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Lincoln Electric POWER MIG 256 User Manual

Lincoln Electric POWER MIG 256
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POWER MIG
®
256
OPERATORʼS MANUAL
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
For use with machine Code Numbers
11780, 11781
For use with machine Code Numbers
• 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
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.

Table of Contents

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Lincoln Electric POWER MIG 256 Specifications

General IconGeneral
Output Current Range30 - 250 A
Duty Cycle60% at 250 A
Wire Feed Speed Range50-700 IPM
Rated Output250A at 30V, 60% Duty Cycle
Wire Diameter Range.030 - .045 in

Summary

Safety Warnings

California Proposition 65 Warnings

Warns about cancer, birth defects, and reproductive harm from engine exhaust.

Arc Welding Hazards

General safety advice for arc welding, emphasizing consulting doctors for pacemakers.

Engine Powered Equipment Safety

Safety precautions for operating engine-powered equipment.

Safety Precautions

Electric Shock Hazards

Details risks of electric shock and necessary precautions when welding.

Arc Ray Protection

Discusses the dangers of arc rays and required eye and skin protection.

Fumes and Gases Hazards

Explains hazards of welding fumes and gases and necessary ventilation.

Safety Guidelines

Fire and Explosion Prevention

Precautions regarding sparks and spatter from welding/cutting to prevent fires.

Compressed Gas Cylinder Safety

Safety guidelines for handling compressed gas cylinders to prevent explosions.

Electrical Equipment Safety

Safety instructions for electrical installation and grounding of equipment.

Product Information

Customer Assistance Policy

Outlines Lincoln Electric's policy regarding customer advice and liability for product use.

Shipping Damage Inspection

Instructions for checking equipment for shipping damage and filing claims.

Online Product Registration

Information on how to register the product online or via fax.

Understanding Safety Indicators

Explains the meaning and severity of WARNING and CAUTION statements.

Installation

Technical Specifications

Lists detailed technical specifications for the POWER MIG® 256 welder.

Input Power and Fuse Requirements

Lists recommended input wire sizes and fuse/breaker ratings.

Output and Capability Ratings

Provides information on the welder's rated output and welding capability.

Physical Dimensions and Environment

Lists dimensions and operating/storage temperature ranges of the machine.

Installation Procedures

Installation Safety Precautions

Essential safety warnings related to the installation process.

Uncrating and Locating the Welder

Instructions for uncrating and selecting a safe location for the welding machine.

Input Power, Grounding, and Connections

Details on connecting input power, grounding, and relevant diagrams.

Installation and Connections

Output Polarity Setup

Instructions for setting the correct electrode polarity for welding.

Gun and Cable Installation

Steps for installing the welding gun and cable assembly.

Installation Details

Shielding Gas Supply Setup

Procedures for installing and connecting the shielding gas supply.

Auxiliary Power Receptacles

Information about the auxiliary 120V receptacle and its circuit breaker.

Coil Claw™ Accessory Installation

Instructions for installing the optional Coil Claw™ accessory.

Operation Safety

Electric Shock Hazard

Safety warning about electric shock hazards during operation.

Fumes and Gases Hazard

Safety warning about the dangers of fumes and gases during operation.

Welding Sparks Hazard

Safety warning about fire and explosion risks from welding sparks.

Arc Rays Hazard

Safety warning about the hazards of arc rays to eyes and skin.

Operation Overview

Product Description

An overview of the POWER MIG® 256's features and capabilities.

Recommended Processes and Equipment

Guidance on recommended welding processes and associated equipment.

Limitations and Controls

States operational limitations and explains the function of each control.

Operation Procedures

Wire Size Conversion Parts

Information on available parts for converting wire sizes.

Changing Drive and Idle Roll Sets

Step-by-step guide for changing drive and idle rolls.

Operation Steps

Loading Wire Reels and Spools

Instructions for loading wire reels, spools, or coils onto the machine.

Starting the Welder

Basic steps to turn on and start the welding machine.

Operation Adjustments

Feeding Wire Electrode

Guidance on feeding the electrode wire through the system.

Idle Roll Pressure Setting

Instructions for properly setting the idle roll pressure.

Operation Configuration

Wire Drive Configuration

Procedures for configuring the wire drive system, including bushing changes.

Operation and Performance

Making a Weld

Detailed steps for making a weld using the machine.

Avoiding Wire Feeding Problems

Tips and procedures to prevent common wire feeding issues.

Fan Control and Protection Features

Explains fan operation, line voltage, and overload protection.

Operation Protection Features

Thermal Overload Protection

Explains the thermal overload protection system and its reset function.

Overcurrent Protection

Details the machine's overcurrent protection mechanism.

Welding Procedure Information Reference

Refers to inside cover for commonly used welding procedures.

Accessories

Drive Roll Kits

Lists available drive roll kits for the POWER MIG® 256.

Magnum GMAW Gun Assemblies

Describes optional Magnum® GMAW gun and cable assemblies.

Spool Gun Compatibility

Overview of Spool Gun connectivity and usage.

Spool Gun Operation

Connecting the Spool Gun

Step-by-step guide for connecting a spool gun.

Making a Weld with Spool Gun

Instructions for making welds using the spool gun.

Spool Gun Welding

Magnum SG Spool Gun Welding

Procedure for making welds with the Magnum SG Spool Gun.

Maintenance

Maintenance Safety Precautions

Safety warnings pertinent to maintenance procedures.

General Maintenance & Drive Rolls

General cleaning, drive roll, and guide plate maintenance.

Contact Tip, Nozzle, and Gun Maintenance

Instructions for contact tip, gas nozzle, gun tube, and cable maintenance.

Maintenance - Gun Components

Liner Removal and Replacement

Steps for removing and replacing the gun cable liner.

Magnum® Pro 250L Liner Instructions

Specific instructions for trimming and installing liners for Magnum guns.

Maintenance - Gun Handle

Gun Handle Disassembly

Guide on how to disassemble the welding gun handle for servicing.

Troubleshooting

How to Use Troubleshooting Guide

Instructions on how to effectively use the troubleshooting section.

Troubleshooting Output Issues

Output Problems

Lists common output problems and their potential causes and solutions.

Troubleshooting Feeding Issues

Wire Feeding Problems

Addresses issues related to wire feeding problems and their resolution.

Troubleshooting Gas Issues

Gas Flow Problems

Details common problems with gas flow and their troubleshooting steps.

Wiring Diagrams

Power MIG 256 (208/230V) Wiring Diagram

Wiring diagram for the 208/230V model.

Wiring Diagrams

Power MIG 256 (230/460/575V) Wiring Diagram

Wiring diagram for the 230/460/575V model.

Dimension Print

Machine Dimensions

Visual representation of the machine's physical dimensions.

Notes

General Notes

General notes or remarks related to the manual content.

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