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Lincoln Electric IDEALARC SP-255, Operator'S Manual

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Lincoln Electric IDEALARC SP-255 Operator'S Manual Download Page 44

F-2

WIRING DIAGRAMS

IDEALARC SP-255

SP-255 WIRING DIAGRAM: 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.

Summary of Contents for IDEALARC SP-255

Page 1: ...STALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machine Code Nu...

Page 2: ...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...

Page 3: ...ical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for co...

Page 4: ...vent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic...

Page 5: ...i s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan t...

Page 6: ...e information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes...

Page 7: ...ive Roll B 10 Wire Reel Loading B 10 Mounting of 10 to 44 lbs Spools B 11 To Start the Welder B 11 Feeding Electrode B 11 Idle Roll Pressure Setting B 11 Making a Auto Mode Weld B 12 Spot Weld Mode B...

Page 8: ...e Cleaning D 1 Contact Tip and Gas Nozzle Installation D 1 Liner Removal and Replacement D 2 Gun Handle Disassembly D 3 Magnum 250SP Gun Parts and Accessories D 3 Troubleshooting Section E How To Use...

Page 9: ...m2 TECHNICAL SPECIFICATIONS IDEALARC SP 255 INPUT SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT CABLE AND FUSE SIZES Height Width Depth Weight 28 2 in 18 8 in 40 1 in 222 Ibs 719 mm 480 mm 1...

Page 10: ...rts such as output terminals or internal wiring All input power must be electri cally disconnected before proceeding WARNING 1 Before starting the installation check with the local power company if th...

Page 11: ...rovided with the SP 255 is factory installed with a liner for 035 045 0 9 1 2 mm electrode and an 035 0 9 mm contact tip Install the 045 tip also provided if this wire size is being used For other wir...

Page 12: ...pect the regulator for damaged threads dirt dust oil or grease Remove dust and dirt with a clean cloth DO NOT USE THE REGULATOR IF OIL GREASE OR DAMAGE IS PRESENT Have an authorized repair station cle...

Page 13: ...m 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 breathing zone WELDING SPARKS can cause...

Page 14: ...ly equipped for these wire sizes The SP 255 is factory equipped with an adjustable CO2 and Argon blend flow regulator A supply of shielding gas is required for GMAW processes WELDING CAPABILITY The SP...

Page 15: ...eneath the START display using the IPM VOLTS key see Gun Switch Keys in this section 3 Spool Gun Start Mode If using optional spool gun mode see Making a Weld with the Spool Gun in Accessories sec tio...

Page 16: ...s been set higher than the rec ommended value and a down arrow indicator appears below the V in VOLTS if the arc voltage is below the recommended value No arrow indicates that you are set to the recom...

Page 17: ...one of five memories chosen by pressing the desired memory number key When the Save key is pressed a prompting message instructing the operator to PRESS MEMORY 1 5 TO SAVE SETUP is displayed This mes...

Page 18: ...ill tell you to press the Process key once you have installed the process required into the SP 255 Once the required process has been installed press the Process key and the setup will be recalled fro...

Page 19: ...the Auto and Manual mode displays The six arrow keys do not function with this key TYPICAL TIMERS OFF KEY PRESS SEQUENCE Auto screen is displayed prior to pressing Timers Off key Timers Off key is pr...

Page 20: ...wer was removed so you may continue to weld right where you left off or press Toggle key to return to toggle mode Left arrow keys If metal thickness is displayed these keys will increase up arrow or d...

Page 21: ...hat the 4 step trigger interlock no longer functions USING 4 STEP TRIGGER INTERLOCK FUNCTION When the function is deactivated the trigger will func tion in the normal mode which welds only when the tr...

Page 22: ...ll must be reversed or changed PROCEDURE FOR CHANGING DRIVE ROLL Different wire sizes may require changing the drive roll The applicable wire sizes are stamped on the drive roll Dual groove rolls must...

Page 23: ...spool until the free end of the electrode is accessible 2 While securely holding the electrode cut off the bent end and straighten the first six inches 152 mm Cut off the first inch 25 mm If the elect...

Page 24: ...tely 3 8 inch 9 5 mm of the end of the contact tip 3 4 inch 19 mm for Outershield electrodes 6 If welding gas is to be used turn on the gas sup ply and set the required flow rate typically 25 35 CFH 1...

