Lincoln Electric POWER MIG 256 Operator's Manual
POWER MIG®256
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 READING THIS MANUAL AND THE
SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
For use with machine Code Numbers
For use with machine Code Numbers
11780, 11781
OPERATORʼS MANUAL
• 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
Copyright © Lincoln Global Inc.
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS 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 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.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
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.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fi elds m ay interf ere wi th some pacemak ers, a nd
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the e lectr ode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
ii
SAFETY
ii
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.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(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. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS 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 and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding ma y produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
vapors
to
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
iii
SAFETY
iii
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
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 and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use on ly com pr essed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Alway s keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Re ad and foll ow the inst ru ctions o n c ompressed ga s
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install 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. National
Electrical Code and the manufacturerʼs recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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 suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, 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 lʼon pique le laitier.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Thank You
vv
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!
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 for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs 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 is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
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.
CUSTOMER ASSISTANCE POLICY
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 identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
Your Product”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
TABLE OF CONTENTS
Page
________________________________________________________________________
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions.................................................................................................A-2
Uncrating the POWER MIG®256 ..........................................................................A-2
Location .................................................................................................................A-2
Input Power, Grounding and Connection Diagram ........................................A-2, A-3
Output Polarity Connections..................................................................................A-3
Gun and Cable Installation ....................................................................................A-3
Shielding Gas ........................................................................................................A-4
Auxiliary Power Receptacle...................................................................................A-4
Coil Claw™ Installation..........................................................................................A-4
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions.................................................................................................B-1
Product Description ...............................................................................................B-2
Recommended Processes and Equipment ...........................................................B-2
Welding Capability.................................................................................................B-2
Limitations..............................................................................................................B-2
Description of Controls ..........................................................................................B-2
Wire Size Conversion Parts...................................................................................B-3
Procedure for Changing Drive Roll........................................................................B-3
Wire Reel Loading .................................................................................................B-4
Mounting of 10 to 44 lb. Spools .............................................................................B-4
To Start the Welder................................................................................................B-4
Feeding Electrode..................................................................................................B-5
Idle Roll Pressure Setting ......................................................................................B-5
Wire Drive Configuration....................................................................................... B-6
Making a Weld.......................................................................................................B-7
Avoiding Wire Feeding Problems ..........................................................................B-7
Fan Control............................................................................................................B-7
Input Line Voltage Protection.................................................................................B-7
Wire Feed Overload Protection .............................................................................B-7
Welding Thermal Overload Protection...................................................................B-8
Overcurrent Protection...........................................................................................B-8
Welding Procedure Information .............................................................................B-8
________________________________________________________________________
vi vi
Accessories.....................................................................................................Section C
Drive Roll Kits........................................................................................................C-1
Dual Cylinder Mounting Kit ...................................................................................C-1
Alternative Magnum GMAW Gun and Cable Assemblies .....................................C-1
Magnum Gun Connection Kit ...............................................................................C-1
Spool Gun..............................................................................................................C-1
Connecting the Spool Gun to the
Making a Weld with the Spool Gun .......................................................................C-2
Making a Weld with the Magnum SG Spool Gun ..................................................C-3
________________________________________________________________________
POWER MIG®256 ....................................................C-2
vii vii
TABLE OF CONTENTS
Page
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Maintenance ............................................................................................D-1
Drive Rolls and Guide Plates.................................................................................D-1
Contact Tip and Gas Nozzle Installation ...............................................................D-1
Gun Tubes and Nozzles........................................................................................D-1
Gun Cable Cleaning ..............................................................................................D-1
Liner Removal and Replacement ..........................................................................D-2
Liner Removal, Installation and Trimming Instructions for Magnum
Gun Handle Disassembly......................................................................................D-3
________________________________________________________________________
Troubleshooting..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ............................................................................E-2 thru E-4
________________________________________________________________________
Wiring Diagram and Dimension Print ............................................................Section F
________________________________________________________________________
®
PRO 250L..D-2
Parts Manual....................................................................................................Appendix
POWER MIG®256 ...................................................................................................P-680
Magnum®PRO 250L Gun .........................................................................P-202-H.2
________________________________________________________________________
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – POWER MIG®256
INPUT – SINGLE PHASE ONLY
Standard Voltage/Phase/Frequency
208/230/1/60 Hz *47/44 Amps *56/52 Amps
230/460/575/1/60 Hz 41/20/16 Amps 47/24/19 Amps
Duty Cycle Amps Volts at Rated Amperes
40% 250 Amps 26 Volts
60% 200 Amps 28 Volts
100% 145 Amps 26 Volts
Welding Current Range (Continuous) Maximum Open Circuit Voltage Welding Voltage Range
30 – 300 Amps 40 Volts 10-28 Volts
RECOMMENDED INPUT WIRE AND FUSE SIZES
Input Current @ 200 Amp Rated Output Input Current @ 250 Amp Rated Output
RATED OUTPUT
OUTPUT
A-1
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
Type S, SO, ST, STO or extra
hard usage input cord
AWG (IEC) Sizes
WIRE SPEED RANGE
Wire Speed 50 – 700 IPM (1.27 – 17.8 m/minute)
PHYSICAL DIMENSIONS
Height Width Depth Weight
With Coil Claw™ Without Coil Claw™
220 lbs
32.56 in. 20.12 in. 19.15 in. 39.9in. 100 kg.
