Lincoln Electric WELDANPOWER 125 IM530-C manual

W eldanpo w er 125 OPERA TOR’S MANUAL For use with Equipment having Code Numbers : 10158, 10160, 11183, 11406 IM530-C September, 2006 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 p[...]

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 Mar. ‘93 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les c[...]

v v 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[...]

T ABLE OF CONTENTS Page Safety .....................................................................................................................i-iv Installation ..................................................................................................................1-7 Technical Specifications .........................................[...]

INST ALLA TION TECHNICAL SPECIFICA TIONS - WELDANPOWER 125 Duty Cycle 30% 60% Amps 125 amps DC Constant Current 100 amps DC Constant Current Volts at Rated Amperes 25 VDC INPUT - GASOLINE ENGINE RA TED OUTPUT - WELDER Welding Ranges 50 - 125 Amps DC Welder Open Circuit Voltage 80 VDC Max. AC Auxiliary Power 4500 Watts 115/230V 1PH 100 % Duty Cycle [...]

– 2 – INST ALLA TION WELDANPOWER 125 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. W ARNING Hazards of Electric Shock, Engine Exhaust & Moving Parts ENGINE EXHAUST can kill. • Use in open, well ven[...]

INST ALLA TION – 3 – WELDANPOWER 125 An incorrect additional arrester may lead to damage to the engine or adversely affect performance. ----------------------------------------------------------------------- CAUTION Spark Arrester (For Codes 10158, 10160) Some federal, state or local laws may require gasoline engines to be equipped with exhaust[...]

– 4 – INST ALLA TION WELDANPOWER 125 FIGURE A.1 and A.1a - WELDANPOWER 125 OUTPUT CONNECTIONS WELDANPOWER 125 ELECTRODE SELECTION GUIDE 75 100 125 50 AMPS AMPS AMPS AMPS WARNING MAX 6 5 3 1 2 4 + - HOURS IDLER WELDANPOWER 125 WELDANPOWER 125 ELECTRODE SELECTION GUIDE ELECTRODE SELECTION GUIDE 75 75 100 100 125 125 50 50 AMPS AMPS AMPS AMPS WARN[...]

INST ALLA TION – 5 – WELDANPOWER 125 MACHINE GROUNDING Because this portable engine driven welder or generator creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (your home, shop, etc.). To prevent dangerous electric shock, other equipment to which this engine d[...]

– 6 – INST ALLA TION WELDANPOWER 125 PLUGS AND HAND HELD EQUIPMENT For further protection against electric shock, any electrical equipment connected to the generator receptacles must use a three-blade, grounded type plug or an Underwriter’s Laboratories (UL) approved double insulated tool with a two blade plug. Never operate this machine with[...]

INST ALLA TION – 7 – WELDANPOWER 125 CAUTION Certain Electrical devices cannot be powered by the Weldanpower 125. See Table A.2 TABLE A.2 ELECTRICAL DEVICE USE WITH THE WELDANPOWER 125 Type Resistive Capacitive Inductive Capacitive / Inductive Common Electrical Devices Heaters, toasters, incandescent light bulbs, electric range, hot pan, skille[...]

NOTES – 8 – WELDANPOWER 125[...]

OPERA TION – 9 – WELDANPOWER 125 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 breat[...]

– 10 – OPERA TION WELDANPOWER 125 GRAPHIC SYMBOLS USED ON THIS EQUIPMENT OR IN THIS MANUAL W ARNING / CAUTION CHOKE OIL FUEL AIR CLEANER CIRCUIT BREAKER GROUND (AUXILIAR Y POWER) WORK CLAMP ELECTRODE WELDING ARC F AST For Codes 10158, 10160 only . SLOW[...]

OPERA TION – 11 – WELDANPOWER 125 PRODUCT DESCRIPTION The Weldanpower 125 is designed for commercial use welder / generator applications. As a welder it provides 125 amps of DC constant current for welding with DC stick electrodes. A single dial lets you select a full range of welding output from 50 to 125 amps. (For Codes 10158, 10160) As a ge[...]

– 12 – OPERA TION WELDANPOWER 125 CONTROLS AND SETTINGS All welder/generator controls are located on the Output Control Panel. Gasoline engine controls are mounted on the engine. See Figure B.1, B.1a and the figures in the engine operation section. WELDANPOWER 125 WELDANPOWER 125 ELECTRODE SELECTION GUIDE ELECTRODE SELECTION GUIDE 75 100 125 50[...]

– 13 – WELDANPOWER 125 ENGINE OPERA TION Engine Control Function/Operation Rocker “ Run/Stop ” Switch (For Codes 10158, 10160 Only) The two position “Run/Stop” switch is marked “I” and “O” on the red rocker and is located on the rear of the engine. In the run (I) position, the engine ignition circuit is energized, and the engine[...]

