Lincoln Electric SP-255 manual

IDEALARC SP-255 OPERA TOR’S MANUAL IM533 June, 1998 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 MANUA[...]

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 PRÉCA UTIONS 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 APR96 IDEALARC SP-255 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Safety Precautions................[...]

vii IDEALARC SP-255 MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 General Maintenance .....................[...]

A-1 INST ALLA TION AUG 95 IDEALARC SP-255 75C Copper Wire 75C Copper Wire in Conduit in Conduit Input Fuse or Input Ampere AWG (IEC) AWG (IEC) Voltage/ Breaker Size Rating on Sizes Sizes Frequency (Super Lag) Nameplate For lengths For lengths Ground Wire up to 100 ft. exceeding 100 ft. 208 60 53 8 (10 mm 2 ) 6 (16 mm 2 ) #10 (6 mm 2 ) 230 60 50 10 [...]

A-2 INST ALLA TION IDEALARC SP-255 OCT94 Read entire Installation section before starting installation. SAFETY PRECA UTIONS UNCRA TING THE SP-255 Remove the staples from the bottom edge of the car- ton and lift off. Cut the tape securing the two rear wheels to the wooden shipping pallet. Using a 1/2 inch (or 13 mm) wrench or socket, remove the two [...]

The 230/460/575 volt 60 Hz model is not equipped with a plug, input cable or receptacle. 4. Using the following instructions have a qualified electrician connect the receptacle or cable to the input power lines and the system ground per the U.S. National Electrical Code and any applicable local codes. See the “Technical Specifications” page at [...]

A-4 INST ALLA TION IDEALARC SP-255 OCT94 However, the thumbswitch functions available on the Magnum 250SP gun will only be operable from the front panel keypad. The gun trigger switch must be capable of switching 5 milliamps at 15 volts DC– resistive. The gun trigger switch connected to the gun trig- ger control cable must be a normally open, mom[...]

IDEALARC SP-255 B-1 OPERA TION Read entire Operation section before operating the SP-255. 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 [...]

IDEALARC SP-255 B-2 OPERA TION PR ODUCT DESCRIPTION The SP-255 is a complete semiautomatic constant voltage DC arc welding machine built to meet NEMA specifications. It combines a constant voltage power source and a constant speed wire feeder with a micro- computer-based controller. This forms an intelligent welding system that really puts the auto[...]

B-3 OPERA TION JAN96 IDEALARC SP-255 are held closed. The left pair will automatically contin- ue to increment or decrement the selection above it at a slow, steady rate as long as the key is pressed. The center and right pairs will continue to increment and decrement the selections above them at a slow rate, but then the rate will gradually increa[...]

B-4 OPERA TION IDEALARC SP-255 Center arrow keys—set Wire Diameter Right arrow keys—set Welding Gas The following 16 processes are programmed into the SP-255: PROCEDURE KEYS AUTO KEY Pressing the Auto Key once places the SP-255 into the automatic mode of operation. Auto mode provides automatic setup of the recommended wire feed speed and arc vo[...]

B-5 OPERA TION IDEALARC SP-255 Repressing the Auto Key sets the recommended pro- cedure for the metal thickness displayed. MANUAL KEY Permits individual setting of wire feed speed and arc voltage for manual procedure setup. The manual screen displays wire feed speed, arc voltage, and a cursor that indicates which parameter, wire feed speed, or arc [...]

B-6 OPERA TION IDEALARC SP-255 OCT94 The six arrow keys perform no function during a recall. NOTE: The presently displayed setup is lost because it is replaced by the setup recalled from memory. If you wish to save the present setup, save it to an unused memory first (see Save key), and then recall the memory required. TYPICAL MEMORY NUMBER KEY PRE[...]

B-7 OPERA TION IDEALARC SP-255 STITCH KEY Turns on the Stitch weld timers and displays selec- tions of the stitch ON and OFF times. Pressing the Stitch key a second time returns the screen to the previous display without turning off the stitch timers. Any time the Stitch weld timers are on and the display is in the Auto or Manual mode, the abbrevia[...]