Page 25: ...ld gun in one place during ON time and move gun just beyond edge of molten metal during OFF time NOTE For smoothest welds on thinner metal point gun slightly toward direction of travel AVOIDING WIRE F...

Page 26: ...d out what process is required The memory number indicates which memory 4 or 5 doesn t match B 14 OPERATION IDEALARC SP 255 LINE message will be displayed see Section on Explanation of Prompting and E...

Page 27: ...ese error types turn off the arc voltage wire feed speed and solenoid Press the Process key per second message and check all settings before continuing to weld XXXX IC31 RTI SWI IOT XIRQ PWOF DATA Rem...

Page 28: ...rawn from the machine and the output has been reduced to prevent the current from exceeding safe levels This will typically occur in Manual mode using 045 1 2mm wire and WFS greater than 275 IPM 7 0m...

Page 29: ...r other metal common to work 1 Transfer switch in FEEDER position a Disables spool gun trigger wire feed and gas output C 1 ACCESSORIES OCT94 IDEALARC SP 255 3 64 1 2 mm ALUMINUM FEEDING KIT K673 1 Th...

Page 30: ...h elec trodes electrically HOT 2 Transfer switch in SPOOL position a Disables feeder gun wire feed and gas output However closing feeder gun trigger will make both electrodes electrically HOT and acti...

Page 31: ...ers have been set pressing the Stitch key again returns the display to the original Spool screen with the Stitch timer status indicated in the bottom left corner TOGGLE KEY The first time this key is...

Page 32: ...C 4 NOTES IDEALARC SP 255...

Page 33: ...as holes in the diffuser 4 If using an optional adjustable slip on nozzle slip the appropriate gas nozzle onto the nozzle insulator Either a stan dard 40 12 7 mm or optional 62 15 9 mm I D slip on gas...

Page 34: ...nd should be flush to 12 3 2 mm extended for the short circuiting transfer process and 12 3 2 mm recessed for spray transfer LINER REMOVAL AND REPLACEMENT NOTE Changing the liner for a different wire...

Page 35: ...NTACT TIPS Standard Duty S19391 6 025 0 6 mm S19391 7 030 0 8 mm S19391 1 035 0 9 mm S19391 2 045 1 2 mm Heavy Duty S19392 1 035 0 9 mm S19292 2 045 1 2 mm Tapered S19393 5 025 0 6 mm S19393 6 030 0 8...

Page 36: ...D 4 NOTES IDEALARC SP 255...

Page 37: ...TROUBLESHOOTING 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 machi...

Page 38: ...activated Allow the machine to cool and then reduce the duty cycle and or wire feed speed 3 Make sure input voltage is correct and matches nameplate rating and reconnect panel configuration 1 Remove...

Page 39: ...tches nameplate rating and reconnect panel configuration 2 Make sure settings for wire feed speed and voltage are correct for process being used 3 Make sure output polarity is cor rect for process bei...

Page 40: ...ng polarity is correct for the process being used 4 Make sure the shielding gas is correct for the process being used 5 The gun and cable assembly may be faulty Replace RECOMMENDED COURSE OF ACTION If...

Page 41: ...re feeding path 2 Make sure the correct size con tact tip gun liner and drive rolls are being used 1 The thumbswitch circuit in the gun and cable assembly may be faulty Repair or replace 1 There may h...

Page 42: ...ive rolls are not turning when the gun trigger is pulled there is a problem within the SP 255 3 If using a Spool Gun adapter kit make sure transfer switch is in the correct position RECOMMENDED COURSE...

Page 43: ...5 WIRING DIAGRAM L9688 DUAL VOLTAGE 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 t...

Page 44: ...5 WIRING DIAGRAM 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 t...

Page 45: ...F 3 DIMENSION PRINT IDEALARC SP 255 SP 255 DIMENSION PRINT M16352 1 31 92B Inches Millimeters...

Page 46: ...NOTES...

Page 47: ...NOTES...

Page 48: ...NOTES...

Page 49: ...NOTES...

Page 50: ...etin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for sh...

Page 51: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 52: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 53: ...ay be used with the environ mental systems described above This includes hoses filters belts and hose adapters Expendable Parts Lincoln is not responsible for the replacement of any expendable part th...

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