WIRE FEEDER/WELDERS
®
Output
POWER MIG 255XT
CV
DC
SM
POWER MIG®. The Professional’s Choice .
The POWER MIG® 255XT sets the standard for MIG 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.
Input
1
PHASE
60
It’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
Hz
SM
POWER MIG® 255XT is considered The Professional’s Choice .
Spool Gun Capable
Processes
MIG, Flux-Cored
Medium Duty
Heavy Duty
Advantage Lincoln
Arc Performance:
Professional Features:
• 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
• 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 MIG® 255XT has the electronics and
second gas solenoid built-in to drive either the Magnum® 250LX
spool gun or the Magnum® SG spool gun.
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.
• 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.
• Three-year warranty on parts and labor (90 days warranty on gun).
• 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.
TECHNICAL SPECIFICATIONS
Dimensions
H x W x D
inches (mm)
Product
Name
Product
Number
Rated Output
Current/Voltage/Duty Cycle
Input Current @
Rated Output(1)
Net Weight
lbs. (kg)
Input Power
Output Range
POWER MIG® 255XT
One-Pak®
Spool Gun Pkg.
30-300 Amps
50-700 ipm WFS
(1.3-17.7 m/min)
Max. OCV: 40V
K2702-1
208/230/1/60
250A/26V/40%
250A/26V/40%
56/52A(1)
31.8 x 18.9 x 38.8
(808 x 408 x 985)
220
(100)
POWER MIG® 255XT
Base Unit
K2701-1
K2701-2
208/230/1/60
56/52A(1)
30-300 Amps
50-700 ipm WFS
(1.3-17.7 m/min)
Max. OCV: 40V
230/460/575/1/60
50/24/19A
(1)
Input current is at the rated output with the 115V auxiliary receptacle also drawing 15 amps.
Publication E7.54 7/08
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A CLOSER LOOK
FEATURES CONʼT.
Compare These Innovations – Make the Professional’s Choice !
SM
C
B
A
A Lockable storage compartment with tool
tray stows your welding consumables and
valuable personal tools.
Timer Functions
Easy Load Gas Cylinder Platform
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 Built-in gun holder conveniently stores
welding gun.
C Handy MIG Gun Expendables Chart.
Easy Load Wire Compartment
Extra–Length 15 ft. (4.5 m) Gun
Additional Gas Solenoid – Controls Gas
Flow to a Spool Gun
Professional Heavy Duty Wire Drive System
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.
Wide idler arm hinge provides improved
drive roll clamping pressure.
Split guides support the wire
through the entire drive
system to minimize
feeding problems.
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.
Two gear driven rolls. No tools needed
to swap rolls on or off.
Separate drive gear reduces pressure
on motor shaft for long life.
Removable outer wire guide for
easy access.
POWER MIG® 255XT
[3]
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A CLOSER LOOK
Key Controls
A. Digital meter displays preset wire feed speed.
C
D
E
A
B
B. Presettable digital wire speed control with fine
resolution at low settings.
C. Digital meter displays preset voltage setting and
actual voltage while welding.
F
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.
G
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).
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
1
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
1
connector (Magnum® SG gun requires K2445-1, 6- to 7-pin
control cable adapter plug.)
2
3
Connect the spool gun’s power cable to the output terminal
in the wire drive compartment.
2
3
Hook the spool gun gas line to the solenoid gas fitting and
you’re ready to weld!
POWER MIG® 255XT
[4]
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A CLOSER LOOK
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® 255XT.
®
POWER MIG 255XT 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.
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.
Avoid the time-consuming liner, contact tip, drive roll and machine
polarity changes necessary when preparing your machine’s wire drive
®
®
MAGNUM SG SPOOL GUN
MAGNUM 250LX SPOOL GUN - FACTORY READY
• 250A, 60% duty cycle.
• 300A, 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.
• .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.
• Adjustable speed control at the handle – allows you to tailor the
WFS setting at the gun.
• See E12.22 for Expendable Parts.
• See E12.25 for Expendable Parts.
• Order K487-25 spool gun and K2445-1 control cable adapter.
• Order K2490-1.
ONE-PAK® (K2702-1) INCLUDES:
• POWER MIG® 255XT (K2701-1)
• Magnum® 250LX Spool Gun (K2490-1)
• Spool Gun Holder (K1738-1)
• Dual Cylinder Mounting Kit (K1702-1)
• Extra Regulator (K586-1)
POWER MIG® 255XT
[5]
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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.
®
®
MAGNUM REPLACEMENT PARTS
MAGNUM REPLACEMENT PARTS
Industry
Reference No.
Industry
Reference No.
Description
Order No.
Description
Order No.
