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IM676
MARCH, 2001
RED-D-ARC
PM 255
For use with machines having Code Numbers:
10709
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 THI
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i i 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 cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. 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” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v for selecting a QUALITY product. We want you to take pride in operating this product ��� as much pride as we have in bringing Thank You this product to 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. Please record your equipment id
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vi vi MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions.................................................................................................A-2 Uncrating the PM 255.................................................................
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vii vii MASTER TABLE OF CONTENTS FOR ALL SECTIONS (cont.) Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 General Maintenance ............................................................................................D-1 Drive Rolls and guide Tubes ....................................................
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A-1 A-1 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 40% 250 Amps 26 Volts 60% 200 Amps 28 Volts 100% 145 Amps 26 Volts OUTPUT Welding Current Range (Continuous) Maximum Open Circuit Voltage Welding Voltage Range 30 – 300 Amps 40 Volts 10-28 Volts RECOMMENDED INPUT WIRE AND FU
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A-2 A-2 INSTALLATION Read entire installation section before starting INPUT POWER, GROUNDING AND installation. CONNECTION DIAGRAMS SAFETY PRECAUTIONS WARNING WARNING ELECTRIC SHOCK can kill. � Do not touch electrically live parts such as ELECTRIC SHOCK can kill. output terminals or internal wiring. � Only qualified personnel should perform � All input power must be electrically dis- this installation. connected before proceeding. � Only personnel that have read and under- stood the PM 255 Operat
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A-3 A-3 INSTALLATION FIGURE A.1 — Dual Voltage Machine Input Connections 3. The 230/460/575 volt 60 Hz model is not equipped with an input cable or a plug. 4. Using the instructions in Figure A.3, have a quali- fied electrician connect the receptacle or cable to the input power lines and the system ground per the U.S. National Electrical Code and any applica- ble local codes. See “Technical Specifications” at the beginning of this chapter for proper wire sizes. For long runs over 100 feet, larg
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A-4 A-4 INSTALLATION FIGURE A.2 — Triple Voltage Machine Input Connections FIGURE A.3 — Receptacle Diagram OUTPUT POLARITY CONNECTIONS CONNECT TO A SYSTEM The welder, as shipped from the factory, is connected GROUNDING WIRE. SEE for electrode positive (+) polarity. This is the normal THE UNITED STATES NATIONAL ELECTRICAL polarity for GMA welding. CODE AND/OR LOCAL CODES FOR OTHER If negative (–) polarity is required, interchange the DETAILS AND MEANS FOR PROPER GROUND- connection of the two cabl
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A-5 A-5 INSTALLATION GUN AND CABLE INSTALLATION The Magnum 250L gun and cable provided with the 2. Remove the cylinder cap. Inspect the cylinder PM 255 is factory installed with a liner for .035-.045" valves and regulator for damaged threads, dirt, (0.9-1.2 mm) electrode and an .035" (0.9 mm) contact dust, oil or grease. Remove dust and dirt with a tip. Install the .045 tip (also provided) if this wire size clean cloth. is being used. DO NOT ATTACH THE REGULATOR IF OIL, GREASE OR DAMAGE IS PRESE
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B-1 B-1 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. 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 con
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B-2 B-2 OPERATION PRODUCT DESCRIPTION LIMITATIONS The PM 255 is a complete semiautomatic constant voltage DC arc welding machine built to meet NEMA The PM 255 MAY NOT operate satisfactorily if pow- specifications. It combines a constant voltage power ered with a portable or in-plant generating system. source and a constant speed wire feeder with a micro- computer-based controller to form a reliable high-per- formance welding system. A simple control scheme, DESCRIPTION OF CONTROLS consisting of
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B-3 B-3 OPERATION 6. Position the Readi-Reel so that it will rotate in a direction when feed- PROCEDURE FOR CHANGING ing so as to be de- reeled from top of the coil. DRIVE AND IDLE ROLL SETS 7. Set one of the Readi-Reel inside cage wires on the slot in the retain- 1. Turn off the power source. ing spring tab. 2. Release the pressure on the idle roll by swinging 8. Lower the Readi-Reel to depress the retaining spring and align the the adjustable pressure arm down toward the back other inside c
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B-4 B-4 OPERATION 3. If the only result was drive roll slippage, loosen the FEEDING WIRE ELECTRODE adjustment knob on the conductor plate and pull the gun cable forward about 6" (15 cm). There should be a slight waviness in the expose wire. If WARNING there is not waviness, the pressure is too low. Tighten the adjustment knob 1/4 turn, reinstall the When triggering, the electrode and drive mecha- gun cable and repeat the above steps. nism are electrically “hot” relative to work and ground and re
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B-5 B-5 OPERATION It is not necessary to repeat either of the above proce- dures each time the unit is powered up. The unit will WARNING remember the run-in mode from the previous power When using an open arc process, it is necessary down and return you to that same state upon your to use correct eye, head, and body protection. next power up. Thus, you need only perform one of the above procedures when you want to change the 8. Position electrode over joint. End of electrode may run-in mode. be
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B-6 B-6 OPERATION FAN CONTROL WELDING THERMAL OVERLOAD PROTECTION The fan is designed to come on automatically when a weld arc is established. The fan will stay on for a mini- The PM 255 has built-in protective thermostats that mum of 6 minutes after the weld arc is terminated. respond to excessive temperature. They open the The fan will also stay on when the machine’s welding wire feed and welder output circuits if the machine and feeding are disabled during thermostatic over exceeds the maximu
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C-1 C-1 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 PM 255. All items in Bold are sup- The following Magnum 250L gun and cable assem- plied standard with the POWER MIG. blies are separately available for use with the PM 255. Each is rated 200 amps 60% duty cycle (or 250 amps 40% duty) and is equipped with the integrated con- Wire Size Drive Roll Kit nector, twist-lock trigger connector, fix
