Page 1
WIRE FEEDER/WELDERS
CV
DC
1
PHASE
60
Hz
POWER MIG®255XT
POWER MIG®. The Professional’s ChoiceSM.
The POWER MIG®255XT sets the standard for MIG and flux-cored welding
in light industrial job shop fabrication, maintenance or repair work. Diamond
Core Technology
range, low spatter levels and a forgiving arc on steel, stainless and
aluminum – even for demanding out-of-position work.
It’s Spool Gun Ready, so it’s fast and easy to tackle difficult aluminum
applications. Exclusive 115 volt auxiliary power means you can power lights,
grinders, and chargers right where you work! And, the MAXTRAC
system with a patented Split Wire Guide system and tachometer feedback
ensures trouble-free wire delivery. Add the extra length 15 foot gun cable
and innovative convenience features and you begin to understand why the
POWER MIG
Medium Duty Heavy Duty
™
delivers a wide voltage sweet spot across the welding
®
255XT is considered The Professional’s ChoiceSM.
Spool Gun Capable
®
drive
Processes
MIG, Flux-Cored
Output
Input
Advantage Lincoln
Arc Performance:
• Diamond Core Technology™, a patented choke design, delivers:
- A forgiving arc, even with large stickout changes
- Excellent out-of-position arc action
- A wide voltage sweet spot at a given wire feed speed
- Low spatter
Superb Quality:
• MAXTRAC
®
cast aluminum industrial wire drive features dual
driven rolls, easy-turn numeric tension indicator, brass-to-brass
gun connections and Lincoln’s 100% wire-supporting split wire
guide system.
• Three-year warranty on parts and labor (90 days warranty on gun).
TECHNICAL SPECIFICATIONS
Product
Name
POWER MIG
POWER MIG
(1)
®
255XT
®
One-Pak
Spool Gun Pkg.
®
255XT
Base Unit
Input current is at the rated output with the 115V auxiliary receptacle also drawing 15 amps.
Product
Number
K2702-1 208/230/1/60 250A/26V/40% 56/52A
K2701-1 208/230/1/60 250A/26V/40% 56/52A
K2701-2 230/460/575/1/60 50/24/19A
Input Power
Rated Output
Current/Voltage/Duty Cycle
Professional Features:
• Digital meters display, preset voltage and wire feed speed, and
actual voltage and preset wire feed speed while welding.
• Generous 15 ft. (4.5 m) gun and cable assembly makes it easy to
reach your work.
• Spool Gun Ready – The POWER MIG
second gas solenoid built-in to drive either the Magnum
spool gun or the Magnum
• The most economic spool gun solution in the 250A category –
costing hundreds less.
• 115V auxiliary receptacle (208/230V model only) to power a grinder
or other auxiliary equipment in your work area.
• Free Timer Functions adds 4-step trigger interlock, spot mode,
adjustable run-in speed for smoother arc starting, and adjustable
burnback time to minimize wire sticking in puddle.
Input Current @
Rated Output
(1)
(1)
®
SG spool gun.
(1)
Output Range
30-300 Amps
50-700 ipm WFS
(1.3-17.7 m/min)
Max. OCV: 40V 31.8 x 18.9 x 38.8
30-300 Amps
50-700 ipm WFS
(1.3-17.7 m/min)
Max. OCV: 40V
®
255XT has the electronics and
Dimensions
H x W x D
inches (mm)
(808 x 408 x 985)
®
250LX
Net Weight
lbs. (kg)
(100)
220
Publication E7.54 7/08
www.lincolnelectric.com
Page 2
A CLOSER LOOK
PERFORMANCE
What Is It?
Diamond Core Technology™is a patented innovative
choke design that filters the welding arc. It provides
dynamic optimized arc filtering across the entire
welding range of amperages. Other arc stabilization
methods are “fixed” – or only working at certain
amperages – resulting in harsh arc characteristic
Results:
• Great starts and low spatter.
• Outstanding performance on
a wide variety of materials –
steel, stainless and aluminum.
• A wide sweet spot for optimal
arc performance.
Great For:
• Steel, stainless and aluminum.
• Out-of-position work.
• Long arc applications.
• Weaving techniques.
changes over the welding range.
