Lincoln Electric POWER MIG 255XT User manual

PO ER MIG®. The Professional’s ChoiceSM .
The POWER M G®255XT sets the standard for M G and flux-cored welding
in light industrial job shop fabrication, maintenance or repair work. Diamond
Core Technology™delivers a wide voltage sweet spot across the welding
range, low spatter levels and a forgiving arc on steel, stainless and
aluminum – even for demanding out-of-position work.
t’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®drive
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 M G®255XT is considered The Professional’s ChoiceSM.
WIRE FEEDER/WELDERS
CV
DC
1
PHASE
60
Hz
Publication E7.54 7/08
www.lincolnelectric.com
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).
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 M G®255XT has the electronics and
second gas solenoid built-in to drive either the Magnum®250LX
spool gun or the Magnum®SG spool gun.
•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.
POWER MIG®255XT Output
Input
(1) Input current is at the rated output with the 115V auxiliary receptacle also drawing 15 amps.
TECHNICAL SPECIFICATIONS
Product
Name Product Number Input Power Rated Output Current/Voltage/Duty Cycle Input Current @ Rated Output(1) Output Range
Dimensions
H x x D
inches (mm) Net eight
lbs. (kg)
POWER M G®255XT
One-Pak®
Spool Gun Pkg.
K2702-1 208/230/1/60 250A/26V/40% 56/52A(1)
30-300 Amps
50-700 ipm WFS
(1.3-17.7 m/min)
Max. OCV: 40V 31.8 x 18.9 x 38.8
(808 x 408 x 985)
220
(100)
POWER M G®255XT
Base Unit
K2701-1 208/230/1/60 250A/26V/40% 56/52A(1) 30-300 Amps
50-700 ipm WFS
(1.3-17.7 m/min)
Max. OCV: 40V
K2701-2 230/460/575/1/60 50/24/19A
Processes
M G, Flux-Cored
Spool Gun Capable
Medium Duty Heavy Duty

PERFORMANCE
POWER MIG®255 T
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[2]
A CLOSER LOOK
FEATURES
PROCESS CAPABILITIES
Electrode Electrode Shielding Minimum Maximum
Process ire Polarity Gas Thickness Thickness(1)
MIG .025", .030", .035", .045"
Mild Steel (0.6, 0.8, 0.9, 1.1 mm) DC+ 100% CO2or 24 ga. (.024") 1/2" (.500")
SuperArc®L50, L-56 Ar/CO2Blend (0.6 mm) (19.1 mm)
SuperGlide®S-3, S-6
MIG .030", .035", .045" Ar/CO2Blend 20 ga. (.036") 1/2" (.500")
Stainless (0.8, 0.9, 1.1 mm) DC+ or Tri-Mix (0.9 mm) (19.1 mm)
Blue Max®308LSi, 309LSi, 316LSi
MIG 3/64" 1/16" (.063") 1/2" (.500")
Aluminum (1.2 mm) DC+ 100% Argon (1.6 mm) (19.1 mm)
SuperGlaze®4043 and 5356
Flux-Cored, .035", .045" 100% CO2or 12 ga. (.109") 1/2" (.500")
Gas-Shielded (0.9, 1.1 mm) DC+ Ar/CO2Blend (2.7 mm) (19.1 mm)
Mild Steel Outershield®71M and MC-710
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 nnershield®NR®-211-MP(2) and NR®-212
(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.
Grinders
Batter Chargers
for Cordless Tools
Work Lights
Welding Fume
Extraction
Rotar Tools
Saws
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.(1)
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
changes over the welding range.
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.
(1)115V auxiliary power is only available on 208/230V models.

POWER MIG®255 T
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[3]
A CLOSER LOOK
FEATURES CONʼT.
Easy Load Gas Cylinder Platform ALockable storage compartment with tool
tray stows your welding consumables and
valuable personal tools.
BBuilt-in gun holder conveniently stores
welding gun.
CHandy MIG Gun Expendables Chart.
Easy Load Wire Compartment
Split guides support the wire
through the entire drive
system to minimize
feeding problems.
Wide idler arm hinge provides improved
drive roll clamping pressure.
Removable outer wire guide for
easy access.
Input bushing protects the wire from damage.
Reliable brass-to-brass gun receiver
bushings provide connectivity to
Magnum
®
or competitive guns. Easier
interchangeability, better mechanical
support and electrical current transfer.
Easy turn numeric tension indicator with
optimized ranges for different wire types.
Internal tachometer feedback drive
system allows you to maintain
constant wire feed speed
for consistent welds.
Separate drive gear reduces pressure
on motor shaft for long life.
Two gear driven rolls. No tools needed
to swap rolls on or off.
Professional Heavy Duty Wire Drive System
Extra–Length 15 ft. (4.5 m) Gun Additional Gas Solenoid – Controls Gas
Flow to a Spool Gun
Compare These Innovations – Make the Professional’s ChoiceSM
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.
B
C
A