827 mm 512 mm 487 mm 1014 mm
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-4°F to 104°F(-20°C to +40°C)
* With 115V receptacle loaded to 15A.
STORAGE TEMPERATURE RANGE
-40°F to 185°F(-40°C to +85°C)
POWER MIG®256
A-2
Read entire installation section before starting
installation.
INSTALLATION
SAFETY PRECAUTIONS
A-2
INPUT POWER, GROUNDING AND
CONNECTION DIAGRAM
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.
• Only personnel that have read
and understood the POWER MIG
256 Operatorʼs Manual should
install and operate this equipment.
• Machine must be grounded per
any national, local or other applicable electrical codes.
• The POWER MIG®256 power
switch is to be in the OFF position when installing work cable
and gun and when connecting
other equipment.
UNCRATING THE POWER MIG®256
Cut banding and lift off cardboard carton. Cut banding
holding the machine to the skid. Remove foam and
corrugated packing material. Untape accessories from
Gas Bottle Platform. Unscrew the two wood screws
(at the Gas Bottle Platform) holding the machine to
the skid. Roll the machine off the skid assembly.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such as
output terminals or internal wiring.
®
1. Before starting the installation, check with the local
power company if there is any question about
whether your power supply is adequate for the voltage, amperes, phase, and frequency specified on
the welder rating plate. Also be sure the planned
installation will meet the U.S. National Electrical
Code and local code requirements. This welder
may be operated from a single phase line or from
one phase of a two or three phase line.
2. Models that have multiple input voltages specified
on the nameplate (e.g. 208/230) are shipped connected for the highest voltage. If the welder is to be
operated on lower voltage, it must be reconnected
according to the instructions in Figure A.1 for dual
voltage machines and Figure A.2 for triple voltage
machines.
• All input power must be electrically disconnected before proceeding.
LOCATION
Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
the louvers out the front. A location that minimizes the
amount of smoke and dirt drawn into the rear louvers
reduces the chance of dirt accumulation that can
block air passages and cause overheating.
WARNING
Make certain that the input power is electrically
disconnected before removing the screw on the
reconnect panel access cover.
------------------------------------------------------------------------
FIGURE A.1 — Dual Voltage Machine Input
Connections
POWER MIG®256
INSTALLATION
A-3 A-3
3. The 208/230 volt 60 Hz model POWER MIG is
shipped with a 10 ft. input cable and plug connected 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 grounding terminal at the top to
allow the power cable to hang down without bending.
The 230/460/575 volt 60 Hz model is not equipped
with a plug, an input cable or a receptacle.
FIGURE A.2 — Triple Voltage Machine Input
Connection
OUTPUT POLARITY CONNECTIONS
The welder, as shipped from the factory, is connected
for electrode positive (+) polarity. This is the normal
polarity for GMAW.
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 attached to the work clamp, is to
be connected to the positive (+) labeled terminal.
GUN AND CABLE INSTALLATION
The
Magnum®PRO
250L gun and cable provided with the
POWER MIG®256 is factory installed with a liner for .035.045" (0.9-1.1 mm) electrode and an .035" (0.9 mm) contact
tip.
Install the .045” tip (also provided) if this wire size
is being used.
WARNING
Turn the welder power switch off before installing
gun and cable.
