Lincoln Electric SA-250 manual

S A-250 OPERA TOR’S MANUAL For Machines with Code Numbers 10890 IM747 January, 2003 Safety Depends on You Lincoln arc welding 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 [...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS 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. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ?[...]

Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay par[...]

vi vi T ABLE OF CONTENTS Page ________________________________________________________________________ Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Pre-[...]

A-1 INST ALLA TION SA-250 A-1 Make/Model Description Horsepower Operating Displacement cu. in.(ltrs) Starting Capacities @ 1800RPM S PEED System 1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced. * [...]

A-2 INST ALLA TION SA-250 A-2 PRE-OPERA TION INST ALLA TION EXHAUST SP ARK ARRESTER Some federal, state or local laws may require that engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder does not qualify as a sp[...]

PRE-OPERA TION SER VICE READ the engine operating and maintenance instruc- tions supplied with this machine. OIL This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W/30 oil. This oil should be acceptable for most typical ambient temperatures. Consult the engine operation manual for specific engine manu[...]

A-4 INST ALLA TION SA-250 A-4 Battery Charging The SA-250 is equipped with a wet charged battery. The charging current is automatically regulated when the battery is low (after starting the engine) to a trickle current when the battery is fully charged. When replacing, jumping or otherwise connecting the battery to the battery cables, the proper po[...]

B-1 OPERA TION B-1 SAFETY PRECAUTIONS GENERAL DESCRIPTION The SA-250 is a heavy duty, engine driven, DC arc welding power source, capable of providing constant current output for stick welding or DC TIG welding. This welder is wound with all copper coils, rated at 300 amps/32 Volts. With the addition of the optional Wire Feed Module, the SA - 250 w[...]

B-2 OPERA TION B-2 ENGINE OPERA TION Operate the welder with the doors closed. Leaving the doors open changes the designed air flow and can cause overheating. STARTING the SA-250 PERKINS 104-22 DIESEL ENGINE 1. Turn the “IDLER” switch to “HIGH”. 2. Turn the “IGNITION” switch to “ON”. 3. Press the Glow Plug button for 20 to 30 second[...]

B-3 OPERA TION B-3 SA-250 WELDER OPERA TION DUTY CYCLE The NEMA output rating of the SA-250 is 300 amperes at 32 arc volts on a 60% duty cycle (consult Specifications in this manual for alternate ratings). Duty cycle is based on a ten minute period; thus, the welder can be loaded at rated output for six minutes out of every ten minute period. CONTR[...]

B-4 OPERA TION B-4 SA-250 AUXILIARY POWER The AC auxiliary power, supplied as a standard, has a rating of 3.0 kVA of 115/230 VAC (60 hertz). With the 3.0 kVA, 115/230 VAC auxiliary power, one 115V duplex and one 230V duplex, grounding type receptacle are provided. The circuit is protected with circuit breakers. The rating of 3.0 kVA permits a maxim[...]

C-1 ACCESSORIES C-1 SA-250 OPTIONAL FEA TURES (Field Installed) Accessory Set (K704) - Includes electrode and work cables, headshield, work clamp and electrode holder. TIG Module (K930-2) - Portable, high frequency unit with gas valve for TIG welding. Rated at 300 amps / 60% duty cycle. (Request Publication E3.205). Power Plug Kit (K802D) - A power[...]

D-1 MAINTENANCE D-1 MAINTENANCE GENERAL INSTRUCTIONS • Blow out the welder and controls with an air hose at least once every two months. In particularly dirty locations, this cleaning may be necessary once a week. Use low pressure air to avoid driving dirt into the insulation. • “Current Range Selector” contacts should not be greased. To ke[...]

D-2 MAINTENANCE D-2 Lincoln brushes have a curved face to fit the commu- tator. Have an experienced maintenance man seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes. After stoning, blow out the dust with low pressure air. To seat slip ring brushes, p[...]

D-3 D-3 SA-250 MAINTENANCE I EVERY 400 HOURS OR 12 MONTHS EVERY 200 HOURS OR 6 MONTHS EVERY 100 HOURS OR 3 MONTHS FIRST SERVICE-(20 / 50 HOURS) EVERY DAY OR EVERY 8 HOURS If necessary use shorter periods. These preventive maintenance periods apply to average conditions of operation. Perkins #1300366020 TYPE OR QUANTITY Above operations to be carrie[...]

E-1 TROUBLESHOOTING E-1 SA-250 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair possible [...]

E-2 WELDER TROUBLESHOOTING E-2 SA 250 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS [...]

E-3 ENGINE TROUBLESHOOTING E-3 SA 250 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS [...]

E-4 ENGINE TROUBLESHOOTING E-4 SA-250 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS [...]

E-5 TROUBLESHOOTING SA-250 E-5 ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the Auto Position, Engine Will Not Return to Low Idle in Approximately 15 Seconds After Welding and Auxiliary Loads are Removed Set Idler Control Switch to the Auto Position Check for Continuity through Idler Control Switch Open Closed Measure DC Volt[...]

E-6 TROUBLESHOOTING SA-250 E-6 ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the AUTO Position, Engine Will Not Pick Up Speed When: The Arc is Struck Reed Switch in Weld Circuit Defective -- Will Not Close To Check: Short the Red Lead on P.C. Board to Welder Frame. The Auxiliary Power Load is Turned ON Power Load Too Small Try[...]

F-1 DIAGRAMS F-1 SA-250 M20016 C + - + - R W B SLIP RINGS 346 A 54 3 2 1 CB3 CB1 115 VOLT RECEPTACLE 230 VOLT RECEPTACLE WELDER LEAD BL OCK AC AC 42 602A U CB2 CB4 1 2 3 4 5 6 600A 41 GENERAT O R N -W 48 START + 52 + IDLER SOLENOI D - P9 J8 POSIT IVE 400D 400E - 51 56 RHEOSTAT EXC ALTERNATOR + PUMP SOLENOID 50 50B (CC+) & (CV+ W ITH W.F.M.) S B[...]

F-2 DIMENSION PRINT F-2 SA-250 M8869-24 A 28.00 22.00 22.14 24.50 27.12 25.00 31.75 51.50 6.00 32.82 42.63 43.13 48.50 53.75 61.00 65.25 67.00 8.12 3.00 .88 16.30 33.75 N.B. N.A. N.A. N.A. N.B. N.C. NOTES: N.A. .81 HOLES N.B. .69 HOLES N.C. CENTER OF GRAVITY WI TH OIL AND COOLANT IN ENGI NE, BUT NOT F UEL.[...]

NOTES SA-250[...]

NOTES SA-250[...]

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W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA EL[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

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