Magnum® 250L Gun and Cable Assembly
Fixed Gas Nozzle Model
Adjustable Gas Nozzle/Diffuser Assembly
Adjustable Slip-On
For .035"-045" (0.9-1.2 mm) wire sizes
12 ft. (3.6 m) cable
3/8" (9.5 mm)
1/2" (12.7 mm)
5/8" (15.9 mm)
KP1935-3
KP1935-2
KP1935-1
22-37
22-50
22-62
K533-7
Adjustable Gas Nozzle Model
For .035"-.045" (0.9-1.2 mm) wire sizes
10 ft. (3.0 m) cable
Requires:
K533-1
K533-3
Nozzle Insulator Assembly
Gas Diffuser Assembly:
.023"-030" (0.6-0.8 mm)
.035"-.045" (0.9-1.2 mm)
KP2025-1
32
15 ft. (4.5 m) cable
KP2026-2
KP2026-1
52-23
52
Cable Liners
For All Gun Cable Lengths
.025"-.030" (0.6-0.8 mm)
.030"-.035" (0.8-0.9 mm)
.035"-.045" (0.9-1.2 mm)
3/64" (1.2 mm) Aluminum
KP1934-2
KP1934-3
KP1934-1(1)
KP1955-1(2)
42-23-15
Gasless Nozzle/Diffuser Assembly
(Innershield Nozzle)
42-3035-15
42-4045-15
42N-3545-15
KP1947-1
KP2026-1
Requires:
Gas Diffuser Assembly
52
Contact Tips
Gun Tube Assembly
Standard (60°)
45°
Standard Duty
.025" (0.6 mm)
.030" (0.8 mm)
.035" (0.9 mm)
.040" (1.0 mm)
.045" (1.2 mm)
KP2015-1(1)
KP2041-1(2)
KP2020-6
KP2020-7
KP2020-1(1)
KP2020-8
KP2020-2(2)
14-23
14-30
14-35
14-40
14-45
(1) Included with POWER MIG® 255XT.
(2) Included in the K1703-1 Aluminum Feeding Kit.
Heavy Duty
.035" (0.9 mm)
.040" (1.0 mm)
.045" (1.2 mm)
KP2021-1
KP2021-6
KP2021-2
14H-35
14H-40
14H-45
DRIVE ROLL KITS
Tapered
.025" (0.6 mm)
.030" (0.8 mm)
.035" (0.9 mm)
.040" (1.0 mm)
.045" (1.2 mm)
KP2022-5
KP2022-6
KP2022-1
KP2022-7
KP2022-2
14T-23
14T-30
14T-35
14T-40
14T-45
Wire Size
Order Number
.023"-.030" (0.6–0.8 mm)
.035" (0.9 mm)
.035"/.045" combination
.040" (1.0 mm)
KP1696-030S
KP1696-035S(1)
KP1696-1
KP1696-2
KP1696-045S
Solid
Aluminum
3/64" (1.2 mm)
KP2010-5(2)
.045" (1.2 mm)
Fixed Gas Nozzles/Diffuser Assembly
Fixed (flush)
.035" (0.9 mm)
.045" (1.2 mm)
KP1697-035C
KP1697-045C
Cored
3/8" (9.5 mm)
1/2" (12.7 mm)
5/8" (15.9 mm)
Fixed (recessed)
3/8" (9.5 mm)
KP1931-1
KP1931-2(1)
KP1931-3
23-37-F
23-50-F
23-63-F
Aluminum
3/64" (1.2 mm)
KP1695-3/64A(2)
(1) Included with POWER MIG® 255XT. (2) Included in the K1703-1 Aluminum Feeding Kit.
KP1930-1
KP1930-2
KP1930-3
23-37
23-50
23-62
1/2" (12.7 mm)
5/8" (15.9 mm)
Requires: Gas Diffuser Assembly
.025-.045" (0.6-1.2 mm)
KP2026-3(1)
52FN
POWER MIG® 255XT
[ 6]
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RECOMMENDED OPTIONS
GENERAL OPTIONS
®
®
Magnum SG Spool Gun
Magnum SG Spool Gun Control
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
Cable Adapter
Allows the K487-25 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
Requires K2445-1 Adapter
®
Magnum 250LX Spool Gun
Control Cable Extension
®
Magnum 250LX Spool Gun
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
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.
Spool Gun Holder
Provides neat storage of spool
gun.
Order K1738-1
K2490-1
Factory Ready
®
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.
Dual Cylinder Mounting Kit
Permits side-by-side mounting
of two full size gas cylinders,
with easy loading. Attaches
easily to POWER MIG®
undercarriage.
See Publications E12.10 and
E13.10 for details.
Order K1702-1
Note: Requires K466-6 Adapter Kit.
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
®
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
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.
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.
Order K1703-1
Request Publication E13.40
POWER MIG® 255XT
[ 7]
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®
POWER MIG 255XT ORDER FORM
PRODUCT DESCRIPTION
ORDER NUMBER
QUANTITY
PRICE
®
POWER MIG 255XT 208/230
K2701-1
K2701-2
K2702-1
®
POWER MIG 255XT 230/460/575
®
®
POWER MIG 255XT ONE-PAK SPOOL GUN PKG.
RECOMMENDED GENERAL OPTIONS
Magnum® SG Spool Gun
Magnum® 250LX Spool Gun
Dual Cylinder Mounting Kit
Canvas Cover
K487-25
K2490-1
K1702-1
K2378-1
K1703-1
Aluminum Feeding Kit
POWER MIG® 255XT/Magnum® SG Spool Gun Control Cable Adapter
Magnum® 250LX Spool Gun Control Cable Extension
Spool Gun Holder
K2445-1
K2519-1
K1738-1
Magnum® Guns
See publications E12.10, E13.10
Magnum® Connection Kit
K466-6
8" O.D. Spool Adapter
K468
Welding Fume Extractors
See publication E13.40
TOTAL:
C U S T O M E R A S S I S T A N C E P O L I C Y
The business of The Lincoln Electric Companyis 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.
THE LINCOLN ELECTRIC COMPANY
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