POWER MIG®255 T
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[4]
A CLOSER LOOK
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
connector (Magnum®SG gun requires 2445-1, 6- to 7-pin
control cable adapter plug.)
Connect the spool gun’s power cable to the output terminal
in the wire drive compartment.
Hook the spool gun gas line to the solenoid gas fitting and
you’re ready to weld!
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).
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.
B
A
D
C
F
E
1
G
2
3
1
2
3

POWER MIG®255 T
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[5]
A CLOSER LOOK
POWER MIG®255 T SPOOL GUN SOLUTIONS
The economic Magnum®SG or premium Magnum®250LX spool guns
are recommended for easy changeovers to a second electrode mate-
rial 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
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 487-25 spool gun and 2445-1 control cable adapter.
MAGNUM®250L 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 2490-1.
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!
Adjust speed on the gun and watch the wire feed speed
change on the POWER MIG
®
255 T.
OONNEE--PPAA
®®
((22770022--11)) IINNCCLLUUDDEESS::
• POWER MIG®255XT ( 2701-1)
• Magnum®250LX Spool Gun ( 2490-1)
• Spool Gun Holder ( 1738-1)
• Dual Cylinder Mounting it ( 1702-1)
• Extra Regulator ( 586-1)

Industry
Description Order No. Reference No.
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(1) 42-4045-15
3/64" (1.2 mm) Aluminum KP1955-1(2) 42N-3545-15
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(1) 14-35
.040" (1.0 mm) KP2020-8 14-40
.045" (1.2 mm) KP2020-2(2) 14-45
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(2)
Fixed Gas Nozzles/Diffuser Assembly
Fixed (flush)
3/8" (9.5 mm) KP1931-1 23-37-F
1/2" (12.7 mm) KP1931-2(1) 23-50-F
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) 52FN
POWER MIG®255 T
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[ 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.
(1) ncluded with POWER M G®255XT.
(2) ncluded in the K1703-1 Aluminum Feeding Kit.
MAGNUM
®
REPLACEMENT PARTS MAGNUM
®
REPLACEMENT PARTS
Industry
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 nsulator 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
( nnershield Nozzle) KP1947-1
Requires:
Gas Diffuser Assembly KP2026-1 52
Gun Tube Assembly
Standard (60°) KP2015-1(1)
45° KP2041-1(2)
ire Size Order Number
.023"-.030" (0.6–0.8 mm) KP1696-030S
Solid .035" (0.9 mm) KP1696-035S(1)
.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(2)
(1) ncluded with POWER M G®255XT. (2) ncluded in the K1703-1 Aluminum Feeding Kit.
DRIVE ROLL KITS

POWER MIG®255 T
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[ 7]
RECOMMENDED OPTIONS
Magnum®SG Spool Gun Control
Cable Adapter
Allows the 487-25 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 466-6 Adapter it.
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
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
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

CUSTOMER ASSISTANCE POLICY
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 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®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
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.
THE LINCOLN ELECTRIC COMPANY
22801 St. Clair Ave., Cleveland, OH 44117-1199 • 216.481.8100 • www.lincolnelectric.com
POWER MIG®255 T ORDER FORM
PRODUCT DESCRIPTION ORDER NUMBER QUANTITY PRICE
POWER MIG®255XT 208/230 K2701-1
POWER MIG®255XT 230/460/575 K2701-2
POWER MIG®255XT ONE-PAK®SPOOL GUN PKG. K2702-1
RECOMMENDED GENERAL OPTIONS
Magnum®SG Spool Gun 487-25
Magnum®250LX Spool Gun 2490-1
Dual Cylinder Mounting it 1702-1
Canvas Cover 2378-1
Aluminum Feeding it 1703-1
POWER MIG®255XT/Magnum®SG Spool Gun Control Cable Adapter 2445-1
Magnum®250LX Spool Gun Control Cable Extension 2519-1
Spool Gun Holder 1738-1
Magnum®Guns See publications E12.10, E13.10
Magnum®Connection it 466-6
8" O.D. Spool Adapter 468
Welding Fume Extractors See publication E13.40
TOTAL: