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RETURN TO MAIN MENU
IM533
IDEALARC SP-255
June, 1998
For use with machine Code Numbers
10164, 10165
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
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR'S MANUAL
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
• 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

Summary of Contents

  • Page 1

    RETURN TO MAIN MENU IM533 IDEALARC SP-255 June, 1998 For use with machine Code Numbers 10164, 10165 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 ...

  • Page 2

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

  • Page 4

    WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent 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.

  • Page 5

    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.

  • Page 6

    This statement appears where the information this equipment. 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!

  • Page 7: Table Of Contents

    Aluminum Feeding Kit (optional K673-1)...C-1 8" Spool Adapter (K468)...C-1 Dual Cylinder Mounting Kit (K671-1) ...C-1 Spool Gun Description...C-1 Spool Gun Adapter Kit (optional K672-1) ...C-1 Making a Weld with the Spool Gun Adapter Kit and Spool Gun Installed ...C-1 Page (continued) APR96 IDEALARC SP-255...

  • Page 8: Table Of Contents

    Magnum 250SP Gun Parts and Accessories ...D-3 Troubleshooting ...Section E How To Use Troubleshooting Guide...E-1 Troubleshooting Guide ...E-2 Wiring Diagrams ...Section F Wiring Diagram L9688 (208/230V) ...F-1 Wiring Diagram L9689 (230/460/575V) ...F-2 Dimension Print M16352...F-3 Parts Lists ...Appendix IDEALARC SP-255 Page...

  • Page 9: Technical Specifications, Idealarc

    Ground Wire exceeding 100 ft. 6 (16 mm #10 (6 mm 8 (10 mm #10 (6 mm 12 (4 mm #10 (6 mm 12 (4 mm #10 (6 mm Weight 222 Ibs 101 kg STORAGE TEMPERATURE ±40°C AUG 95 IDEALARC SP-255...

  • Page 10: Safety Precautions, Uncrating The Sp-255, Location

    SP-255. LOCATION Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front. A location that minimizes the amount of...

  • Page 11: Output Polarity Connections, Gun And Cable Installation

    OUTPUT POLARITY CONNECTION Turn the welder power switch off before changing output connection. The welder, as shipped from the factory, is connected for electrode positive (+) polarity. This is the normal polarity for GMA welding. If negative (–) polarity is required, interchange the connections of the two cables located in the wire drive compartment near the front panel.

  • Page 12: Shielding Gas

    Welding and Cutting” published by the American Welding Society. 1. Set gas cylinder in rear platform of SP-255. Hook chain in place to secure cylinder to rear of welder. 2. Remove the cylinder cap. Inspect the cylinder valves for damaged threads, dirt, dust, oil or grease.

  • Page 13

    • Keep flammable material away. • Do not weld on closed contain- ers. ARC RAYS can burn eyes and skin. • Wear eye, ear and body protec- tion. Observe all safety information throughout this manual. IDEALARC SP-255...

  • Page 14: Product Description, Recommended Processes And Equipment, Welding Capability, Limitations, Description Of Controls And Keys

    It is capable of high- er duty cycles at lower output currents. LIMITATIONS The SP-255 may not operate as designed if powered with a portable or in-plant generator. IDEALARC SP-255 OPERATION DESCRIPTION OF CONTROLS AND KEYS POWER SWITCH Place the lever in the “ON”...

  • Page 15

    Therefore, it is very important that the wire type, wire diameter, and welding gas on the display match the actual wire type, wire diame- ter, and welding gas being used for the weld. Left arrow keys—set Wire Type FIGURE 3 JAN96 IDEALARC SP-255...

  • Page 16

    Increasing or decreasing metal thickness automati- cally increases or decreases both wire feed speed and arc voltage simultaneously. See gauge chart on instruction label on inside of SP-255 door for IDEALARC SP-255 OPERATION available sizes. on, metal thickness is not displayed and, therefore, the left arrow keys will not function.

