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Lincoln Electric 225 manual

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Table of contents for the manual

  • Page 1

    WELDMARK 225 OPERA TOR’S MANUAL For Machines with Code Number 10946 IM766 April, 2002 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 EQ[...]

  • Page 2

    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. ________________________________________________[...]

  • Page 3

    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[...]

  • Page 4

    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[...]

  • Page 5

    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 ?[...]

  • Page 6

    Thank You for selecting a QUALITY product We want you to take pride in operating this 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 particular attention to the safety instructions w[...]

  • Page 7

    vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications ................................................................................................A-1,A-2 Installation Instructions. ........................[...]

  • Page 8

    A-1 INST ALLA TION WELDMARK 225 A-1 * Based on a 10 min. period. TECHNICAL SPECIFICA TIONS - WELDMARK 225 WEM 2239-1 INPUT - GASOLINE ENGINE RA TED OUTPUT - WELDER HEIGHT WIDTH DEPTH WEIGHT 30.3 in. 19.2 in. 42.3 in. 770 mm 488 mm 1074 mm 511 lbs. (232kg.) OUTPUT - GENERA TOR Welding Output * AC Constant Current 225A / 25V / 100% DC Constant Curren[...]

  • Page 9

    A-2 INST ALLA TION WELDMARK 225 A-2 AC STICK / TIG (CC) OUTPUT A 225 OUTPUT RANGE B 50 OUTPUT RANGE A B OUTPUT AMPS OUTPUT VOLTS AC (RMS) 0 50 100 150 200 250 0 10 20 30 40 50 60 70 80 DC STICK / TIG (CC) OUTPUT OUTPUT AMPS OUTPUT VOLTS DC (RMS) A 210 OUTPUT RANGE B 50 OUTPUT RANGE A B 0 50 100 150 200 250 300 350 0 10 20 30 40 50 60 70 80 CV OUTPU[...]

  • Page 10

    A-3 INST ALLA TION WELDMARK 225 A-3 INST ALLA TION INSTRUCTIONS Safety Precautions Machine Grounding Because this portable engine driven welder or genera- tor creates it’s own power, it is not necessary to con- nect it’s frame to an earth ground, unless the machine is connected to premises wiring (your home, shop, etc.). To prevent dangerous el[...]

  • Page 11

    A-4 INST ALLA TION WELDMARK 225 A-4 Some of the factors to be considered are as follows: 1. Design capacity of trailer vs. weight of equipment and likely additional attachments. 2. Proper support of, and attachment to, the base of the welding equipment so there will be no undue stress to the framework. Pre-Operation Service READ the engine operatin[...]

  • Page 12

    • Damage to the fuel tank may cause fire or explosion. Do not drill holes in the WELDMARK 225 base or weld to the WELDMARK 225 base. A-5 INST ALLA TION WELDMARK 225 A-5 Angle of Operation Internal combustion engines are designed to run in a level condition which is where the optimum perfor- mance is achieved. The maximum angle of operation for th[...]

  • Page 13

    A-6 INST ALLA TION WELDMARK 225 A-6 Connection of the LN-7 to the Weldmark 225 • Shut the welder off. • Connect the LN-7 and the K240 contactor kit per instructions on the connection diagram S17742 (can be found in the back of this manual). • Place the “RANGE” switch to the “WIRE FEED” position and the “POLARITY” switch to the des[...]

  • Page 14

    Load From WEM 2239-1 115V/230V Dual Voltage Each Half of Total From Receptacle Each 115V Both 115V Duplex Duplexes 0 20* 70 1.1 KW 20* 60 3.4 KW 20* 40 5.7 KW 20* 20 8.0 KW 0 0 A-7 INST ALLA TION WELDMARK 225 A-7 115 V Duplex Receptacles The 115V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double [...]

  • Page 15

    A-8 INST ALLA TION WELDMARK 225 A-8 TABLE lll ELECTRICAL DEVICE USE WITH THE WELDMARK 225 Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker. Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage appliances with electrical contr[...]

  • Page 16

    A-9 INST ALLA TION WELDMARK 225 A-9 Standby Power Connections The Weldmark 225 is suitable for temporary, standby, or emergency power using the engine manufacturer ’ s recommended maintenance schedule. The Weldmark 225 can be permanently installed as a standby power unit for 230V-3 wire, single phase 35 ampere service. (Connections must be made b[...]

  • Page 17

    A-10 INST ALLA TION WELDMARK 225 A-10 Connection of Weldmark 225 to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes. 230 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 230 VOLT 115 VOLT 115 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVIC[...]