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 applicable
local codes. See "Technical Specifications" at the
beginning of this chapter for proper wire sizes. For
long 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 A.3 —Receptacle Diagram
CONNECT TO A SYSTEM
GROUNDING WIRE. SEE THE
UNITED STATES NATIONAL
ELECTRICAL CODE AND/OR
LOCAL CODES FOR OTHER
DETAILS AND MEANS FOR
PROPER GROUNDING.
CONNECT TO HOT WIRES OF
A THREE-WIRE, SINGLE
PHASE SYSTEM OR TO ONE
PHASE OF A TWO OR
THREE PHASE SYSTEM.
(See Figure A.4)
1. Lay the cable out straight.
2. Unscrew the Hand Screw on the drive unit front
end (inside wire feed compartment) until tip of
screw no longer protrudes into Gun Adapter opening as seen from front of machine. (See Figure A.4)
3. Insert the male end of gun cable into the Gun
Adapter through the opening in front panel. Make
sure connector is fully inserted and tighten Hand
Screw.
4. Connect the Gun Trigger Connector from the gun
and cable to the mating Receptacle inside the
compartment located left just inside the opening on
the Front Panel. Make sure that the keyways are
aligned, insert and tighten retaining ring.
FIGURE A.4
Hand Screw
Receptacle
Gun Trigger
Connector
Gun Adapter
POWER MIG®256
Male End
Gun and Cable
A-4
INSTALLATION
SHIELDING GAS
[For Gas Metal Arc Welding(GMAW) Processes]
Customer must provide cylinder of appropriate type shielding gas for the process being used.
A-4
7. Standing to one side, open the cylinder valve slowly a
fraction of a turn. When the cylinder pressure gauge
pointer stops moving, open the valve fully.
WARNING
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% CO2, the regulator
adapter will be required to connect the regulator to the gas
bottle.
CYLINDER may explode if
damaged.
• Gas under pressure is explosive.
Always keep gas cylinders in an upright
position and always keep chained to
undercarriage or stationary support.
See American National Standard Z49.1, “Safety in
Welding and Cutting” published by the American
Welding Society.
------------------------------------------------------------------------
INSTALL SHIELDING GAS SUPPLY AS FOLLOWS:
1. Set gas cylinder on rear platform of POWER MIG®256.
Hook chain in place to secure cylinder to rear of welder.
2. Remove the cylinder cap. Inspect the cylinder valves and
regulator for damaged threads, dirt, dust, oil or grease.
Remove dust and dirt with a clean cloth.
DO NOT ATTACH THE REGULATOR IF OIL, 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.
WARNING
Be sure to keep your face away from the valve
outlet when “cracking” the valve.
--------------------------------------------------------------------------------
4. Attach the flow regulator to the cylinder valve and tighten
the union nut(s) securely with a wrench.
NOTE: If connecting to 100% CO2cylinder, the regulator
adapter provided must be installed between the regulator
and cylinder valve.
5. Attach one end of the inlet gas hose to the outlet fitting of
the flow regulator, the other end to the POWER MIG
256 rear fitting marked “Feeder” and tighten the union
nuts securely with a wrench.
6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting
spring pressure is released.
®
Never stand directly in front of or behind the flow regulator when opening the cylinder valve. Always stand to
one side.
--------------------------------------------------------------------------------
8. The flow regulator is adjustable. Adjust it to the flow rate
recommended for the procedure and process being used
before making the weld.
AUXILIARY POWER RECEPTACLES
(For 208/230V Models only)
This machine is equipped with 15Amp 120V receptacle with
15Amp Circuit Breaker. The receptacle is UL and CSA
approved.
COIL CLAW™ INSTALLATION
The Coil Claw™ and mounting screws are provided
as an optional accessory for the
This user-install accessory provides cable management for the machine.
POWER MIG®256
.
WARNING
Turn the welder power switch OFF
before installing Coil Claw™.
------------------------------------------------------------------------
1. Unwrap Coil Claw™ from its protective paper and
remove the bag of mounting screws from the back
of the Coil Claw™.
2. Mount the Coil Claw™ using the provided
ing screws to the left side of the machine, when
viewed from the front. Make sure the Coil Claw™ is
firmly mounted. (See Figure A.5)
FIGURE A.5
MOUNTING
SCREWS
mount-
COIL CLAW™
POWER MIG®256
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