Lincoln Electric WELDANPOWER 230+ Operating Manual
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Lincoln Electric WELDANPOWER 230+ Operating Manual

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IMA 572F
December 2003
OPERATING MANUAL
WELDANPOWER
230+
®
PETROL - Part Number KA 1390
Code Nos. 70021 and below
DIESEL - Part Number KA 1409-1 Code Nos. 70027 and below
WELDANPOWER 230+ PETROL
WELDANPOWER 230+ DR
SAFETY DEPENDS ON YOU
Lincoln Electric welders are designed and built with safety in mind. However, your overall safety can be
increased by proper installation and thoughtful operation on your part. Read and observe the general safety
precautions on page 2 and follow specific installation and operating instructions included in this manual.
Most importantly, think before you act and be careful.
THE LINCOLN ELECTRIC COMPANY
(AUSTRALIA) PTY. LTD.
A.B.N. 36 000 040 308
SYDNEY. AUSTRALIA
A Subsidiary of
THE LINCOLN ELECTRIC CO. U.S.A.
Associated Subsidiaries in Australasia, Asia, Canada, Europe, North and South America.
THE WORLD'S LEADER IN WELDING AND CUTTING PRODUCTS

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Summary of Contents for Lincoln Electric WELDANPOWER 230+

  • Page 1 WELDANPOWER 230+ DR SAFETY DEPENDS ON YOU Lincoln Electric welders are designed and built with safety in mind. However, your overall safety can be increased by proper installation and thoughtful operation on your part. Read and observe the general safety precautions on page 2 and follow specific installation and operating instructions included in this manual.

  • Page 2: Arc Welding Safety Precautions

    PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. READ AND UNDERSTAND BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING MANUAL FOR THE WELDER AND/OR OTHER EQUIPMENT TO BE USED AS WELL AS THE FOLLOWING GENERAL INFORMATION. ARC WELDING SAFETY PRECAUTIONS ARC RAYS can burn ELECTRIC SHOCK can kill 1.
  • Page 3 FOR ENGINE powered CYLINDER may explode if equipment damaged 5. a. Use only compressed gas cylinders containing the a. Turn the engine off before troubleshooting maintenance work unless correct shielding gas for the process used and maintenance work requires it to be running. properly operating regulators, designed for the gas and pressure used.

  • Page 4: Welding, Emf & Pacemakers

    WELDING, EMF & PACEMAKERS All welders should follow safe practices that minimise their Welders with pacemakers exposure to electric and magnetic fields (EMF). There is no question that the fields in arc welding can interfere For welders wearing implanted pacemakers, safe welding with a pacemakers function.

  • Page 5: Assessment Of Area

    • for using with other Lincoln Electric/LiquidArc equipment. as filtering the mains supply. Consideration should be given to • designed for industrial and professional use.

  • Page 6: Specifications

    GENERAL DESCRIPTION The Weldanpower 230+ is a twin-cylinder, petrol or diesel driven, multi-process arc welder and AC power generator. It is built in a heavy gauge steel case for durability on the job site. SPECIFICATIONS Weldanpower 230+ Ordering Welding Auxiliary Dimensions &...

  • Page 7: Tig Welding Options/Accessories

    Electric starting. be purchased separately. K892-1 Remote Control Receptacle Kit - Required when using Factory installed engine hour meter. a K930-2 TIG Module with an optional amptrol. Built-in feet for easy mounting to truck bed or trailer. K939-1 Docking Kit - For mounting the K930-2 TIG Module on All copper alternator windings and high quality insulation for top of the Weldanpower 230+.
  • Page 8 Page 8 Weldanpower 230+ IMA 572F...

  • Page 9: Installation Instructions

    INSTALLATION INSTRUCTIONS Oil: Safety Precautions WARNING The Weldanpower 230+ is shipped with the engine crankcase filled with oil. Check the oil level before starting the engine. If it is not up to the full mark on the dip stick, add oil as required. make certain that the oil filler cap is tightened securely.

  • Page 10: Installation

    NB. Depending on the age of the dry charged battery, When welding at a considerable distance from the welder, be sure correct activation may take up to 48 hours. you use ample size welding cables. Listed below are copper cable sizes recommended for the rated current and duty cycle.

  • Page 11: Location / Ventilation

    230+. Maximum Open Circuit Voltage at 3300 RPM is 80 volts RMS. Duty Cycle: 100% for both welding and auxiliary power. Weldanpower 230+ Connection of Lincoln Electric Wire Feeders: Constant Current 230 Amps AC @ 25 Volts WARNING 210 Amps DC @ 25 Volts...

  • Page 12: "Idler" Switch

    Starting the Engine Briggs & Stratton Ruggerini Be sure all Pre-Operation Maintenance has been performed. 13kW Vanguard RD201 Also, read the Engine Owner’s Manual. Low Idle - No Load 0.9L/hr 0.8L/hr Remove all loads connected to the AC power receptacles. 2200 RPM To start the engine, set the “Idler Control”...

  • Page 13: Stick (Constant Current) Welding

    WARNING OPERATION AS A WELDER Stick (Constant Current) Welding Health aspects of the use of thoriated tungsten electrodes. Connect welding cables to the “TO WORK” and “ELECTRODE” studs. Start the engine. Set the “Polarity” switch to the desired Thorium oxides are found in thoriated tungsten electrodes up to polarity.