PROCESS CAPABILITIES
Process Wire Polarity Gas Thickness Thickness
MIG .025", .030", .035", .045"
Mild Steel (0.6, 0.8, 0.9, 1.1 mm) DC+ 100% CO
MIG .030", .035", .045" Ar/CO
Stainless (0.8, 0.9, 1.1 mm) DC+ or Tri-Mix (0.9 mm) (19.1 mm)
Blue Max
MIG 3/64" 1/16" (.063") 1/2" (.500")
Aluminum (1.2 mm) DC+ 100% Argon (1.6 mm) (19.1 mm)
Flux-Cored, .035", .045" 100% CO
Gas-Shielded (0.9, 1.1 mm) DC+ Ar/CO
Mild Steel Outershield
Electrode Electrode Shielding Minimum Maximum
or 24 ga. (.024") 1/2" (.500")
®
SuperArc
SuperGlide
®
308LSi, 309LSi, 316LSi
®
SuperGlaze
4043 and 5356
®
71M and MC-710
L50, L-56 Ar/CO2Blend (0.6 mm) (19.1 mm)
®
S-3, S-6
2
Blend 20 ga. (.036") 1/2" (.500")
2
or 12 ga. (.109") 1/2" (.500")
2
Blend (2.7 mm) (19.1 mm)
2
(1)
Flux-Cored, .035", .045" 18 ga. (.050") 3/4" (.750")
Self-Shielded (0.9, 1.1 mm) DC- — (1.2 mm) (12.7 mm)
Mild Steel Innershield
(1)
Lincoln Electric recommends multiple pass welds on 1/2" (12.7 mm) material. Consult the appropriate application procedures and guidelines for selecting the correct wire size,
gas type and number of passes.
(2)
.035" and .045" (0.9 and 1.1 mm) NR®-211-MP is only recommended up to 5/16" (7.9 mm) thick material.
®
NR®-211-MP
(2)
and NR®-212
FEATURES
Energize Your Shop!
— The POWER MIG
255XT features a 115 volt auxiliary power
receptacle which allows you to power
grinders, lights, cordless tool chargers
or any other power tools.
Battery Chargers
for Cordless Tools
(1)
(1)
115V auxiliary power is only available on 208/230V models.
®
Saws
Grinders
Rotary Tools
Welding Fume
Extraction
Work Lights
POWER MIG®255XT
[2]
www.lincolnelectric.com
Page 3
A CLOSER LOOK
FEATURES CONʼT.
Compare These Innovations – Make the Professional’s ChoiceSM!
C
B
A
Timer Functions
Adds 4-step trigger interlock, spot mode,
adjustable run-in speed for smoother arc
starting, and adjustable burnback time to
minimize wire sticking in puddle.
Easy Load Wire Compartment
Professional Heavy Duty Wire Drive System
Internal tachometer feedback drive
system allows you to maintain
constant wire feed speed
for consistent welds.
Split guides support the wire
through the entire drive
system to minimize
feeding problems.
Reliable brass-to-brass gun receiver
bushings provide connectivity to
®
Magnum
support and electrical current transfer.
or competitive guns. Easier
interchangeability, better mechanical
Easy Load Gas Cylinder Platform
Extra–Length 15 ft. (4.5 m) Gun Additional Gas Solenoid – Controls Gas
A Lockable storage compartment with tool
tray stows your welding consumables and
valuable personal tools.
B Built-in gun holder conveniently stores
welding gun.
C Handy MIG Gun Expendables Chart.
Flow to a Spool Gun
Easy turn numeric tension indicator with
optimized ranges for different wire types.
Wide idler arm hinge provides improved
drive roll clamping pressure.
Input bushing protects the wire from damage.
Two gear driven rolls. No tools needed
to swap rolls on or off.
[3]
Separate drive gear reduces pressure
on motor shaft for long life.
Removable outer wire guide for
easy access.
POWER MIG®255XT
www.lincolnelectric.com
Page 4
A CLOSER LOOK
Key Controls
A. Digital meter displays preset wire feed speed.
B. Presettable digital wire speed control with fine
resolution at low settings.
C. Digital meter displays preset voltage setting and
actual voltage while welding.
D. Built-in gun holder.
E. Presettable digital voltage control with fine resolution
at low settings.
F. Angled gun connection for improved feedability.
G. Second gas solenoid for spool gun use.
A
B
QUALITY AND RELIABILITY
• Fan-As-Needed™(F.A.N.™) provides cooling of transformer and other components when welding,
reducing power consumption, noise and extending welder life.
• Thermostatic protection from current overload and excessive temperatures.
• Printed circuit boards are environmentally-shielded using Lincoln's engineered potting and protective
frame trays.
