Lincoln Electric IM10096 manual

PO WER MIG ® 256 OPERA T ORʼS MANUAL IM10096 July, 2011 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[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. I ns t al l equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. Nat[...]

iv SAFETY iv 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 LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à[...]

v v T h a n k Y o u for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick referenc[...]

vi vi T ABLE OF CONTENTS Page ________________________________________________________________________ Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safe[...]

vii vii T ABLE OF CONTENTS Page ________________________________________________________________________ Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Gene[...]

A-1 A-1 INST ALLA TION Input Ampere Input Voltage Fuse or Breaker Rating On Frequency (Hz) Size (Super Lag) Nameplate 208/60 60 56A 8 230/60 60 52A 10 230/60 60 47A 10 460/60 30 24A 14 575/60 25 19A 14 TECHNICAL SPECIFICA TIONS – POWER MIG ® 256 INPUT – SINGLE PHASE ONL Y RA TED OUTPUT OUTPUT RECOMMENDED INPUT WIRE AND FUSE SIZES Height Width [...]

FIGURE A.1 — Dual Voltage Machine Input Connections A-2 A-2 INST ALLA TION Read entire installation section before starting installation. SAFETY PRECAUTIONS INPUT POWER, GROUNDING AND CONNECTION DIAGRAM 1. Before starting the installation, check with the local power company if there is any question about whether your power supply is adequate for [...]

Hand Screw Male End Gun and Cable Gun Adapter Receptacle Gun Trigger Connector 3 . The 208/230 volt 60 Hz model POWER MIG is shipped with a 10 ft. input cable and plug connect- ed to the welder. Obtain a receptacle and mount it in a suitable location. Be sure it can be reached by the plug on the input cable attached to the welder. Mount with the gr[...]

SHIELDING GAS [For Gas Metal Arc Welding ( GMAW ) Processes] Customer must provide cylinder of appropriate type shield- ing gas for the process being used. A gas flow regulator, for Argon blend gas, an inlet gas hose, and a regulator adapter are factory provided with the POWER MIG ® 256. When using 100% CO 2 , the regulator adapter will be require[...]

B-1 B-1 OPERA TION Read entire Operation section before operating the POWER MIG ® 256. 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 ve[...]

B-2 B-2 OPERA TION PRODUCT DESCRIPTION The POWER MIG ® 256 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 microcomputer-based controller to form a reliable high- performance welding system. A simple control sc[...]

3 2 1 4 5 6 7 8 B-3 B-3 OPERA TION To make spot plug welds, punch 3/16" (5 mm) holes in the top sheet. Set the Spot Time control to approximately 1.2 seconds and set the procedure for the metal thickness to be welded. Install spot weld nozzle (if available) on gun and press it against the top sheet so the top and bottom sheets are tight togeth[...]

B-4 B-4 OPERA TION FIGURE B.3 POWER MIG ® 256 WIRE REEL LOADING - READI REELS, SPOOLS OR COILS To Mount a 30 Lb. (14 kg) Readi-Reel Package (Using the Molded Plastic K363-P Readi-Reel Adapter:) (See Figure B.3) 1. Open the Wire Drive Compartment Door. 2. Depress the Release Bar on the Retaining Collar and remove it from the spindle. 3. Place the O[...]

The pressure arm controls the amount of force the drive rolls exert on the wire. Proper adjustment of both pressure arm gives the best welding performance. For best results, set both pressure arms to the same value. Set the pressure arm as follows (See Figure B.4): Aluminum wires between 1 and 3 Cored wires between 3 and 4 Steel, Stainless wires be[...]

B-6 B-6 OPERA TION GUN RECEIVER BUSHING LOOSEN TIGHTEN THUMB SCREW OUTER WIRE GUIDE SOCKET HEAD CAP SCREW CONNECTOR BLOCK WIRE DRIVE CONFIGURA TION (See Figure B.5) Changing the Gun Receiver Bushing ELECTRIC SHOCK can kill. • Turn the input power OFF at the weld- ing power source before installation or changing drive rolls and/or guides. • Do n[...]

B-7 B-7 OPERA TION MAKING A WELD 1. Check that the electrode polarity is correct for the process being used, then turn the power switch ON. 2. Set desired arc voltage and wire speed for the particular electrode wire, material type and thickness, and gas (for GMAW) being used. Use the Application Chart on the door inside the wire compartment as a qu[...]

