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RETURN TO MAIN INDEX
SVM 111-A
January, 1996
IDEALARC SP-250
For use with machines having Code Numbers: 9402
9546
9723
10001
10002
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 importantl
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i i SAFETY ARC WELDING can be hazardous. WARNING 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 & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974
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ii ii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 4.a. Remove fire hazards from the welding area. 5.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hoses
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iii iii SAFETY FOR ENGINE ELECTRIC AND MAG- powered equipment. NETIC FIELDS 7.a. Turn the engine off before troubleshooting and maintenance may be dangerous work unless the maintenance work requires it to be running. ____________________________________________________ 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and 7.b. Operate engines in open, well-ventilated welding machine
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v RETURN TO MAIN INDEX TABLE OF CONTENTS Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Select Proper
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INSTALLATION TABLE OF CONTENTS - INSTALLATION SECTION - INSTALLATION SECTION ........................................ Section A Technical Specifications ...................................................A-1 Safety Precautions ...........................................................A-2 Select Proper Location.....................................................A-2 Stacking.......................................................................A-2 Input Electrical Connections....................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Idealarc SP-250 INPUT - SINGLE PHASE/ 60 HERTZ ONLY Standard Voltage Input Current at Rated Output 208/230/1/60 53/49 Amps 230/460/575 50/25/20 Amps RATED OUTPUT Duty Cycle Amps Volts at Rated Amps 100% 145 amps 26 60% 200 amps 28 35% 250 amps 26 OUTPUT Current Range Maximum Open Circuit Voltage Wire Speed Range 30A - 250A 10V - 40V 50 - 600 IPM (1.27-15.2 m./minute) RECOMMENDED INPUT WIRE & FUSE SIZE 0 0 Input Voltage/ Fuse (Superlag) Type 75 C
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A-2 A-2 INSTALLATION Read entire Installation Section before installing 1. Before starting the installation, check with the local the IDEALARC SP-250 power company to determine if there is any ques- tion about whether your power supply is adequate for the voltage, amperes, phase, and frequency SAFETY PRECAUTIONS specified on the welder nameplate. Also be sure ELECTRIC SHOCK CAN KILL. the planned installation will meet the U.S. National Electrical Code and local code requirements. This WARNI
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A-3 A-3 INSTALLATION proper grounding of the welder frame when the FUSE AND WIRE SIZES welder plug is inserted into the receptacle. Protect the input circuit with the super lag fuses or 4. Use proper wire sizes. See the Specification table delay type circuit breakers listed on the Specifications for proper wire sizes. For cable lengths over 100 page of this manual for the machine being used. The feet, larger copper wires should be used. tripping action of delay type circuit breakers decr
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A-4 A-4 INSTALLATION For the 230/460/575V/ 60 HZ model which is not 1. Set the gas cylinder on the rear platform of the SP equipped with a plug, an input cord, or a receptacle, 250. the input power supply leads are connected directly to the Reconnect Panel as shown Figure A.3. Refer to the 2. Hook the chain in place to secure cylinder to rear specifications table at the beginning of this chapter for of welder. proper wiring sizes. 3. Remove the cylinder cap. 1. Connect the input power lea
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A-5 A-5 INSTALLATION 11. Before opening the cylinder valve, turn the regula- RECONNECT PROCEDURE tor adjusting knob counter clockwise until the pres- sure is released from the adjusting spring. Multiple voltage machines are shipped connected to the highest input voltage listed on the machine's rating 12. Open the cylinder valve slowly a fraction of a turn. plate. Before installing the machine, check that the Reconnect Panel in the Input Box Assembly is con- a. When the cylinder pressure ga