B-8 OPERA TION IDEALARC SP-255 The first time this key is pressed it turns on toggle mode and recalls the setup in memory 4. This mode allows you to toggle between the setups in memory 4 and memory 5. Each time the key is pressed, it alter- nates between the two memories. The toggle screen displays the memory number the current setup was recalled f[...]

B-9 OPERA TION IDEALARC SP-255 the one that did not match (see Memory Number Key Section). 4-STEP TRIGGER INTERLOCK KEYS Pressing and Controls whether 4-step trigger interlock is activated or deactivated. (See “Using 4-Step Trigger Interlock Function” section.) NOTE: 4-Step Trigger is automatically deactivated if either the spot or stitch timer[...]

B-10 OPERA TION IDEALARC SP-255 GUN SWITCHES Gun Trigger Switch — Turns on arc voltage, wire feeder, and gas solenoid (except with Innershield) when closed. Also causes the screen to display the Auto or Manual screens (depending on which mode it is in), when the trigger is pulled. Turns off arc voltage, wire feeder, and gas solenoid when opened. [...]

B-11 OPERA TION IDEALARC SP-255 Check to be sure the retaining spring has fully returned to the locking position and has securely locked the Readi-Reel cage in place. Retaining spring must rest on the cage not the welding elec- trode. To remove Readi-Reel from Adapter, depress retain- ing spring tab with thumb while pulling the Readi-Reel cage from[...]

B-12 OPERA TION IDEALARC SP-255 OCT94 3. If the only result was drive roll slippage, loosen the gun cable Fast-Mate™ connection nut from the front of the SP-255 and pull the gun cable forward about 6” (152 mm). There should be a slight wavi- ness in the exposed wire. If there is no waviness, the pressure is too low. Tighten the thumbscrew 1/4 t[...]

B-13 OPERA TION IDEALARC SP-255 12. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off SP-255. SPO T WELD MODE Arc spot plug welds are used when continuous welds are not needed or to hold thin sheet metal together prior to stitch welding or continuous weld[...]

EXPLANA TION OF PROMPTING AND ERR OR MESSA GES On Screen Error Message Message Explanation PROCESS MUST MATCH WIRE & GAS ONLY SET UP FOR .035 STAINLESS ONLY ARGON USED WITH ALUMINUM ONLY SET UP FOR .045 OUTERSHIELD NO GAS REQUIRED WITH INNERSHIELD MEMORY 1 NOW CONTAINS SETUP MEMORY 2 IS EMPTY MEMORY 4 DOESN’T MATCH WIRE & GAS Reminder tha[...]

REQ’S: STAINLESS WIRE .035 Ar0 2 PRESS PROCESS WHEN INSTALLED DATA ***ERROR*** CHECK SETTINGS PRESS PROCESS TO CHECK SETTINGS MOTOR OVERLOADED CHECK GUN, DRIVE XXXX ***ERROR*** CHECK SETTINGS PRESS PROCESS TO CHECK SETTINGS GUN SWITCH BEING USED FOR TOGGLE CONNECT FOR NEG. POLARITY LOW LINE: CHECK RECONNECT PANEL PRESS ANY KEY TO STOP MESSAGE An [...]

B-16 IDEALARC SP-255 OCT94 OPERA TION On Screen Error Message Message Explanation HIGH LINE: CHECK RECONNECT PANEL PRESS ANY KEY TO STOP MESSAGE CURRENT OVERLOAD REDUCE OUTPUT PRESS ANY KEY TO STOP MESSAGE SXXXXX-X ROM ASSEMBLY C SXXXXX-X ROM ASSEMBLY R SPOOL GUN HAS BEEN CONNECTED PRESS MANUAL TO ENTER SETTINGS SPOOL GUN HAS BEEN REMOVED PRESS PRO[...]

for use of the K487 Spool Gun (with remote speed control), or the K469 Spool Gun (requires K518 Connection Adapter). It also provides single switch transfer of Trigger and Wire Speed Controls between the 250SP gun or the spool gun for same polarity welding with different wire and gas processes. The kit includes a spool gun adapter mod- ule assembly[...]

