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Lincoln Electric RED-D-ARC PM 255, Operator'S Manual, Page: 38 / 38

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Lincoln Electric RED-D-ARC PM 255 Operator'S Manual Download Page 38

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 Sales and Service through Subsidiaries and Distributors Worldwide 

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Cleveland, Ohio 44117-1199  U.S.A.   TEL: 216.481.8100   FAX: 216.486.1751   WEB SITE: www.lincolnelectric.com

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 World's Leader in Welding and Cutting Products 

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Summary of Contents for RED-D-ARC PM 255

Page 1: ...owever 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 For use with machines having Code Numbers 10709 North America s Largest Fleet of Welding Equipment 1 800 245 3660 ...

Page 2: ...EARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available...

Page 3: ...l earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i ...

Page 4: ...t 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 Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding an...

Page 5: ...t non inflamma bles 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pantalons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloigner ...

Page 6: ... be followed to avoid minor personal injury or damage to this equipment CAUTION 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 Please record you...

Page 7: ...pools 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 Fan Control B 6 Input Line Voltage Protection B 6 Wire Feed overload Protection B 6 Welding Thermal Overload Protection B 6 Overcurrent Protection B 6 Welding Procedure Information B 6 Accessories Section C Drive Roll Kits C 1 Alu...

Page 8: ...zle 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 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: ...NPUT SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES Height Width Depth Weight 31 79 in 18 88 in 38 78 in 220 Ibs 808 mm 480 mm 985 mm 100 kg PHYSICAL DIMENSIONS Wire Speed 50 700 IPM 1 27 17 8 m minute WIRE SPEED RANGE 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 Duty Cycle Amp...

Page 10: ...an kill Only qualified personnel should perform this installation Only personnel that have read and under stood the PM 255 Operating Manual should install and operate this equipment Machine must be grounded per any nation al local or other applicable electrical codes The POWER MIG power switch is to be in the OFF position when installing work cable and gun and when connecting other equipment WARNI...

Page 11: ...ng runs over 100 feet larger copper wires should be used Fuse the two hot lines with super lag type fuses as shown in the following diagram 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 FIGURE ...

Page 12: ...he 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 The electrode cable which is attached to the wire drive is to be connected to the negative labeled terminal and the work lead which is a...

Page 13: ...L GREASE OR DAMAGE IS PRESENT Inform your gas supplier of this condition Oil or grease in the presence of high pressure oxygen is explosive 3 Stand to one side away from the outlet and open the cylinder valve for an instant This blows away any dust or dirt which may have accumulated in the valve outlet Be sure to keep your face away from the valve outlet when cracking the valve 4 Attach the flow r...

Page 14: ...d ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on closed contain ers ARC RAYS can burn eyes and skin Wear eye ear and body protec tion Observe all safety information throughout this manual WARNING...

Page 15: ... rated 12 ft 3 6 m GMAW gun and cable assembly equipped for these wire sizes Use of GMAW processes requires a supply of shielding gas 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 LIMITATIONS The PM 255 MAY NOT operate sat...

Page 16: ...ction when feed ing so as to be de reeled from top of the coil 7 Set one of the Readi Reel inside cage wires on the slot in the retain ing spring tab 8 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 9 Slide cage all the way onto the adapter until the retaining spring pops up fully CHECK TO BE SURE THE RETAINING SPRI...

Page 17: ...utput 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 Back the adjustment knob out 1 2 turn run new wire through gun and repeat above steps 3 If the only result was drive roll slippage loosen the adjustment knob on the conductor plate and pull the gun cable forward about 6 15 cm There should be a slight wavi...

Page 18: ...low rate typically 25 35 CFH 12 16 liters min 6 When using Innershield electrode the gas nozzle may be removed from the insulation on the end of the gun and replaced with the gasless nozzle This will give improved visibility and eliminate the possibility of the gas nozzle overheating 7 Connect work cable to metal to be welded Work clamp must make good electrical contact to the work The work must a...

Page 19: ...or proper size tip liner and drive rolls for any obstructions or bends in the gun cable and any other factors that would impede the wire feeding to resume welding simply pull the trig ger There is no circuit breaker to reset as the protec tion is done with reliable solid state electronics WELDING THERMAL OVERLOAD PROTECTION The PM 255 has built in protective thermostats that respond to excessive t...

