable inner tube until the copper strands are butted against the incoming connector shoulder.
  • Page 21: How To Use Troubleshooting Guide

    TO USE TROUBLEShOOTING GUIDE 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.
  • Page 22: Troubleshooting

    Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Drive rolls turn, but wire will not feed or wire feeding is rough. Variable or “hunting” arc. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 23 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Poor arc striking with sticking or “blast-offs”, weld porosity, narrow and ropy looking bead, or electrode stubbing into plate while welding. Tip seizing in diffuser. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 24 NOTES MAGNUM® PRO 250, 350, 450 AND 550...
  • Page 25 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
  • Page 26 Spanish PRECAUCION French German Portuguese Japanese Chinese Korean Arabic WARNING AVISO DE ATTENTION WARNUNG ATENÇÃO...
  • Page 27 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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