Table of Contents
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RETURN TO MAIN MENU
IM10096
POWER MIG
256
®
July, 2011
11780, 11781
For use with machine Code Numbers
For use with machine Code Numbers
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.
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
• 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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Related Manuals for Lincoln Electric POWER MIG 256
Summary of Contents for Lincoln Electric POWER MIG 256
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Page 1: Power Mig
RETURN TO MAIN MENU IM10096 POWER MIG ® July, 2011 11780, 11781 For use with machine Code Numbers For use with machine Code Numbers 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 ... -
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
SAFETY ELECTRIC SHOCK can ARC RAYS can burn. kill. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”... - Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
- Page 5 SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
- Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 7: Table Of Contents
TABLE OF CONTENTS Page ________________________________________________________________________ Installation .......................Section A Technical Specifications ..................A-1 Safety Precautions....................A-2 Uncrating the POWER MIG ® 256 ................A-2 Location .........................A-2 Input Power, Grounding and Connection Diagram ........A-2, A-3 Output Polarity Connections ..................A-3 Gun and Cable Installation ..................A-3 Shielding Gas ......................A-4 Auxiliary Power Receptacle ...................A-4 Coil Claw™... - Page 8 TABLE OF CONTENTS Page ________________________________________________________________________ Maintenance ....................Section D Safety Precautions ....................D-1 General Maintenance ....................D-1 Drive Rolls and Guide Plates.................D-1 Contact Tip and Gas Nozzle Installation ...............D-1 Gun Tubes and Nozzles ..................D-1 Gun Cable Cleaning ....................D-1 Liner Removal and Replacement ................D-2 ®...
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Page 9: Installation
INSTALLATION TECHNICAL SPECIFICATIONS – POWER MIG ® INPUT – SINGLE PHASE ONLY Standard Voltage/Phase/Frequency Input Current @ 200 Amp Rated Output Input Current @ 250 Amp Rated Output 208/230/1/60 Hz *47/44 Amps *56/52 Amps 230/460/575/1/60 Hz 41/20/16 Amps 47/24/19 Amps RATED OUTPUT Duty Cycle Amps... -
Page 10: Safety Precautions
INSTALLATION Read entire installation section before starting INPUT POWER, GROUNDING AND installation. CONNECTION DIAGRAM SAFETY PRECAUTIONS WARNING WARNING ELECTRIC SHOCK can kill. ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as • Only qualified personnel should output terminals or internal wiring. -
Page 11: Output Polarity Connections
INSTALLATION OUTPUT POLARITY CONNECTIONS 3. The 208/230 volt 60 Hz model POWER MIG is shipped with a 10 ft. input cable and plug connect- The welder, as shipped from the factory, is connected ed to the welder. Obtain a receptacle and mount it for electrode positive (+) polarity. -
Page 12: Shielding Gas
INSTALLATION 7. Standing to one side, open the cylinder valve slowly a SHIELDING GAS fraction of a turn. When the cylinder pressure gauge [For Gas Metal Arc Welding(GMAW) Processes] pointer stops moving, open the valve fully. Customer must provide cylinder of appropriate type shield- WARNING ing gas for the process being used. -
Page 13: Operation
OPERATION Read entire Operation section before operating the POWER MIG ® 256. 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 14: Product Description
OPERATION PRODUCT DESCRIPTION LIMITATIONS The POWER MIG 256 is a complete semiautomatic ® POWER MIG ® 256 WILL NOT operate satisfactorily if constant voltage DC arc welding machine built to meet powered with a portable or in-plant generating system. NEMA specifications. It combines a constant voltage DESCRIPTION OF CONTROLS power source and a constant speed wire feeder with a microcomputer-based controller to form a reliable high-... -
Page 15: Wire Size Conversion Parts
OPERATION The drive rolls installed with the POWER MIG® 256 To make spot plug welds, punch 3/16" (5 mm) holes have two grooves one for .035(0.9mm) wire Solid in the top sheet. Set the Spot Time control to Steel electrode and the other for .045(1.1mm) wire. approximately 1.2 seconds and set the procedure for Drive roll size is stenciled on each side of the drive the metal thickness to be welded. -
