Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
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 L’Arc 1. Protegez-vous contre la seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
PM 255 Thank You for selecting a QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringingthis product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pa...
Page 7 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page
vi vi MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Safet...
Page 9 - INSTALLATION; TECHNICAL SPECIFICATIONS – PM 255
A-1 A-1 INSTALLATION 75°C Copper Wire 75°C Copper Wire Input Ampere in Conduit in Conduit Input Voltage/ Fuse or Breaker Rating On AWG (IEC) Sizes AWG (IEC) Sizes (For lengths (For lengths Frequency (Hz) Size (Super Lag) Nameplate up to 100 ft.) exceeding 100 ft.) 230/60 60 46 10 (6 mm 2 ) 8 (10 mm ...
Page 10 - Before starting the installation, check with the local; SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.
A-2 A-2 INSTALLATION INPUT POWER, GROUNDING ANDCONNECTION DIAGRAMS 1. Before starting the installation, check with the local p o w e r c o m p a n y i f t h e r e i s a n y q u e s t i o n a b o u twhether your power supply is adequate for the volt-age, amperes, phase, and frequency specified onthe ...
Page 11 - FIGURE A.1 — Dual Voltage Machine Input Connections; with an input cable or a plug.
A-3 A-3 INSTALLATION 4. Using the instructions in Figure A.3, have a quali- fied electrician connect the receptacle or cable tothe input power lines and the system ground perthe U.S. National Electrical Code and any applica-ble local codes. See “Technical Specifications” atthe beginning of this chap...
Page 12 - FIGURE A.3 — Receptacle Diagram; OUTPUT POLARITY CONNECTIONS; FIGURE A.2 — Triple Voltage Machine Input Connections
A-4 A-4 INSTALLATION FIGURE A.3 — Receptacle Diagram CONNECT TO A SYSTEMGROUNDING WIRE. SEETHE UNITED STATESNATIONAL ELECTRICALCODE AND/OR LOCALCODES FOR OTHERDETAILS AND MEANSFOR PROPER GROUND-ING. CONNECT TO HOTWIRES OF A THREE-WIRE, SINGLE PHASESYSTEM OR TO ONEPHASE OF A TWO ORTHREE PHASE SYSTEM....
Page 14 - OPERATION
B-1 B-1 OPERATION R e a d e n t i r e O p e r a t i o n s e c t i o n b e fo r eoperating the PM 255. ELECTRIC SHOCK can kill. • D o n o t t o u c h e l e c t r i c a l l y l i v e p a r t s o r e l e c t r o d e w i t h s k i n o rw e t c l o t h i n g . I n s u l a t e y o u r s e l ffrom work and...
Page 15 - Voltage Control
B-2 B-2 OPERATION PRODUCT DESCRIPTION The PM 255 is a complete semiautomatic constantvoltage DC arc welding machine built to meet NEMAspecifications. It combines a constant voltage powersource and a constant speed wire feeder with a micro-computer-based controller to form a reliable high-per-formanc...
Page 16 - TO START THE WELDER
B-3 B-3 OPERATION PROCEDURE FOR CHANGINGDRIVE AND IDLE ROLL SETS 1. Turn off the power source. 2. Release the pressure on the idle roll by swinging the adjustable pressure arm down toward the backof the machine. Lift the cast idle roll assembly andallow it to sit in an upright position.. 3. Remove t...
Page 17 - FEEDING WIRE ELECTRODE; INSTRUCTIONS TO ENTER SLOW RUN-IN
B-4 B-4 OPERATION FEEDING WIRE ELECTRODE When triggering, the electrode and drive mecha-nism are electrically “hot” relative to work andground and remain “hot” several seconds afterthe gun trigger is released. NOTE: Check that drive rolls, guide plates and gun parts are proper for the wire size and ...
Page 18 - MAKING A WELD
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 willremember the run-in mode from the previous powerdown and return you to that same state upon yournext power up. Thus, you need only perform one ofthe above procedures when yo...
Page 19 - FAN CONTROL; s welding; INPUT LINE VOLTAGE PROTECTION; High Line Voltage; If the line voltage exceeds; Low Line Voltage; You may not be able to get; OVERCURRENT PROTECTION; Welding Procedure Information
B-6 B-6 OPERATION FAN CONTROL The fan is designed to come on automatically when aweld arc is established. The fan will stay on for a mini-mum of 6 minutes after the weld arc is terminated.The fan will also stay on when the machine ’ s welding and feeding are disabled during thermostatic overt e m p ...
