Lincoln Electric IDEALARC IM402-B User's Manual
Contents
1. or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the2. Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d
3. nals Note the ohmmeter reading using the 10 to 100 scale 4 Reverse the ohmmeter leads Note the readings 5 The reading taken in steps 3 and 4 should be different If the readings are the same and near zero the rectifier has shorted IF the readings are the same and near full scale the rectifier has failed open 6 Repeat steps 3 4 and 5 between the DC posi tive red terminal and each of the AC yellow terminals 7 Repeat steps 3 4 and 5 between the DC nega tive black terminal and each of the AC yel low terminals NOTE Since it is unlikely that all rectifiers of a full wave bridge would fail simultaneously check the test method and the ohmmeter if the checking indicates that all rectifiers have failed TROUBLE A Welder will not weld B Welder welds but soon stops welding DC only TROUBLESHOOTING CAUSE WHAT TO DO 1 Line switch not turned Supply line fuse blown Power circuit dead Broken power lead Wrong voltage Electrode or work lead loose or broken Open transformer circuit Polarity switch not Proper ventilation hindered Welder loaded beyond rating Fan motor inoperative Poor internal connections Excessive dust accumulation in welder Bi metallic thermostat dirty Place line switch in On posi tion Replace Look for reason for blown fuse first Check supply line voltage Repair Chec
4. graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POU R contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER De TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des
5. 100 150 re emp imm Les 200 250 Ft 1 0 bbmm 1 0 bbmm OPERATION Safety Precautions WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on closed containers e rH 4 Do ARC RAYS can burn eyes and skin Wear eye ear and body protection K De See additional warning information at the front of this operator s manual Be sure the Idealarc 250 is properly installed and that all accessories are properly hooked up before attempting operation DUTY CYCLE This machine is rated at a 30 duty cycle at 250 amps or 50 duty cycle at 200 amp output Duty cycle is based on a 10 minute period Therefore the welder can be loaded at 200 amperes for 5 minutes out of each 10 minute period Higher duty cycles can be used at lower currents see rating plate information CONTROL OPERATION A Current Control Handle Rotating the hand wheel raises and lowers the output current allowing the operator to dial the desired current Clockwise rotation reduces the current while counter clockwise rotation increases the current Turning the curre
6. 1VNH31NI HO S1VNINH31 LNdLNO SV HONS S1HVd AT1VOIHIO3 13 HONOL LON OG SIHL ONIOIAH3S HO ONITIVLSNI 340439 3503 IHL LV HOLIMS LOANNOOSIG ONISN 440 OL 1ndNI N801 e EIN INS MY ZH 0S 9uv 1V3dIl dINV 0Sc IWVH9VIG ONIHIM M00D 091 1VISONH3Hl N OILO3NNO9 31411938 1 334409 1112819 MO138 318V1 335 932111915 ut N OILISOd QV31 13NVd L93NNO934 NOTES Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG 5 BIR Chinese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra eoo SS MARHE FRANEACRHEUCE ATUBSHELTFEL e ER AER H amp ORAS RMI HR e 3544 SHES 91 se yya AU PHA e 2749 HAS A
7. Current Welding sse 8 TG WV STING tees a 8 DESIGN aae D tase en Aad ne EE 8 OPTIONS ACCESSORIES A COMPATIBLE LINCOLN 8 Power Factor Capacitors REOR 8 E 8 E E E E IE 8 Standard ACCeSSOry TEE 8 TECHNICAL SPECIFICATIONS ur 9 INSTALLATION eege ere eegend eege EES E 10 11 Safety 10 Machine tea 10 LOCATION 10 CONNECTIONS i ETE 10 crie 11 Installation of Field Installed Options 11 Output Cable Size and Connection ss 11 Wie S 12 EAM 12 peus 12 Control Operation esataria 12 MAINTENANCE enee oe 13 Safety M 13 General coded nn erg seen REA ra VoU xa und aae ERN need 13 TROUBLESHOOTING icti Debut Ne uva uti at ete 13 15 Kuele lee le soeur rove reete eo E Rr ex teen OD See ei Du memes een