B-8 B-8 OPERA TION 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. The thermos[...]

C-1 C-1 ACCESSORIES DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that are available for the POWER MIG ® 256.The item in Bold is supplied standard with the POWER MIG ® 256. TABLE C.1 K2378-1 Canvas Cover K468 Spindle Adapter - for 8” (203.2mm) O.D. spool. K363P READI-REEL™ ADAPTER The K363P Readi-Reel Adapter mounts to the 2&[...]

C-2 C-2 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: • [...]

C-3 C-3 See the following procedure for setting the Wire Speed Feed using the Magnum SG Spool Gun: To determine spool gun wire feed speed use a hand tachometer, or calculate the speed using the following equation: IPM= Length of wire fed (inches) x 60 Time fed (seconds) 4 . To return to normal POWER MIG ® 256 welding, release the spool gun trigger[...]

D-1 D-1 MAINTENANCE 3. If using optional adjustable slip-on nozzles. (Refer to www.lincolnelectric.com ) • Be sure the nozzle insulator is fully screwed onto the gun tube and does not block the gas holes in the diffuser. • Slip the appropriate gas nozzle onto the nozzle insulator. Either a standard .50" (12.7 mm) or optional .62" (15.[...]

D-2 D-2 MAINTENANCE 5 . Fully seat the liner bushing into the connector. tighten the set screw on the brass cable connector. The gas diffuser, at this time, should not be installed onto the end of the gun tube. 6. With the gas diffuser still removed from the gun tube, be sure the cable is straight, and then trim the liner to the length shown in Fig[...]

D-3 D-3 MAINTENANCE GUN HANDLE DISASSEMBL Y 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) u[...]

E-1 E-1 TROUBLESHOOTING If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair possible machine[...]

E-2 E-2 TROUBLESHOOTING 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. Input power is applied to POWER MIG ® 256. Output voltage and wire feed is pre- sent when gun trigger is not pulled (not activated). Machine output is low. Welds are “cold”, [...]

E-3 E-3 TROUBLESHOOTING PROBLEMS (SYMPTOMS) Poor arc striking with electrode sticking or blasting off. Rough wire feeding or wire will not feed but drive rolls are turning. POSSIBLE CAUSE 1. Make sure settings for wire feed speed and voltage are correct for process being used. 2 . The gas shielding may be improper for process being used. 3 . Check [...]

E-4 E-4 TROUBLESHOOTING PROBLEMS (SYMPTOMS) The wire feed stops while welding. When trigger is released and pulled again the wire feed starts. No control of wire feed speed. Other machine functions are nor- mal. Gas does not flow when gun trigger is pulled. POSSIBLE CAUSE 1. Check the wire feed drive rolls and motor for smooth operation. 2. Check f[...]

F-1 F-1 WIRING DIAGRAMS L12464-2 A. 01 COLOR CODE: ELECTRICAL SYMBOLS PER E1537 GENERAL INFORMATION 265 263 260 261 U - BLUE R - RED W - WH IT E B - BLACK INDICATES CONNECTOR CAVITY NO. 262 267 264 OUTPUT CHOKE POWER FACTOR ENHANCEMENT CHOKE 204B SECONDARY VOLTAGES SHOWN ARE NO LOAD RMS VALUES WIR E DRIVE MOTOR/ GEARBO X C3 C1 205 206S 206B R 1 SCR[...]

F-2 F-2 WIRING DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number. L125[...]

F-3 F-3 DIMENSION PRINT M19231-1 A.0 2 19.15 39.92 12.00 38.58 32.56 29.73 30.43 20.12 POWER MIG ® 256[...]

NOTES[...]

W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A T E N ÇÃO Spanish French G erman P ortuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INS TRUCTION FOR THIS EQ UIPMENT AND THE CONSUMABLES T O BE USED AND FOLL O W Y OUR EMPL O YER’S S AFETY PRA CTICES. SE RECOMIEND A LEER Y ENTENDER LAS INS TRUCCIONES DEL F [...]

W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A T E N ÇÃO S panish F rench German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A AS INS TRUÇÕES DO F ABRIC ANTE P ARA ESTE EQ UIP AMENT O E AS P ARTES DE USO , E SIGA A S PRÁ TIC A S DE SEGURANÇ A DO EMPRE GADOR. • Keep your head out of fumes. • Use ventilation or exhaust[...]

• 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 • World's Leader in Welding and Cutting Products •[...]