– 14 – OPERA TION WELDANPOWER 125 Break-in Period It is normal for any engine to use larger quantities of oil until break-in is accomplished. Check the oil level twice a day during the break-in period (about 50 running hours). Change the oil after the first 5 hours of operation. See the Engine Instruction Manual for further details. IN ORDER TO[...]

OPERA TION – 15 – WELDANPOWER 125 2. Select the appropriate electrode. See Table B.2 or the ELECTRODE SELECTION GUIDE on the machine Output Control Panel. 3. Attach the work clamp securely to the work you are welding. 4. Insert the electrode into the electrode holder. 5. Set the current control dial to the desired output current. 6 . Start the [...]

– 16 – OPERA TION WELDANPOWER 125 TABLE B.2 ELECTRODE SELECTION GUIDE CURRENT RANGE (AMPS) AWS ELECTRODE CLASSIFICATION ELECTRODE TYPE POLARITY 3/32 SIZE 1/8 SIZE 5/32 SIZE E6010 FLEETWELD® 5P DC+ 50-75 75-125 - E6011 FLEETWELD® 35 DC+ 50-75 70-110 80-125 E6011 FLEETWELD® 180 DC+ 50-80 55-110 105-125 E6013 FLEETWELD® 37 DC± 70-95 100-125 -[...]

OPERA TION – 17 – WELDANPOWER 125 TABLE B.3 AUXILIARY POWER APPLICATIONS Suggested Power Applications Running Watts *Start-up Watts (Continuous) (Surge) *Air Compressor - 1 HP 2,000 4,000 - 8,000 *Air Compressor - 3/4 HP 1,250 3,100 - 5,000 *Airless Sprayer - 1/3 HP 600 1,500 - 2,400 Chain Saw 1,200 Circular Saw 1,200 Coffee Maker 1,000 *Deep F[...]

– 18 – ACCESSORIES WELDANPOWER 125 OPTIONS/ACCESSORIES The following options/accessories are available for your WELDANPOWER 125 from your local Lincoln Distributor: Accessory Kit (K875) – Includes the following: • Twenty feet (6.1 meters) of #6 AWG electrode cable with lug. • Fifteen feet (4.6 meters) of #6 work cable with lugs. • Work [...]

MAINTENANCE – 19 – WELDANPOWER 125 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. • If guards are missi[...]

– 20 – MAINTENANCE WELDANPOWER 125 To service the pre-cleaner : Remove the wing nuts and cover for Codes 10158, 10160) Remove the cover for (Codes 11183, 11406). Carefully remove the foam pre-cleaner from the filter element. 1. Wash in liquid detergent and water. 2. Squeeze dry in a clean cloth. 3. Saturate in clean engine oil. 4. Squeeze in a [...]

How T o Use T roubleshooting Guide This Troubleshooting Guide is designed to be used by the machine Owner/Operator. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety, please observe all safety notes and precautions detailed in the S[...]

– 22 – TROUBLESHOOTING WELDANPOWER 125 Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you [...]

– 23 – TROUBLESHOOTING WELDANPOWER 125 Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you [...]

– 24 – TROUBLESHOOTING WELDANPOWER 125 Observe Safety Guidelines detailed in the beginning of this manual. T roubleshooting Guide If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local Authorized Field Service Facility for technical troubleshooting assistance before you [...]

WIRING DIAGRAM – 25 – D1 C1 ROTOR (+) (-) (+) (-) (+) (-) D2 (+) (-) R1 STATOR 115 VOLT CHOKE ENGINE W IRING MAG OUTPUT STUDS L1 202 230 VOLT 203 203 204 CCW 1 HOUR METER IDLE SW ITCH HI AUTO 209 CB1 CB2 + 200A 200 201A 201 201B RED RUN/STOP SWITCH Y 3.3 100 W WH ITE T ERMINALS 208 600 FD IDLER SOLENOID 201B GREEN GREEN NOTE: ALL CASE FRONT COM[...]

– 26 – WIRING DIAGRAM ) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..[...]

– 27 – WELDANPOWER 125 WIRING DIAGRAM D1 C1 (+) (-) (+) (-) (+) (-) STATOR 120 VOLT CHOKE A.01 L1 202 240 VOLT HOUR METER CB1 CB2 + 201A 201 WH ITE T ERMINALS 600 FD 201B NOTE: ALL CASE FRONT COMPONENTS SHOWN VIEW ED FROM REAR. ELECTRICAL SYM BOLS PER E1537 3 5 6 7 15 W IRING DIA GRA M - W E LDA NPO W E R 1 2 5 (FOR CODE 11406) 6 5 3 4 12 20A 2[...]

– 28 – 20.00 508 REF. 21.13 537 REF. R 7.92 201 REF. 13.62 346 REF. 30.00 762 REF. LINCOLN LINCOLN ELECTRIC ELECTRIC M17614 2-17-95 DIMENSION PRINT WELDANPOWER 125[...]

NOTES WELDANPOWER 125 – 29 –[...]

– 30 – NOTES WELDANPOWER 125[...]

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 P ARA E[...]

– 32 – 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 P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to rem[...]

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