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Red-D-Arc PM 255 Operator's Manual

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RED-D-ARC
PM 255
For use with machines having Code Numbers:
OPERATOR'S MANUAL
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
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 NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.
And, most importantly, think before you act and be careful.
1-800-245-3660
North America's Largest Fleet of Welding Equipment
10709
IM676
MARCH, 2001

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Summary of Contents for Red-D-Arc PM 255

  • Page 1 For use with machines having Code Numbers: OPERATOR’S MANUAL Red-D-Arc Spec-Built Welding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on You This welder is designed and built with safety in mind.
  • Page 2 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 cancer, birth defects, or other reproductive harm.

  • Page 3: Electric Shock Can Kill

    (MSDS) and follow your employer’s safety practices. MSDS forms are available from 3.j. Also see Items 6.c. and 8. your welding distributor or from the manufacturer. 5.e. Also see item 1.b. Mar ‘95 PM 255...
  • Page 4 This can create fire hazards or overheat lifting chains Electrical Code, all local codes and the manufacturer’s or cables until they fail. recommendations. 6.h. Also see item 1.c. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. Mar ‘95 PM 255...
  • Page 5 épaisse, pantalons sans revers, et chaussures montantes. 5. Toujours porter des lunettes de sécurité dans la zone de Mar. ‘93 soudage. Utiliser des lunettes avec écrans lateraux dans les PM 255...
  • Page 6 This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life. CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. PM 255...

  • Page 7: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................Section A Technical Specifications ..................A-1 Safety Precautions....................A-2 Uncrating the PM 255 ....................A-2 Location .........................A-2 Input Power, Grounding and connection Diagrams ........A-2, A-3 Output Polarity Connections ..................A-4 Gun and Cable Installation ..................A-5 Shielding Gas ......................A-5...
  • Page 8 Gun Handle Disassembly ..................D-2 Accessories and Expendable Replacement Parts..........D-3 Troubleshooting ....................Section E How to Use Troubleshooting Guide...............E-1 Troubleshooting Guide ................E-2 thru E-4 Wiring and Dimension Diagrams ..............Section F Parts Manual ....................Appendix PM 255 ....................P382 Series Magnum 250L Gun ..................P202-H.2 PM 255...

  • Page 9: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – PM 255 INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current @ 200 Amp Rated Output Input Current @ 250 Amp Rated Output 230/460/575/60 Hz 41/20/16 Amps 50/24/19 RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes...

  • Page 10: Safety Precautions

    • Only personnel that have read and under- stood the PM 255 Operating Manual should 1. Before starting the installation, check with the local install and operate this equipment. power company if there is any question about •...
  • Page 11 The center contact in the receptacle is for the grounding connection. A green wire in the input cable connects this contact to the frame of the welder. This ensures proper grounding of the welder frame when the welder plug is inserted into the receptacle. PM 255...

  • Page 12: Output Polarity Connections

    (–) labeled terminal and WIRE, SINGLE PHASE the work lead, which is attached to the work clamp, is SYSTEM OR TO ONE to be connected to the positive (+) labeled terminal. PHASE OF A TWO OR THREE PHASE SYSTEM. PM 255...

  • Page 13: Gun And Cable Installation

    American Welding Society. being used before making the weld. Install shielding gas supply as follows: 1. Set gas cylinder on rear platform of PM 255. Hook chain in place to secure cylinder to rear of welder. PM 255...

  • Page 14: Operation

    OPERATION Read entire Operation section before operating the PM 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.

  • Page 15: Product Description

    See Accessories section. WELDING CAPABILITY The PM 255 is rated at 250 amps @ 26 volts, at a 40% duty cycle based on a ten minute cycle time. It is capable of higher duty cycles at lower output currents and capable of up to 300 Amps at lower duty cycles.