8. Do not stack on top of any other type machine A Make sure the first or bottom unit is setting on a level well supported surface B The units must be stacked with their front flush making sure the two holes in the base rails of the unit being stacked on top are over the two holes located on the top front corners of the unit being stacked on Fasten the units together with 5 16 8 mm bolts nuts and lockwashers through these holes C Remote fastening bolts before lifting unit off stacks Installation of Field Installed Options For installation of compatible field installed options see Field Installed Options section and refer to the instructions included with those options Output Cable Size and Connection A WARNING ELECTRIC SHOCK can kill Turn the power switch of the welding power source OFF before connecting or disconnect ing output cables The output leads are connected to the output termi nals marked WORK and ELECTRODE They are located at the lower right and lower left corners of the front panel The 60 Hz Idealarc 250 provides 1 2 studs for weld cable connections The 50 Hz Idealarc 250 provides European weld cable connector recepta cles Minimum cable sizes recommended are listed in the table below CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE AND WORK CABLES 200 Amps 250 Amps 50 Duty Cycle 30 Duty Cycle 0 100 Ft 3 30mm 3 30mm 2 35mm 2 35mm
9. UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria eta A 59tEM d 257 e manm e c EUR E e FH BK aR e 847A SAAACEFE 247 HHPI AS 21244214 SSE S e 964 Lee duly nde AAA s jja si ag uu oe Glial 9 e power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e X7TTLZA K UAUCRBRUD e e SHA A
10. following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 5 EZ ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 5 f AUG 06 material to protect yo
11. 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 responsive 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 Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Da
12. instructions are on the diagram pasted to the inside of the side panel Consult rating plate on the rear panel for machine input voltage rating The welder frame must be grounded A stud marked with the symbol located under the reconnect panel is provided for this purpose See the U S National Electrical Code for details on proper ground ing methods Fuse the input circuit with the recommended super lag fuses Choose an input and grounding wire size accord ing to local codes or use the following table Delay type circuit breakers may be used in place of fuses Using fuses or circuit breakers smaller than recommended may result in nuisance tripping from welder inrush currents even if not welding at high currents RECOMMENDED INPUT WIRE GROUND WIRE AND FUSE SIZES 200 Amp Output and 50 Duty Cycle Input Amps Without Input Freq P F Volts Cap 200 50 60 Copper Wire Sizes Fuse Size 75 C in Conduit Super Lag Without Without Grounding F P F Conductor 208 60 220 230 50 60 380 400 440 460 50 60 500 50 575 60 STACKING A WARNING HEZE FALLING EQUIPMENT can cause injury Do not lift this machine using lift bale if it is equipped with a heavy accessory such as undercarriage or gas cylinder Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not stack more than three high
13. 13 Troubleshooting Procedures is 14 15 WIRING DIAGRAMS EN 16 17 PARTS LIST GENERAL DESCRIPTION The Idealarc 250 is a single phase constant current arc welding power source available in an AC DC model only Designed for stick welding it may also be used for TIG welding when used with the K799 Hi Freq unit RECOMMENDED PROCESSES AND EQUIPMENT AC and DC Constant Current Welding AC DC 35 300 Amps 60 Hz 40 250 Amps 50 60 Hz 35 250 Amps 50 Hz Duty Cycle 60 Hz 100 140 Amps 5096 200 Amps 3096 250 Amps 50 Hz 100 140 Amps 6096 180 Amps 3096 250 Amps TIG Welding The K799 can be used with this machine to provide high frequency stabilization and a gas valve for TIG welding It operates on 115V 50 60 Hz power water valve for water cooled TIG torches is available as an option When TIG welding AC or DC may be used but when AC TIG welding the duty cycle must be decreased by one half DESIGN FEATURES Power On Off switch Polarity switch selects AC DC or DC Continuous current control dials with exact welding current needed for each job Settings are precise and free from creep Spring loaded knob on the continuous current control crank pulls out for easy adjustment and snaps back out of the way when released Meets NEMA Class II specifications Recessed front panel protects controls Large safety margins and protective circuits protect rectifiers from transie
14. Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS N FOR ENGINE powered equipment Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 1 h To avoid scalding not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine part
15. G ONISN 330 OL 10ndNI IHL OQNINUVMY ZH 09 0S 8 ZH 09 DAV dINV 092 INVHOVIG ONIAIM Jequunu epoo juewe9edel jueunredeg s sjeued einsoj oue y Jo euo uo euiuoeu y pejsed si epoo e oul siy Aq eq jou Aew AjUO 10 SI 5141 310 177615 22918 Yad S1OS8WAS 1V91H19313 19VL10A 1 LS3H9IH 803 A134N93S LSNW SNOILO3NNOO Q3193NNOO AHOLOV4J Q3ddIHS JYV SANIHOVW aW S1109 H3ddOO H DIH QV31 dv9 S3NIHOVW NO NOILO3NNOO Q31108 3NIHOVW 3GISNI WOY4 DNIHOO 7 uossauddns HOLIMS ALIHY10d SLIOA 1 s SLIOA 1 008 08 00 08 02 gaa 4311411934 u3MOd 3000 1v2I812313 TVNOILVN H3d OL Low 3 TANVd 193NNO23UH VN 300419413 SHOLI9VdV9 HO10V4 HOLIMS 1VNOl1dO 3NIT SIHL 391AH3S HO TIVLSNI GINOHS 13NNOSH3d Q3l3ITVQO AINO e ueo d3AOW3H SH3A09 HLIM 31VH3dO LON OG e 39V L 10A H9IH H1HV3 0009 Y OL Q3123NNOO 38 LSNW M3H2S 4 SONIGNIM
16. HS Aj ii Juill e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas ONRWPAN ERVALEEE CREATE CHERTMRAARS MSR e do Gel tee Asal OMAR Aga y Gils 13 jlgall l a Ja y e el S i di Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Hx BIR Chinese LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR 2 k 38 BA EF AR DO S SE EAB RRR 0 SSE HAL oka rie xl 4g EPEA HHCH TLTRHOREREC E77 A Be 55 RERE o Saal cana 444 dl Gala quil Jud al gll oig quil agil y LINCOLN 8 World s Leader in Welding and Cutting Products 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
17. RETURN TO MAIN MENU IM402 B IDEALARL AC DC 250 207 For use with machines having Code Number 9491 thru 11104 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 thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Ee H OPERATOR S MANUAL 150 9001 Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 LI NCOLN Copyright 2007 Lincoln Global Inc World s Leader in Welding and Cutting Products 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 l SAFETY 1 A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS 1 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For
18. SAI OMAR JUS Yt Gall el ja oye daa dea ag d ily gS AA Gadi Jai JS aua woe Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e KAPTU SODMTOBEEER EVA fbi I els Hc AIX uie why Jus ALIM Aal Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo ERU B1SICRRBREUCF ARAOBFHRBAR ez 79 Sol Soares d y due de Lily us cl di pis e READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE
19. V 72 72 70 Input Power Standard Voltages 208 230 460 220 380 440 230 460 575 380 415 500 Rated Input Current 230V 60Hz 220V 50Hz With Condensers Without Condensers Idle Input Current 230V With Condensers Without Condensers Power Factor 200 Amp Load With Condensers Without Condensers PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 27 00 in 19 00 in 21 50 in 350 165 159 686 mm 483 546 mm INSTALLATION Safety Precautions A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on closed containers 5 2 2 Do ARC RAYS can burn eyes and skin Wear eye ear and body protection K Da See additional warning information at the front of this operator s manual Connect the Idealarc 250 grounding terminal located under the reconnect panel marked to a good electrical ground per the U S National Electrical Code and any applicable local codes the power switch on the Idealarc 250 OFF before connecting or disconnecting output cables or other equipment Only qua
20. ated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY 7 WELDING and CUTTING SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching
