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Lincoln Electric RED-D-ARC PM 255 Operator's Manual

Lincoln electric welder user 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
RETURN TO MAIN MENU
IM676
MARCH, 2001

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Summary of Contents for Lincoln Electric RED-D-ARC PM 255

  • Page 1 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 ...
  • Page 2 351040, 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 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 sparks and hot 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 Thank You Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

  • Page 7: Table Of Contents

    Wire Size Conversion parts ...B-2 Procedure for Changing Drive Roll ...B-3 Wire Reel Loading ...B-3 Mounting of 10 to 44 lbs. Spools ...B-3 To Start the Welder...B-3 Feeding Wire Electrode ...B-4 Idle Roll Pressure Setting ...B-4 Setting Run-in Speed...B-4 Making a Weld ...B-5 Avoiding Wire Feeding Problems ...B-5...
  • Page 8 MASTER TABLE OF CONTENTS FOR ALL SECTIONS (cont.) Maintenance ...Section D Safety Precautions ...D-1 General Maintenance ...D-1 Drive Rolls and guide Tubes ...D-1 Contact Tip and Gas Nozzle Installation ...D-1 Gun Tubes and Nozzles ...D-1 Cable Cleaning ...D-1 Liner Removal and Replacement ...D-2 Gun Handle Disassembly ...D-2 Accessories and Expendable Replacement Parts...D-3 Troubleshooting ...Section E...

  • Page 9: Installation

    TECHNICAL SPECIFICATIONS – PM 255 Standard Voltage/Frequency 230/460/575/60 Hz Duty Cycle 100% Welding Current Range (Continuous) Maximum Open Circuit Voltage 30 – 300 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage/ Fuse or Breaker Frequency (Hz) Size (Super Lag) 230/60 460/60 575/60...

  • Page 10: Safety Precautions

    Roll the machine off the skid assembly. LOCATION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front. A location that minimizes the amount of...
  • 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

    PHASE OF A TWO OR THREE PHASE SYSTEM. INSTALLATION OUTPUT POLARITY CONNECTIONS The welder, as shipped from the factory, is connected for electrode positive (+) polarity. This is the normal polarity for GMA welding. If negative (–) polarity is required, interchange the connection of the two cables located in the wire drive compartment near the front panel.

  • Page 13: Gun And Cable Installation

    American Welding Society. 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. INSTALLATION 2. Remove the cylinder cap. Inspect the cylinder valves and regulator for damaged threads, dirt, dust, oil or grease.

  • Page 14: Operation

    Read entire Operation section before operating the PM 255. Observe all safety information throughout this manual. OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. •...

  • Page 15: Product Description

    PRODUCT 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.

  • Page 16: Wire Reel Loading

    Turn the “Power Switch” switch to “ON”. This lights the red LED dis- play lights. With the desired voltage and wire speed selected, oper- 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

    The optimum idle roll setting can be determined as follows: 1. Press end of gun against a solid object that is elec- trically isolated from the welder output and press the gun trigger for several seconds. 2. If the wire “birdnests”, jams or breaks at the drive roll, the idle roll pressure is too great.

  • Page 18: Making A Weld

    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.

  • Page 19: Fan Control

    PROTECTION The PM 255 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 tem- perature plus overload.

  • Page 20: Accessories

    DRIVE ROLL 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. Wire Size .023”-.030” (0.6-0.8 mm) Solid .035” (0.9 mm) Steel .045”...

  • Page 21: Operating Instructions For Timer Kit

    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.

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

    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 machine’s use with its feeder gun or the spool gun for same polarity welding with different wire and gas processes.

  • Page 23: Maintenance

    GENERAL MAINTENANCE In extremely dusty locations, dirt may clog the air pas- sages causing the welder to run hot. Blow dirt out of the welder with low-pressure air at regular intervals to eliminate excessive dirt and dust build-up on internal parts.

  • Page 24: Liner Removal And Replacement

    LINER REMOVAL AND REPLACEMENT CAUTION NOTE: Changing the liner for a different wire size requires replacement of the gas diffuser per Table D.1 to properly secure the different liner. LINER REMOVAL, INSTALLATION AND TRIMMING INSTRUCTIONS FOR MAGNUM 250L NOTE: The variation in cable lengths prevents the interchangeability of liners between guns.

  • Page 25: Accessories And Expendable Replacement Parts

    ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS FOR MAGNUM 250L GUN AND CABLE ASSEMBLIES Description CABLE LINER For 15' (4.5 m) or shorter Cable CONTACT TIPS Standard Duty Heavy Duty Tapered Tab (For Aluminum) GAS NOZZLES Fixed (Flush) Fixed (Recessed) Requires: Gas Diffuser As'bly Adjustable Slip-On Requires:...

  • Page 26: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by 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 27 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 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.
  • Page 28 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Poor arc striking with electrode sticking or blasting off. PROBLEMS (SYMPTOMS) Rough wire feeding or wire will not feed but drive rolls are turning. The wire feed stops while welding. When trigger is released and pulled again the wire feed starts.
  • Page 29 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Gas does not flow when gun trigger is pulled. 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.
  • Page 30 WIRING DIAGRAMS OPTION SPOOL 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 Address: Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Titles: Price New Lessons in Arc Welding $5.00...
  • Page 36 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 37 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • 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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