C-2 A CCESSORIES IDEALARC SP-255 OCT94 d. Procedure settings may be stored in memory for later recall. (See “Memory Keys” in Operation section.) 4. The following procedure settings can be used as initial settings for making test welds to determine final settings: SPOT KEY Anytime the Spot weld timer is on and the display is in Spool mode, the w[...]

C-3 A CCESSORIES IDEALARC SP-255 memory 4 is recalled and appears on the display. This whole cycle is repeatable as long as the unit remains in Toggle mode. DISABLING SPOOL GUN When the Spool Gun Adapter box transfer switch is set to FEEDER Gun position, the display will flash between these two mes- sages: Pressing the Process key will return you t[...]

C-4 NO TES IDEALARC SP-255[...]

D-1 MAINTENANCE IDEALARC SP-255 GUN TUBES AND NOZZLES 1. Replace worn contact tips as required. 2. Remove spatter from inside of gas noz- zle and from tip after each 10 minutes of arc time or as required. CABLE CLEANING Clean cable liner after using approximately 300 pounds (136 kg) of electrode. Remove the cable from the wire feeder and lay it out[...]

D-2 MAINTENANCE IDEALARC SP-255 out straight on a flat surface. Remove the liner nut from the Fast-Mate™ connector end of the cable and pull the liner out of the cable. 4 . Insert a new untrimmed liner into the connector end of the cable. Be sure the liner busing is stencilled appropriately for the wire size being used. 5. Fully seat the liner bu[...]

D-3 MAINTENANCE IDEALARC SP-255 GUN HANDLE DISASSEMBL Y The internal parts of the gun handle may be inspected or serviced if necessary. The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counterclockwise (the same direction as removing a right hand[...]

D-4 NO TES IDEALARC SP-255[...]

E-1 TR OUBLESHOO TING IDEALARC SP-255 Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that the machine may exhibit. Find the listing that best describes the symptom that your machine is exhibit- ing. Step 2. PERFORM EXTERNAL RECOM- MENDED TESTS. The second column la[...]

IDEALARC SP-255 E-2 TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING GUIDE PROBLEMS (SYMPT OMS) Major physical or electrical damage is evident. There is no wire feed or open circuit voltage when the gun trigger is pulled. The LCD display is “ON” indicating input power to the SP-255.. Output[...]

IDEALARC SP-255 E-3 TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING 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 LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. CA U[...]

E-4 TR OUBLESHOO TING IDEALARC SP-255 PROBLEMS (SYMPT OMS) The welding arc is unstable or “hunting”. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Check the work cable for loose or faulty connections. 2. Check the contact tip and replace if worn or damaged. 3. Make sure the welding polarity is correct for the process being used. 4. Make sure the shield[...]

E-5 TR OUBLESHOO TING IDEALARC SP-255 Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING GUIDE PROBLEMS (SYMPT OMS) The SP-255 stops feeding wire while welding and the MOTOR OVERLOADED message appears on the LCD display. The voltage and/or wire feed speed are being changed even though the gun thumbswitch or front [...]

IDEALARC SP-255 E-6 TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING 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 LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. CA U[...]

F-1 WIRING DIA GRAMS IDEALARC SP-255 SP-255 WIRING DIA GRAM: L9688 (DU AL V OL T A GE) 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.[...]

F-2 WIRING DIA GRAMS IDEALARC SP-255 SP-255 WIRING DIA GRAM: L9689 (230/460/575V) 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.[...]

F-3 DIMENSION PRINT IDEALARC SP-255 SP-255 DIMENSION PRINT – M16352 (1-31-92B) Inches (Millimeters)[...]

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W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO 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 EL[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA 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[...]

• 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 World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors STATEMENT OF LIMITED WARRANTY The Lincoln Electric Company (Lincoln) warrants [...]