• Low input current draw for energy-efficient low cost operation.
• Power source line voltage regulation holds voltage setting constant to maintain weld quality even when
the input voltage fluctuates ±10%.
• Manufactured under a quality system certified to ISO 9001 requirements and ISO 14001 Environmental Standards.
• Approved by Canadian Standards Association (CSA).
• Three-year warranty on parts and labor (90 days warranty on gun).
C
D
E
F
G
SPOOL GUN READY!
The POWER MIG®255XT has built-in electronics to drive either a
Magnum®SG Spool Gun or a Magnum®250LX Spool Gun. In
addition, a second gas solenoid is provided to supply and control
gas flow to the spool gun.
Easy as 1-2-3!
Simply plug the spool gun control cable into the built-in 7-pin
1
connector (Magnum®SG gun requires K2445-1, 6- to 7-pin
control cable adapter plug.)
Connect the spool gun’s power cable to the output terminal
2
in the wire drive compartment.
Hook the spool gun gas line to the solenoid gas fitting and
3
you’re ready to weld!
1
2
3
[4]
POWER MIG®255XT
www.lincolnelectric.com
Page 5
A CLOSER LOOK
Improved Spool Gun Operation!
It’s easy to start welding with a spool gun. Set wire feed speed
at the gun – see the pre-set wire feed speed displayed on the
POWER MIG®255XT meter.
Faster set-up – No more guessing on wire feed speed!
POWER MIG®255XT SPOOL GUN SOLUTIONS
The economic Magnum®SG or premium Magnum®250LX spool guns
are recommended for easy changeovers to a second electrode material such as stainless steel or aluminum.
Avoid the time-consuming liner, contact tip, drive roll and machine
polarity changes necessary when preparing your machine’s wire drive
Adjust speed on the gun and watch the wire feed speed
change on the POWER MIG
®
255XT.
for use with those materials. Spool guns are especially recommended
for feeding soft aluminum wire.
Lincoln’s spool guns accommodate 4" (100 mm) diameter 1 lb.
(.45 kg) spools and feature convenient wire feed speed control at
the gun handle.
MAGNUM®SG SPOOL GUN
• 250A, 60% duty cycle.
• .025"- 3/64" (0.6-1.2 mm) electrode diameter capability.
• Wire feed speeds from 50-650 ipm (1.2 -16.5 m/min.).
• 25 ft. (7.6 m) gun cable length – compare to the competition.
• Adjustable speed control at the handle – allows you to tailor the
WFS setting at the gun.
• See E12.22 for Expendable Parts.
• Order K487-25 spool gun and K2445-1 control cable adapter.
MAGNUM®250LX SPOOL GUN - FACTORY READY
• 300A, 60% duty cycle.
• .025” - 3/64" (0.6-1.2 mm) electrode diameter capability.
• Wire feed speeds up to 800 ipm (20.3 m/min.).
• 25 ft. (7.6 m) gun cable length with 7-pin MS-Type Connector.
• WFS control for fine adjustment of wire feed speed at the gun.
• Zippered cable jacket is standard.
• See E12.25 for Expendable Parts.
• Order K2490-1.
OONNEE--PPAAKK
®®
((KK22770022--11)) IINNCCLLUUDDEESS::
• POWER MIG®255XT (K2701-1)
• Magnum®250LX Spool Gun (K2490-1)
• Spool Gun Holder (K1738-1)
• Dual Cylinder Mounting Kit (K1702-1)
• Extra Regulator (K586-1)
POWER MIG®255XT
[5]
www.lincolnelectric.com
Page 6
A CLOSER LOOK
THE MAGNUM®250L GUN
• Magnum®250L gun and cable assembly, shipped with the
POWER MIG®255XT, is equipped to feed .035"-.045" (0.9-1.2
mm) solid steel wire.
• Lightweight and flexible for easy maneuverability.
• Fiberglass handle with non-slip grooves to maximize comfort
and control.
• Heavy duty gun trigger switch for positive electrical contact
and long life.
• Magnum®replacement parts are fully compatible with other
leading brands. Industry reference numbers are provided for
ease of interchangeability.
MAGNUM®REPLACEMENT PARTS
Description Order No. Reference No.