  • Page 17

    1. The message is displayed for 2.5 seconds, and then the original Auto screen is displayed. MEMORY NUMBER KEY Pressing the desired Memory Number key recalls the setup saved in that memory (including process, proce- dure, and timer functions if used). IDEALARC SP-255...

  • Page 18

    Process key and the setup will be recalled from memory 1 and the display will show the required process. Press Auto key or close the gun trig- ger to display the procedure stored in memory 1. IDEALARC SP-255 OCT94 OPERATION TIMER KEYS...

  • Page 19

    IPM to under VOLTS. Pressing the IPM VOLTS key again causes the cursor to disappear. Pressing the IPM VOLTS key again causes the cursor to appear under IPM. This sequence continues each time the IPM VOLTS key is pressed. TOGGLE KEY IDEALARC SP-255...

  • Page 20

    (down arrow) wire feed speed setting. If in Auto mode, increasing or decreasing wire feed speed will simultaneously cause an increase or decrease in the arc voltage and can change the IDEALARC SP-255 OPERATION metal thickness setting. Right arrow keys — Increases (up arrow) or decreases (down arrow) arc voltage setting.

  • Page 21

    The 4-step trigger feature does not function when using SPOT or STITCH timed welding modes. (See “Spot and Stitch Weld Modes” in this section.) IDEALARC SP-255...

  • Page 22: Gun Switches, Wire Drive Roll, Procedure For Changing Drive Roll, Wire Reel Loading

    .030-.035" (0.8-0.9 mm) solid steel electrode, and the other for .045" (1.2 mm) solid steel electrode. The welder is shipped with the drive roll installed in the .030-.035" (0.8-0.9 mm) position as indicated by the stencilling on the exposed side of the drive roll.

  • Page 23: Mounting Of 10 To 44 Lbs. Spools, To Start The Welder, Feeding Electrode

    LED back lighting of the LCD display and a readable screen should be visible on the display. With the desired weld mode selected, operate the gun trigger for welder output and to energize the wire feed motor. FEEDING ELECTRODE WARNING When inching, the electrode and drive mechanism are always “hot”...

  • Page 24

    4. If Spot or Stitch timing modes are required, per- form either step 4.a. for Spot or step 4.b. for Stitch; otherwise, go to step 5. 4.a.Press then select: IDEALARC SP-255 OCT94 OPERATION Press 4.b.Press Press 5. Inch the electrode through the gun and cable and then cut the electrode within approximately 3/8 inch (9.5 mm) of the end of the contact tip [3/4...

  • Page 25: Spot Weld Mode, Stitch Weld Mode, Avoiding Wire Feeding Problems, Fan Control

    LOW LINE VOLTAGE—You may not be able to get maximum output from the machine if the line voltage is less than rated input. If the output you want is not obtainable because of insufficient line voltage, a LOW B-13 IDEALARC SP-255...

  • Page 26: Wire Feed Overload Protection, Welding Thermal Overload Protection, Overcurrent Protection

    MATCH WIRE & GAS memory 4 doesn’t match the process in the machine. Press memory 4 to find out what process is required. The memory number indicates which memory, 4 or 5, doesn’t match. IDEALARC SP-255 OPERATION WELDING THERMAL OVERLOAD PROTECTION The SP-255 has built-in protective thermostats that respond to excessive temperature.

  • Page 27

    (approximately 1.3 sec.) allowing the operator to view the increase or decrease in that setting. OPERATION This table shows all of the actual lettering which appears in place of XXXX. There is no reason to note which of these occurred unless it occurs frequently. B-15 IDEALARC SP-255...

  • Page 28

    TO ENTER SETTINGS SPOOL GUN HAS BEEN REMOVED PRESS PROCESS TO ENTER SETTINGS IDEALARC SP-255 OCT94 OPERATION Message Explanation Indicates to operator that the line voltage is too high, and the output voltage has been reduced to protect the capacitor bank voltage rating limits. The operator can continue to weld, but the voltage will be less than what is set on the machine.

