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)