Industry
Magnum®250L Gun and Cable Assembly
Fixed Gas Nozzle Model
For .035"-045" (0.9-1.2 mm) wire sizes
12 ft. (3.6 m) cable K533-7
Adjustable Gas Nozzle Model
For .035"-.045" (0.9-1.2 mm) wire sizes
10 ft. (3.0 m) cable K533-1
15 ft. (4.5 m) cable K533-3
Cable Liners
For All Gun Cable Lengths
.025"-.030" (0.6-0.8 mm) KP1934-2 42-23-15
.030"-.035" (0.8-0.9 mm) KP1934-3 42-3035-15
.035"-.045" (0.9-1.2 mm) KP1934-1
3/64" (1.2 mm) Aluminum KP1955-1
Contact Tips
Standard Duty
.025" (0.6 mm) KP2020-6 14-23
.030" (0.8 mm) KP2020-7 14-30
.035" (0.9 mm) KP2020-1
.040" (1.0 mm) KP2020-8 14-40
.045" (1.2 mm) KP2020-2
Heavy Duty
.035" (0.9 mm) KP2021-1 14H-35
.040" (1.0 mm) KP2021-6 14H-40
.045" (1.2 mm) KP2021-2 14H-45
Tapered
.025" (0.6 mm) KP2022-5 14T-23
.030" (0.8 mm) KP2022-6 14T-30
.035" (0.9 mm) KP2022-1 14T-35
.040" (1.0 mm) KP2022-7 14T-40
.045" (1.2 mm) KP2022-2 14T-45
Aluminum
3/64" (1.2 mm) KP2010-5
Fixed Gas Nozzles/Diffuser Assembly
Fixed (flush)
3/8" (9.5 mm) KP1931-1 23-37-F
1/2" (12.7 mm) KP1931-2
5/8" (15.9 mm) KP1931-3 23-63-F
Fixed (recessed)
3/8" (9.5 mm) KP1930-1 23-37
1/2" (12.7 mm) KP1930-2 23-50
5/8" (15.9 mm) KP1930-3 23-62
Requires: Gas Diffuser Assembly
.025-.045" (0.6-1.2 mm) KP2026-3
(1)
(2)
(1)
(2)
(2)
(1)
(1)
42-4045-15
42N-3545-15
14-35
14-45
23-50-F
52FN
MAGNUM®REPLACEMENT PARTS
Description Order No. Reference No.
Adjustable Gas Nozzle/Diffuser Assembly
Adjustable Slip-On
3/8" (9.5 mm) KP1935-3 22-37
1/2" (12.7 mm) KP1935-2 22-50
5/8" (15.9 mm) KP1935-1 22-62
Requires:
Nozzle Insulator Assembly KP2025-1 32
Gas Diffuser Assembly:
.023"-030" (0.6-0.8 mm) KP2026-2 52-23
.035"-.045" (0.9-1.2 mm) KP2026-1 52
Gasless Nozzle/Diffuser Assembly
(Innershield Nozzle) KP1947-1
Requires:
Gas Diffuser Assembly KP2026-1 52
Gun Tube Assembly
Standard (60°) KP2015-1
45° KP2041-1
(1)
Included with POWER MIG®255XT.
(2)
Included in the K1703-1 Aluminum Feeding Kit.
Industry
(1)
(2)
DRIVE ROLL KITS
Wire Size Order Number
Solid .035" (0.9 mm) KP1696-035S
.023"-.030" (0.6–0.8 mm) KP1696-030S
.035"/.045" combination KP1696-1
.040" (1.0 mm) KP1696-2
.045" (1.2 mm) KP1696-045S
Cored
.035" (0.9 mm) KP1697-035C
.045" (1.2 mm) KP1697-045C
Aluminum 3/64" (1.2 mm) KP1695-3/64A
(1)
Included with POWER MIG®255XT.
(2)
Included in the K1703-1 Aluminum Feeding Kit.
(1)
(2)
[ 6]
POWER MIG®255XT
www.lincolnelectric.com
Page 7
RECOMMENDED OPTIONS
GENERAL OPTIONS
Magnum®SG Spool Gun
250 Amp, 60% Duty Cycle with
25 ft. of cable length. Feeds
.025” - 3/64” inch diameter wire.
Single Turn remote wire feed
speed control at the gun.
Adjustable wire spool brake and
adjustable drive roll tension.
Order K487-25
Requires K2445-1 Adapter
®
Magnum
250LX Spool Gun
300 Amp, 60% Duty Cycle with
25 ft. of cable length. Feeds
.025” - 3/64” inch diameter wire.