  • Page 29: Spool Adapter (k468), Dual Cylinder Mounting Kit (k671-1), Spool Gun Description

    (K672-1). CAUTION The spool gun module is intended for ® use with Lincoln Electric Magnum™ Spool Guns only. Use with other units may cause damage to the equipment. For Spool Gun operation, refer to the instruction manual provided with the Magnum™...

  • Page 30

    (down arrow) per- cent of wire feed speed. Right arrow keys — Increase (up arrow) or decrease (down arrow) arc voltage. IDEALARC SP-255 OCT94 ACCESSORIES d. Procedure settings may be stored in memory for later recall. (See “Memory Keys”...

  • Page 31

    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 to the last process entered before the Spool gun was attached. IDEALARC SP-255...

  • Page 32

    NOTES IDEALARC SP-255...

  • Page 33: General Maintenance, Safety Precautions, Drive Rolls And Guide Tubes, Gun Tubes And Nozzles, Cable Cleaning

    GENERAL MAINTENANCE In extremely dusty locations, dirt may clog the air passages causing the welder to run hot. Blow dirt out of the welder with low- pressure air at regular intervals to eliminate excessive dirt and dust build-up on internal parts.

  • Page 34: Liner Removal And Replacement

    Allen wrench. 2. Remove the gas diffuser from the gun tube. 3. Lay the gun and cable IDEALARC SP-255 MAINTENANCE 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.

  • Page 35: Gun Handle Disassembly, Magnum 250sp Gun Parts And Accessories

    GUN TUBE ASSEMBLIES Standard (60°) S18920 45° S19890 Included with Idealarc SP-255. Included with K673-1 3/64" (1.2 mm) Aluminum Feeding kit. ❏ 5356 alloy aluminum wire is recommended to alleviate potential soft wire feed- ing problems with push-type wire feeding.

  • Page 36

    NOTES IDEALARC SP-255...

  • Page 37: Troubleshooting 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. ___________________________________________________________________...

  • Page 38

    (not activated). 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. IDEALARC SP-255 TROUBLESHOOTING...

  • Page 39

    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. TROUBLESHOOTING TROUBLESHOOTING GUIDE...

  • Page 40

    TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) The welding arc is unstable or “hunting”. IDEALARC SP-255 TROUBLESHOOTING POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS 1. Check the work cable for loose or faulty connections. 2. Check the contact tip and replace if worn or damaged.

  • Page 41

    See Explanation of Prompting and Error Messages in the Operation section. RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists, contact your local Lincoln Authorized Field Service Facility. IDEALARC SP-255...

  • Page 42

    Gas does not flow when gun trigger is pulled. 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. IDEALARC SP-255 TROUBLESHOOTING...

  • Page 43

    SP-255 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 the machine on one of the enclosure panels. IDEALARC SP-255...

  • Page 44

    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. IDEALARC SP-255 WIRING DIAGRAMS...

  • Page 45

    DIMENSION PRINT SP-255 DIMENSION PRINT – M16352 (1-31-92B) IDEALARC SP-255...

  • Page 46

    NOTES...

  • Page 47

    NOTES...

  • Page 48

    NOTES...

  • Page 49

    NOTES...

  • Page 50

    Address: Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Titles: Price New Lessons in Arc Welding $5.00...

  • Page 51

    ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

  • Page 52

    ● ● Keep your head out of fumes. Turn power off before servicing. ● Use ventilation or exhaust to remove fumes from breathing zone. ● Los humos fuera de la zona de res- ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...

  • Page 53

    Equipment manufactured for the Lincoln Electric Company is subject to the warranty period of the original manufacturer. All engines and engine accessories are warranted by the engine or engine accessory manufacturer and are not covered by this warranty.

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