21. ejnomed e urejDeip oul siy Aq UE eq jou AjUO 10 51 SIUL 310 v Grs 39V110A 1 LS3H9IH 404 25918 H3d ST1OSMWAS 1V91419313 AYOLIVA WO G3ddlHS 34V SANIHOVW ATSAYNIAS Q3N31H9II LSNW SNOILO3NNOO H9IH QV31 dV9 aaw H9IH QV31 00r 919 oez 1101942 3QISNI 9NDIOO1 NOSSauddns 20 025 SES HOLIMS ALIHV10d SLIOA LNdNI SLIOA LNdNI SLIOA LNdNI ZH 09 05 007 00 S1S 09v 0 c 097 0 2 802 NOILISOd QV31 13NVd LOANNODSY 31411934 3MOd 3009 1V2IM10313 1VISONWMN3HlL TWNOILVN 33d OL 31411934 TANVd L193NNOO3N Le vH H9IH ex LIN9419 uaziigvis NOILIANNO9 1934409 d 3 18V1 33S 300312313 SUOLI9VdVI 4012V3 HOLIMS 1VNOILdO aN LNAWdINDA SIHL 39IAN3S YO TIVISNI GINOHS 13NNOS33d Q3ldl1VnO AINO e ueo Q3AO0W33 SH3AO9 HLIM 31V33dO LON OG e 39V110A HOIH 009 V OL 03123NNOO 5 SS TWNYALNI S1VNIWN31 LAdLNO SV HONS SLHVd LOH AT1VOINI2313 HONOL LON OG e HNIHOVW SIHL 9NI2IAN3S YO ONITIVISNI 330338 3SN4 IHL LV HOLIMS LOANNOOSI
22. ent 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations ii SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir
23. ing Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode re if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipm
24. k voltage against rating plate Check reconnect panel jumper Tighten and repair connections Send to repair shop to have coils replaced Center switch handle on DC DC or AC Make sure all case openings are free for proper circulation of air Operate at normal current and duty cycle consistent with rating Check leads and motor bear ings Fan motor can be tested on 115V line with welder on voltage across fan motor should be approximately 115V Check for loose or hot connec tions and tighten Blow out welder with low pres sure Carefully clean in naptha TROUBLESHOOTING CONTINUED TROUBLE CAUSE WHAT TO DO C Variable or sluggish welding 1 Poor work or electrode terminal 1 Check and clean all connections connection Current too low Check recommended currents for rod type and size Low line voltage Check with power company Welding leads too small See Output Cable section Old and badly frayed welding Replace cables D Welder won t shut off Line switch has failed Replace switch mechanically E Polarity switch won t turn Contacts rough and pitted from Replace switch improper switching under load Jequunu epoo y BAIN ueWiyedeq eu eidel si j sjeued y euo uo euiuoeu y pejsed si epoo s
25. lified personnel should perform this installa tion Undercarriages the optional K866 undercarriage is to be installed it should be done before connecting the welder to power lines Instructions are included with the undercarriage Location The machine should be located in a clean dry place where there is free circulation of clean air such that air movement in the back and along the sides will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe the precautions can result in excessive operating temperatures and nuisance shutdown of the machine Input Connections Be sure the voltage phase and frequency of the input power is as specified on the welder rating plate locat ed on the rear panel of the machine Either a single phase or one phase of a three phase line can be used Have a qualified electrician install the machine per the following instructions Remove the left side panel viewed from the front Route the input power lines through the hole in the rear panel and center baffle Lug the input leads with a ring terminal for a 1 4 6mm screw Connect lugged leads to L1 and L2 of the reconnect panel per the wiring diagram pasted to m inside of the side panel Input connection must conform to the U S National Electrical Code and all local codes Models designed for two or three input voltages are shipped connected for the highest voltage Reconnect
26. lunettes avec crans lateraux dans les zones o l on pique le laitier LINCOLN 5 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V v for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment 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 posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind
27. nt control handle also drives the output pointer at the bottom of the nameplate which indicates the stick welding current at NEMA arc volts B Polarity Switch Turn the arc polarity switch in the upper right hand corner of the case front to AC DC or DC as required for the particular application DO NOT CHANGE POLARITY SWITCH WHILE WELDING Doing this can seriously damage the switch C TIG Welding The Idealarc 250 with the optional Hi Freq is an inexpensive equipment combination for part time production or repair TIG welding of alu minum magnesium thin stainless steel and many space age metals The Idealarc 250 can be used for normal stick electrode welding with the Hi Freq attached CAUTION Reduce the Idealarc 250 duty cycle 50 when AC TIG welding i e the welder should be operated for only two and one half minutes out of every ten at rated current of 200 amperes The Hi Freq includes high frequency generator gas valve and needed controls It operates on 115V 50 60 Hz AC power NOTE The Hi Freq unit includes an R F bypass capacitor kit for power source protec tion Installation instructions are in the kit When using the Idealarc 250 with any other high frequency equipment an R F bypass capacitor must be installed Order Kit T12246 To provide protection the welder grounding stud or frame must be connected to ground see instructions on grounding in Machine Installation section Also follow
28. nt voltages and high currents Submersion dipping of assembled transformer and choke in special sealing insulating material gives extra protection against moisture and corrosive atmosphere Stackability Machines can be stacked up to three high Outstanding Arc Stability Transformer design and built in stabilizer provide pop out resistant welding with all electrodes including those which normally require an industrial type AC welder Reconnect panel is provided to permit changing from one input voltage to another without reconnect ing transformer leads OPTIONS ACCESSORIES AND COMPATIBLE LINCOLN EQUIPMENT Factory Installed Options Accessories Power Factor Capacitors Reduce input amps by 30 at rated load Field Installed Options Power Factor Capacitors Reduce input amps by 30 at rated load Undercarriage K866 Consists of a handle axle wheels front bracket and mounting hardware Overall width 24 56 inches 624 mm Hi Freq Kit K799 Converts Idealarc 250 into a TIG welder Request Bulletin E385 for full details Standard Accessory Kit K710 Includes electrode holder work clamp electrode work cables and headshield with lens and coverplate TECHNICAL SPECIFICATIONS IDEALARC AC DC 250 INPUT OUTPUT RATINGS Type AC Input Frequency Output Rating NEMA CLASS II 60 AC Amperes 300 Volts 32 Duty Cycle 20 Current Range 35 300 35 250 40 250 Max O C
29. s and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety did d ds minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the
30. te Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page GENERAL DESCRIPTION irt utr eat ed edet e teinte nettes are dti Eege 8 RECOMMENDED PROCESSES amp EQUIPMENT 8 AC and DC Constant
31. the grounding instructions given in the Hi Freq Instruction manual MAINTENANCE Safety Precautions A WARNING e ELECTRIC SHOCK can kil Have a qualified individual install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts General Maintenance 1 The fan motor has sealed ball bearings which requires no service 2 n dusty locations dirt may clog the air channels causing the welder to run hot Under these conditions carefully blow out the welder at regular intervals 3 Keep the electrode and work cable connection tight 4 Every twelve months or at the first indication of a binding current pointer turn the input power off and remove the left case side Wipe the pointer guide bar clean and lubricate with graphite grease 5 When cleaning the current pointer clean the reactor quadrant teeth drive gear and pinion Lubricate with graphite grease TROUBLESHOOTING Safety Precautions A WARNING ELECTRIC SHOCK can Hil Have a qualified individual install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts Rectifier Troubleshooting 1 Turn the input power off 2 Disconnect all input and output leads from the rectifier bridge 3 Connect an ohmmeter between the DC positive red terminal and one of the AC yellow termi
32. the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Weld
33. ur skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorin
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