  • Page 18

    B-1 OPERA TION WELDMARK 225 B-1 GENERAL DESCRIPTION The Weldmark 225 is a twin-cylinder, gasoline driven, multiprocess arc welder and AC power generator. It is built in a heavy gauge steel case for durability on the job site. DESIGN FEA TURES AC/DC STICK WELDING (Constant Current) • AC 40 - 225 Amps • DC 40 - 210 Amps • 100% Duty Cycle on All[...]

  • Page 19

    B-2 OPERA TION B-2 Welder Controls - Function and Operation ENGINE “ ON-OFF ” Switch When placed in the “ ON ” position, this switch energizes the engine ignition circuit. When placed in the “ OFF ” position, the ignition circuit is de-energized to shut down the engine. ENGINE “ ST ART ” Push-Button Switch Energizes engine starter m[...]

  • Page 20

    B-3 OPERA TION B-3 Starting/Shutdown Instructions Starting the Engine Be sure all Pre-Operation Maintenance has been per- formed. Also, read the Engine Owner ’ s Manual. Remove all loads connected to the AC power recepta- cles. To start the engine, set the “ Idler Control ” switch in the Automatic ( / ) position. Use the choke control as foll[...]

  • Page 21

    B-4 OPERA TION B-4 Welding Process Stick (Constant Current) Welding Connect welding cables to the "TO WORK ” and "ELECTRODE ” studs. Start the engine. Set the "Polarity ” switch to the desired polarity. Set the “ RANGE ” switch to a setting that is equal to or slightly greater than the desired welding current. (The “ RANG[...]

  • Page 22

    B-5 OPERA TION B-5 WELDMARK 225 Summary of Welding Processes CONTROL ELECTRODE CABLE IDLE WHEN NOT TO START PROCESS USED MODE WELDING WELDING STICK No AUTO Hot Touch electrode to work. Welding starts immediately and engine goes to high idle. TIG/K7930-1/K938-1, Yes HIGH Cold Press Amptrol, contactor K936-( ) /K892-1 closes, welding (WITH AMPTROL) s[...]

  • Page 23

    C-1 ACCESSORIES C-1 WELDMARK 225 OPTIONAL EQUIPMENT (Field Installed) K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.). Order: K957-1 Trailer K958-1 Ball Hitch K958-2 L[...]

  • Page 24

    C-2 ACCESSORIES C-2 WELDMARK 225 RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield K892-1 Remote Control Receptacle Kit and K857 Remote Control Kit are optional for remote current control. TIG Magnum ™ TIG Torch Magnum Parts Kit and Argon Gas K930-2 TIG Module[...]

  • Page 25

    D-1 MAINTENANCE D-1 WELDMARK 225 SAFETY PRECAUTIONS Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is co[...]

  • Page 26

    D-2 MAINTENANCE D-2 Engine Adjustments OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed. Severe personal injury and damage to the machine can result if operated at speeds above maximum. ---[...]

  • Page 27

    E-1 TROUBLESHOOTING E-1 WELDMARK 225 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 proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair possible ma[...]

  • Page 28

    E-2 TROUBLESHOOTING E-2 WELDMARK 225 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 Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS[...]

  • Page 29

    E-3 TROUBLESHOOTING E-3 WELDMARK 225 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 Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS[...]

  • Page 30

    WELDMARK 225 F-1 DIAGRAMS F-1 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[...]

  • Page 31

    F-2 DIAGRAMS F-2 WELDMARK 225 CONNECTION OF WELDMARK 225 TO LN-7 & K240 CONT ACTOR KIT WARNING: Turn the power off when making connections. N.A. Use power source polarity switch to set for desired elec- trode polarity. Position the output selector switch on the power source to the CV position. N.B. 3 conductor #16 power cord physically suitable[...]

  • Page 32

    F-3 DIAGRAMS F-3 WELDMARK 225 L OF SHAFT 9.29 21.21 9.31 2.75 17.00 26.59 19.11 30.28 9.09 9.09 UNDERCARRIAGE MOUNTING HOLES 42.25 CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK. 11.31 21.95 FOR OIL FILTER REMOVAL 30.00 8.80 30.00 42.00 C M17215-2 1-30-98E[...]

  • Page 33

    Now A vailable...12th Edition The Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. This printing will go fast so don ’ t delay. Place your order now using the coupon below. The hardbound book conta[...]

  • Page 34

    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[...]

  • Page 35

    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 P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

  • Page 36

    • Manufactured by Livcoln Electric Company • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com[...]