Multi-Turn remote wire feed
speed control at the gun. Deluxe
wire spool break requires no
adjustments. Adjustable drive roll
tension and easy open wire drive
rolls for easy wire loading.
Ergonomic Sure Grip handle.
Contact tip storage built in spool
gun cover.
K2490-1
Factory Ready
Dual Cylinder Mounting Kit
Permits side-by-side mounting
of two full size gas cylinders,
with easy loading. Attaches
easily to POWER MIG
®
undercarriage.
Order K1702-1
Magnum®SG Spool Gun Control
Cable Adapter
Allows the K487-25 Magnum
®
SG
Spool Gun’s 6-pin control cable
plug to connect to the POWER
MIG®255XT’s 7-pin spool gun
control cable receptacle.
Order K2445-1
®
Magnum
250LX Spool Gun
Control Cable Extension
Extend your spool gun reach with
a 25 ft. (7.6 m) Control Cable
Extension. Features a 7-pin female
MS-type connector on the spool
gun end and a 7-pin male MS-type
connector on the power source end.
Order K2519-1
Spool Gun Holder
Provides neat storage of spool
gun.
Order K1738-1
®
Magnum
Guns
Alternate guns can be used with
the POWER MIG®, including
Magnum®200, 300 and 400 MIG
(GMAW) models, as well as
Magnum
®
250XA Fume Extraction
Gun.
See Publications E12.10 and
E13.10 for details.
Note: Requires K466-6 Adapter Kit.
Canvas Cover
Protect your POWER MIG
®
when
not in use. Made from attractive
red canvas that is flame retardant,
mildew resistant and water
repellent. Fits any POWER MIG
machine with or without a gas
cylinder in the cylinder rack.
Will not fit if spool gun holder is
attached to the machine.
Order K2378-1
Aluminum Feeding Kit
Conversion kit for welding with
3/64" (1.2 mm) aluminum wire.
Includes drive rolls, contact tips
(2), non-metallic wire guides and
cable liner.
Order K1703-1
®
Magnum
Connection Kit
Permits use of Magnum®200, 300
and 400 gun and cable assemblies
®
on POWER MIG
Order K466-6
®
.
8" O.D. Spool Adapter
Permits 8" (200mm) O.D. spools
to be mounted on 2" (51 mm)
O.D. spindles.
Order K468
Welding Fume Extractors
Lincoln offers a wide variety
of welding fume extraction
environmental system solutions,
ranging from portable systems
easily wheeled around the shop
to shop-wide central systems
servicing many dedicated welding
stations.
Request Publication E13.40
POWER MIG®255XT
[ 7]
www.lincolnelectric.com
Page 8
POWER MIG®255XT ORDER FORM
PRODUCT DESCRIPTION ORDER NUMBER QUANTITY PRICE
POWER MIG®255XT 208/230 K2701-1
POWER MIG
POWER MIG
RECOMMENDED GENERAL OPTIONS
Magnum
Magnum
Dual Cylinder Mounting Kit K1702-1
Canvas Cover K2378-1
Aluminum Feeding Kit K1703-1
POWER MIG
Magnum
Spool Gun Holder K1738-1
Magnum
Magnum
8" O.D. Spool Adapter K468
Welding Fume Extractors See publication E13.40
®
255XT 230/460/575 K2701-2
®
255XT ONE-PAK®SPOOL GUN PKG. K2702-1
®
SG Spool Gun K487-25
®
250LX Spool Gun K2490-1
®
255XT/Magnum®SG Spool Gun Control Cable Adapter K2445-1
®
250LX Spool Gun Control Cable Extension K2519-1
®
Guns See publications E12.10, E13.10
®
Connection Kit K466-6
TOTAL:
C U S T O M E R A S S I S T A N C E P O L I C Y
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the
needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric
to our customers based on the best information in our possession at that time. Lincoln Electric
with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to
such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has
been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.
Lincoln Electric
of the customer. Many variables beyond the control of Lincoln Electric
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
®
is a responsible manufacturer, but the selection and use of specific products sold by Lincoln Electric®is solely within the control of, and remains the sole responsibility
®
affect the results obtained in applying these types of fabrication methods and service requirements.
®
is not in a position to warrant or guarantee such advice, and assumes no liability,
®
for advice or information about their use of our products. We respond
THE LI NC OLN EL EC TRIC C OM PA NY
22801 St. Clair Ave., Cleveland, OH 44117-1199 • 216.481.8100 • www.lincolnelectric.com
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