Page 20 - ACCESSORIES; DRIVE ROLL KITS
C-1 C-1 ACCESSORIES DRIVE ROLL KITS Refer to Table C.1 for various drive roll kits that areavailable for the PM 255. All items in Bold are sup-plied standard with the POWER MIG. TABLE C.1 3/64" (1.2 mm) ALUMINUM FEEDING KIT (K1703-1) This kit helps push feeding aluminum through stan-dard machine...
Page 22 - Spool Guns only. Use with other units
C-3 C-3 ACCESSORIES SPOOL GUN ADAPTER KIT (K1700-1) (Included in the K1692-1) Remove all input power to the PM 255 before pro-ceeding. The Spool Gun Adapter Kit provides direct connectiona n d u s e o f t h e K 1 6 9 2 - 1 S p o o l G u n ( w i t h r e m o t espeed control) with the PM 255 wire feed...
Page 23 - MAINTENANCE; GUN TUBES AND NOZZLES; Have an electrician install and; GENERAL MAINTENANCE
D-1 D-1 MAINTENANCE 3. If using optional adjustable slip-on nozzles, see Table D.2 in this section. • Be sure the nozzle insulator is fully screwedonto the gun tube and does not block the gasholes in the diffuser. • Slip the appropriate gas nozzle onto the nozzleinsulator. Either a standard .50"...
Page 24 - LINER REMOVAL AND REPLACEMENT
Counterclockwise ➣ D-2 D-2 MAINTENANCE 7. Screw the gas diffuser onto the end of the gun tube and securely tighten. Be sure the gas diffuser iscorrect for the liner being used. (See table and dif-fuser stencil.) 8. Tighten the set screw in the side of the gas diffuser against the cable liner using a...
Page 25 - ACCESSORIES AND EXPENDABLE REPLACEMENT PARTS
D-3 D-3 MAINTENANCE English Metric Description Part No. Size Size CABLE LINERFor 15' (4.5 m) or M16087-2 .025 – .030" 0.6 – 0.8 mm shorter Cable M16087-1 .035 – .045" 0.9 – 1.2 mm M17714-1 3/64" 1.2 mm (Alum. wire) (Alum. wire) CONTACT TIPSStandard Duty S19391-6 .025" 0.6 mm S19391-7...
Page 26 - TROUBLESHOOTING; CAUTION; Look under the column labeled; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 PM 255 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provide...
Page 27 - OUTPUT PROBLEMS; Observe all Safety Guidelines detailed throughout this manual
E-2 E-2 TROUBLESHOOTING PROBLEMS(SYMPTOMS) Major Physical or ElectricalDamage is Evident There is no wire feed or open cir-cuit voltage when the gun trigger ispulled. The machine displays arelit indicating input power to the PM255. Output voltage and wire feed is pre-sent when gun trigger is not pul...
Page 28 - FEEDING PROBLEMS
E-3 E-3 TROUBLESHOOTING PROBLEMS(SYMPTOMS) Poor arc striking with electrodesticking or blasting off. POSSIBLE AREAS OFMISADJUSTMENT(S) 1. Make sure settings for wire feed speed and voltage are correctfor process being used. 2. The Run-In (Fast or Slow) speed may be wrong for process andtechnique bei...
Page 29 - GAS FLOW PROBLEMS
E-4 E-4 TROUBLESHOOTING PROBLEMS(SYMPTOMS) Gas does not flow when gun triggeris pulled. POSSIBLE AREAS OFMISADJUSTMENT(S) 1. Make sure gas supply is con- nected properly and turned “ on ” . 2. If the gas solenoid does actuate (click) when the gun trigger ispulled there may be a restrictionin the gas...
Page 30 - WIRING DIAGRAMS
F-1 F-1 WIRING DIAGRAMS 1 209 555 B W 515 254 262 207 P .M. 208S J9 B T A C H D1 ASBL Y 2-01A 11 1 28.4V 14.2V 14.2V 116.6V 515 206A SCI 541A 326 543 206B 353 GENERAL INFORMA TION CA VITY NUMBERING SEQUENCE (COMPONENT SIDE OF P .C. BOARD) 1 2 1 J7 1 16 J5 9 TO WORK CA VITY J13 WIRE FEED SPEED C1 THR...
Page 31 - DIMENSION PRINT
Page 32 - NOTES
Page 35 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P ...
Page 36 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...