  • Page 16: Wire Reel Loading

    With the desired voltage and wire speed selected, oper- the 12 o'clock position. ate the gun trigger for welder output and to energize the wire feed PM 255 motor.and wire speed selected, operate the gun trigger for welder output and to energize the wire feed motor.

  • Page 17: Feeding Wire Electrode

    (When Timer Option is not installed) 1. Turn the Readi-Reel or spool until the free end of The PM 255 is factory set for fast run-in mode where the electrode is accessible. the wire feed will accelerate directly to the preset wire feed speed when the gun trigger is closed.

  • Page 18: Making A Weld

    7. Connect work cable to metal to be welded. Work clamp must make good electrical contact to the work. The work must also be grounded as stated in “Arc Welding Safety Precautions”. PM 255...

  • Page 19: Fan Control

    WIRE FEED OVERLOAD PROTECTION The PM 255 has solid state overload protection of the wire drive motor. If the motor becomes overloaded, the protection circuitry turns off the wire feed speed and gas solenoid.

  • Page 20: Accessories

    GUN AND CABLE ASSEMBLIES Refer to Table C.1 for various drive roll kits that are available for the PM 255. All items in Bold are sup- The following Magnum 250L gun and cable assem- plied standard with the POWER MIG.

  • Page 21: Operating Instructions For Timer Kit

    Closing the trigger initiates a single timed spot weld cycle. Plug welds are made by using a punch to make a 3/16" (5 mm) diameter hole in the top sheet and arc welding through the hole into the back sheet. PM 255...

  • Page 22: Spool Gun Adapter Kit (Optional K1700-1

    Disables spool gun operation. WARNING b. Closing feeder gun trigger starts feeder gun welding and makes both electrodes electrically Remove all input power to the PM 255 before pro- “HOT”. ceeding. 2. Pulling SPOOL GUN Trigger: The Spool Gun Adapter Kit provides direct connection and use of the K1692-1 Spool Gun (with remote a.

  • Page 23: Maintenance

    2. Screw the appropriate fixed gas nozzle fully onto the diffuser. Either the standard .50" (12.7 mm) flush nozzle or other optional flush or recessed (spray arc) nozzle sizes may be used. (See Table D.2 in this section.) PM 255...

  • Page 24: Liner Removal And Replacement

    6. With the gas diffusor still removed from the gun tube, be sure the cable is straight, and then trim the liner to the length shown in Figure D.1. Remove any burrs from the end of the liner. Counterclockwise PM 255...

  • Page 25: Accessories And Expendable Replacement Parts

    .025 – .030" 0.6 – 0.8 mm As’bly S19418-1 .035 – .045" 0.9 – 1.2 mm Δ Gasless Nozzle M16938 (For Innershield) GUN TUBE ASSEMBLIES Standard (60°) S18920 45° S19890 Included with PM 255 Δ Requires S19418-1 Gas Diffuser Assembly. PM 255...

  • Page 26: Troubleshooting

    CAUTION 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. PM 255...
  • Page 27 Contact your local Authorized assembly is removed from Field Service Facility. machine then the problem is within the PM 255. Machine output is low. Welds are 1. Check input voltage. Make sure “cold”, weld bead is rounded or input voltage matches name-...
  • Page 28 6. Check spindle for ease of rotation. CAUTION 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 assistance before you proceed. PM 255...
  • Page 29 Check or replace. 4. If gas solenoid does not operate when gun trigger is pulled the problem is within the PM 255. 5. Make sure the gun is pushed all the way into gun mount and is properly seated.
  • Page 30 WIRING DIAGRAMS PM 255...
  • Page 31 DIMENSION PRINT PM 255...
  • Page 32 NOTES PM 255...
  • Page 33 NOTES PM 255...
  • Page 34 NOTES PM 255...
  • Page 35 New Lessons in Arc Welding Now Available...12th Edition The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques; With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects, since 1933, the Procedure Handbook is considered by many to such as distortion;...
  • Page 36 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
  • Page 37 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
  • Page 38 • 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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