Page 20: ...mps 40 duty and is equipped with the integrated con nector twist lock trigger connector fixed nozzle and insulator and includes a liner diffuser and contact tips for the wire sizes specified MAGNUM GUN CONNECTION KIT Optional K466 6 Using the optional K466 6 Magnum Connection kit for the PM 255 permits use of standard Magnum 200 300 or 400 gun and cable assemblies TIMER KIT INSTALLATION Optional K...

Page 21: ... to hold thin sheet metal together prior to manual stitch or con tinuous welding To use this feature adjust the On Time 0 5 seconds as appropriate to obtain the desired results 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 To make spot plug wel...

Page 22: ...l be ready to use Closing either gun trigger will cause the electrode of both guns to be electrically HOT Be sure unused gun is positioned so electrode or tip will not contact metal case or other metal common to work 1 Pulling the trigger for the built in feeder gun a Disables spool gun operation b Closing feeder gun trigger starts feeder gun welding and makes both electrodes electrically HOT 2 Pu...

Page 23: ...eed prob lems are experienced try liner replacement and refer to trouble shooting section on rough wire feeding SAFETY PRECAUTIONS ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts GENERAL MAINTENANCE In extremely dusty locations dirt may clog the air pas sages caus...

Page 24: ...ot be installed in another gun unless it can meet the liner cutoff length requirement Liners are shipped with the jacket of the liner extended the proper amount 1 Remove the gas nozzle and nozzle insulator if used to locate the set screw in the gas diffuser which is used to hold the old liner in place Loosen the set screw with a 5 64 2 0 mm Allen wrench 2 Remove the gas diffuser from the gun tube ...

Page 25: ... mm Alum Wire Alum Wire GAS NOZZLES Fixed Flush M16081 1 3 8 9 5 mm M16081 2 1 2 12 7 mm M16081 3 5 8 15 9 mm Fixed Recessed M16080 1 3 8 9 5 mm M16080 2 1 2 12 7 mm M16080 3 5 8 15 9 mm Requires Gas Diffuser As bly S19418 3 025 045 0 6 1 2 mm Adjustable Slip On M16093 2 1 2 12 7 mm M16093 1 5 8 15 9 mm Requires Nozzle Insulator S19417 1 As bly Requires Gas Diffuser S19418 2 025 030 0 6 0 8 mm As ...

Page 26: ...led POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Authorized Fi...

Page 27: ...d reconnect panel configu ration 1 Remove gun assembly from machine If problem is solved gun assembly is faulty Repair or replace 2 If problem persists when gun assembly is removed from machine then the problem is within the PM 255 1 Check input voltage Make sure input voltage matches name plate rating and reconnect panel configuration 2 Make sure settings for wire feed speed and voltage are corre...

Page 28: ...ased and pulled again the wire feed starts POSSIBLE AREAS OF MISADJUSTMENT S 1 The gun cable may be kinked or twisted 2 The wire may be jammed in the gun cable or gun cable may be dirty 3 Check drive roll tension and position of grooves 4 Check for worn or loose drive rolls 5 The electrode may be rusty or dirty 6 Check for damaged or incorrect contact tip 7 Check wire spindle for ease of rotation ...

Page 29: ...un 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 RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Authorized Field Service Facility GAS FLOW PROBLEMS If for any reason you do not understand the test procedures or are unabl...

Page 30: ...3 4 C3 C2 C1 X2 X3 R4 INDICATES CONNECTOR CAVITY NO U BLUE R RED W WHITE B BLACK SECONDARY VOLTAGES SHOWN ARE NO LOAD RMS VALUES OUTPUT CHOKE THERMOSTAT B 206S L1 H2 H5 5 R H4 H1 4 2 1 3 H1 LINE SWITCH S1 RECONNECT PANEL SHOWN CONNECTED FOR 230V TO SINGLE PHASE SUPPLY LINE TO GROUND PER NATIONAL ELECTRICAL CODE ARC VOLTAGE 10 6 5 1 J4 4 3 14 8 252 253 5 4 2 FOR TIMER OPTION 6 GAS SOLENOID 4 3 2 1 ...

Page 31: ...F 2 F 2 DIMENSION PRINT 3 00F M19231 PM 255 ...

Page 32: ...NOTES PM 255 ...

Page 33: ...NOTES PM 255 ...

Page 34: ...NOTES PM 255 ...

Page 35: ...6 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location Orders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only Prices include shipment by 4 th Class Book Rate...

Page 36: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 37: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 38: ...s 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 World s Leader in Welding and Cutting Products ...

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