Page 16: Wire Reel Loading
OPERATION WIRE REEL LOADING - READI FIGURE B.3 REELS, SPOOLS OR COILS ADAPTER 2 IN. O.D. SPINDLE RETAINING SPRING To Mount a 30 Lb. (14 kg) Readi-Reel Package (Using the Molded Plastic K363-P Readi-Reel Adapter:) RETAINING COLLAR (See Figure B.3) BRAKE HOLDING 1. -
Page 17: Feeding Electrode
OPERATION FEEDING WIRE ELECTRODE The pressure arm controls the amount of force the drive rolls exert on the wire. Proper adjustment of both WARNING pressure arm gives the best welding performance. For best results, set both pressure arms to the same When triggering, the electrode and drive mecha- value. -
Page 18: Wire Drive Configuration
OPERATION WIRE DRIVE CONFIGURATION 5. Loosen the socket head cap screw that holds the connector bar against the gun bushing. Important: Do not attempt to completely (See Figure B.5) remove the socket head cap screw. Changing the Gun Receiver Bushing WARNING 6. -
Page 19: Making A Weld
OPERATION 11. When no more welding is to be done, close valve on MAKING A WELD gas cylinder (if used), momentarily operate gun trig- ger to release gas pressure, and turn off POWER 1. Check that the electrode polarity is correct for the process ®... -
Page 20: Welding Thermal Overload Protection
OPERATION WELDING THERMAL OVERLOAD PROTECTION The POWER MIG ® 256 has built-in protective thermostats that respond to excessive temperature. They open the wire feed and welder output circuits if the machine exceeds the maximum safe operating temperature because of a frequent overload, or high ambient temperature plus overload. -
Page 21: Accessories
ACCESSORIES DRIVE ROLL KITS ALTERNATIVE MAGNUM GMAW GUN AND CABLE ASSEMBLIES Refer to Table C.1 for various drive roll kits that are available for the POWER MIG ® 256.The item in Bold ® The following Magnum PRO 250L gun and cable is supplied standard with the POWER MIG ®... -
Page 22: Connecting The Spool Gun To The Power Mig 256
ACCESSORIES CONNECTING THE SPOOL GUN TO CAUTION THE POWER MIG ® (See Figure C.1) Closing either gun trigger will cause the electrode of both guns to be electrically "HOT". Be sure 1. Connect the Spool Gun control cable to the mating unused gun is positioned so electrode or tip will 7-pin receptacle in the Power MIG wire drive not contact metal case or other metal common to... -
Page 23: Making A Weld With The Magnum Sg Spool Gun
ACCESSORIES 4. The following procedure settings for Aluminum See the following procedure for setting the Wire 4043 can be used as initial settings for making test Speed Feed using the Magnum SG Spool Gun: welds to determine final settings: Wire Feed Speed SG Spool Gun Wire Feed Speed Display Approximate Range... -
Page 24: Maintenance
MAINTENANCE SAFETY PRECAUTIONS 3. If using optional adjustable slip-on nozzles. (Refer to www.lincolnelectric.com) WARNING • Be sure the nozzle insulator is fully screwed onto the gun tube and does not block the gas ELECTRIC SHOCK can kill. holes in the diffuser. •... -
Page 25: Liner Removal And Replacement
MAINTENANCE 5. Fully seat the liner bushing into the connector. LINER REMOVAL AND REPLACE- tighten the set screw on the brass cable connector. MENT The gas diffuser, at this time, should not be installed onto the end of the gun tube. NOTE: Changing the liner for a different wire size requires replacement of the gas diffuser per Table D.1 6. -
Page 26: Gun Handle Disassembly
MAINTENANCE GUN HANDLE DISASSEMBLY The internal parts of the gun handle may be inspected or serviced if necessary. The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approxi- mately 60 degrees counterclockwise (the same direction as removing a right hand thread) until the collar reaches a stop. -
Page 27: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 28 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 LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. POWER MIG ®...
- Page 29 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 LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. POWER MIG ®...
- Page 30 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 LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. POWER MIG ®...
- Page 31 WIRING DIAGRAMS POWER MIG ®...
- Page 32 WIRING DIAGRAMS POWER MIG ®...
- Page 33 DIMENSION PRINT POWER MIG ®...
- Page 34 NOTES...
- Page 35 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 •...
- Page 36 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 37 • 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...