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A-6 A-6 INSTALLATION ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHER OF THE TWO INPUT VOLTAGES LISTED ON THE NAMEPLATE. TO CHANGE VOLTAGE CONNECTION PROCEED AS FOLLOWS: 1. REMOVE THE OUTER STEEL HEX NUT FROM THE TERMINAL WHERE THE TRANSFORMER INPUT LEAD IS CONNECTED. 2. SHIFT THE TRANSFORMER INPUT LEAD TO THE TERMINAL THAT THE UNIT IS TO OPERATE ON AND FASTEN SECURELY WITH THE HEX NUT REMOVED IN STEP1. (MAKE CERTAIN THAT BRASS NUTS ARE TIGHT.) FIGURE A.5 - Reconnect Diagram
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A-7 A-7 INSTALLATION GUN LINER & CONTACT TIP CONNECT OUTPUT COMPONENTS INSTALLATION INSTALL THE WORK CLAMP The Magnum 250 SP gun and cable provided with the SP-250 is factory installed with a liner for a .035” or Attach the work clamp to the cable which extends from .045” (0.9 or 1.2mm) diameter electrode and an .035 the front of the machine using the following procedure: (0.9mm) contact tip. 1. Insert the lug on the end of the work cable through 1. If a .045” diameter wire size is to be used
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A-8 A-8 INSTALLATION GUN & CABLE INSTALLATION CAUTION WARNING WARNING: TURN THE WELDER POWER SWITCH The gun trigger switch connected to the gun trig- OFF BEFORE INSTALLING GUN AND CABLE. ger control cable must be a normally open momen- ____________________________________ tary switch. The terminals of the switch must be insulated from the welding circuit. Improper opera- 1. Lay the cable out straight. tion of or damage to the SP-250 might result if this switch is common to an electrical circ
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OPERATION TABLE OF CONTENTS - OPERATION SECTION - OPERATION SECTION ............................................ Section B Safety Instructions............................................................B-1 General Description..........................................................B-1 Recommended Processes and Equipment......................B-2 Operational Features and Controls..................................B-2 Design Features and Advantages...........................B-3 - B-4 Machine Capabi
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B-1 B-1 OPERATION Read and understand this entire section before operat- Proper welding setup is simple. You only need to ing your Idealarc SP-250. select the gauge size of the material to be welded and enter the welding process to used. With that data, the system SAFETY INSTRUCTIONS • automatically computes the proper wire feed WARNING speed and arc voltage relationship for the process. • selects the right procedure for optimum starting, ELECTRIC SHOCK can kill. welding, and burnback. • Do n
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B-2 B-2 OPERATION The system includes the following features: OPERATIONAL FEATURES AND CONTROLS • 2-step or 4-step selectable trigger function (above code 9500 only). Keypad - Consists of 20 membrane keys that have large touch areas. The keys are spaced far enough • both timed spot and stitch welding selections. apart to provide easy selection, even if wearing weld- ing gloves. An audible feedback beep is provided • drop-in 2" (51mm) O.D. wire reel spindle with a 22- whenever a key is pressed t
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B-3 B-3 OPERATION Automatic Burnback - Provides proper burnback of DESIGN FEATURES AND the electrode to prevent it from sticking in the weld pud- ADVANTAGES dle at the end of a weld. Output Terminals - Easily accessible in wire drive section for quick cable connection and polarity rever- UNIT FEATURES: sal. Undercarriage for Hand Mobility - Heavy duty 10" Work Cable - 10 ft. (3.0m) long with work clamp. (254mm) wheels and 4" (102mm) casters are factory installed along with the handle. Handle ca
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B-4 B-4 OPERATION Gun and Cable (K524-1) - A 12.5 ft. (3.8) GMAW gun and cable assembly, rated 200 amps 60% duty, is pro- vided with the SP-250 and includes a liner, diffuser, and contact tips for .035 (0.9mm) and .045 (1.2mm) electrodes. The gun is equipped with a Fast-Mate con- nector with additional control lead connections for the thumb activated 2 momentary position slide switch control designed into the gun handle for use with SP- 250 remote control features. MACHINE CAPABILITY The IDEALAR