  • Page 14: Summary Of Welding Processes

    Summary of Welding Processes Control Electrode Cable Idle When Not To Start Process Used Mode Welding Welding Stick Auto Touch electrode to work. Welding starts immediately and engine goes to high idle. TIG/K930-2/K892-1/K938-1 High Cold Press Amptrol, welding starts immediately. /K936-1 (with Amptrol) Wire Feed, LN-25 with Auto...

  • Page 15: Engine Adjustments

    Maintenance Engine Adjustments: WARNING WARNING Overspeed is hazardous: The maximum allowable high Safety Precautions: idle speed for this machine is 3400 RPM, no load. DO NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed. Severe •...

  • Page 16: Troubleshooting

    WARNING Hardware Both English and Metric fasteners are used in this welder. Engine Maintenance Parts Battery acid can burn eyes and skin: Wear gloves and eye protection and be careful Briggs & Stratton Ruggerini when working near battery. Follow instructions 18hp Vanguard RD201 printed on battery.
  • Page 17 TROUBLESHOOTING TROUBLE CAUSE WHAT TO DO B. Engine will not idle down to 1. Idler switch on High Idle. 1. Set switch on Automatic idler. Low Speed. Insufficient voltage present. 2. Check for proper connection of between terminals #213 and leads (#213, #5E, #215, #209, #5E.
  • Page 18 GROUND TEST PROCEDURE WARNING Place switch ‘S3’ in STOP position (petrol only) and ‘S4’ in HIGH position. Field circuit test: Connect one lead of the mega tester to This procedure is only suitable for applications using DC the front panel ground stud and the other lead to lead No. mega testers up to 500V.
  • Page 19 WELDANPOWER 230+ AP-229 Operative: 18/12/03 Supercedes: 1/4/02 KA1390 Petrol Codes 70021 & below Model Index DO NOT attempt to use this Parts List for machine if its code NUMBERS IN THE TABLE BELOW INDICATE WHICH number is not listed. Contact the Service Department for any COLUMN TO USE IN EACH PARTS LIST FOR EACH code numbers not listed.
  • Page 20 Weldanpower 230+ Petrol AP-229C General Assembly Operative: 18/12/03 Supercedes: 1/6/99 21 22 Shown Ref: AG1368A (A2.9.98M) for Code 1530 When ordering parts quote Parts List No., Part No., Description, Machine Code and Serial Numbers Page 20 Weldanpower 230+ IMA 572F...
  • Page 21 Weldanpower 230+ Petrol General Assembly AP-229C1 Operative: 18/12/03 Supercedes: 1/6/99 # Indicates a change this printing. Use only the parts marked “X” in the column under the * Items not illustrated. heading number called for in the model index page. Recommended Spare Parts are highlighted in bold ITEM DESCRIPTION...
  • Page 22 Weldanpower 230+ Petrol AP-229C2 General Assembly Operative: 18/12/03 Supercedes: 1/6/99 9 10 Ref. AG1368-3 for Code 1421, 1436 Page 22 Weldanpower 230+ IMA 572F...
  • Page 23 Weldanpower 230+ Petrol General Assembly AP-229C1 Operative: 18/12/03 Supercedes: 1/6/99 # Indicates a change this printing. Use only the parts marked “X” in the column under the * Items not illustrated. heading number called for in the model index page. Recommended Spare Parts are highlighted in bold ITEM DESCRIPTION...

  • Page 24: Front Panel Assembly

    Weldanpower 230+ Petrol AP-229D Front Panel Assembly Operative: 18/12/03 Supercedes: 1/6/99 Shown Ref: AL2514-3 (A20.1.99M) for Code 1530 and above Ref: AL2514-1 (A13.12.95) for Codes 1421, 1436 Page 24 Weldanpower 230+ IMA 572F...
  • Page 25 Weldanpower 230+ Petrol Front Panel Assembly AP-229D1 Operative: 18/12/03 Supercedes: 1/6/99 Use only the parts marked “X” in the column under the # Indicates a change this printing. heading number called for in the model index page. * Items not illustrated. Recommended Spare Parts are highlighted in bold ITEM DESCRIPTION...
  • Page 26 WELDANPOWER 230+ WIRING DIAGRAM - PETROL ENGINE Ref: AM3421-1 (A31.1.96M) for Codes 1436, 1421 Page 26 Weldanpower 230+ IMA 572F...
  • Page 27 WELDANPOWER 230+ WIRING DIAGRAM - PETROL ENGINE Ref: AM3421-4 (A12.8.98M) for Code 1530 up to S/N A1980800260 IMA 572F Weldanpower 230+ Page 27...
  • Page 28 WELDANPOWER 230+ WIRING DIAGRAM - PETROL ENGINE Ref: AM3421A4 (A2.9.98M) for Code 1530 Above SN A1980800260 Page 28 Weldanpower 230+ IMA 572F...
  • Page 29 WELDANPOWER 230+ WIRING DIAGRAM - PETROL ENGINE Ref: AM3421-7 (A6.12.00M) for Codes 1591 IMA 572F Weldanpower 230+ Page 29...
  • Page 30 WELDANPOWER 230+ WIRING DIAGRAM - PETROL ENGINE Ref: AM3421B4 (A08-10-03M) for Codes 70016 & 70021 Page 30 Weldanpower 230+ IMA 572F...
  • Page 31 AP-86 Operative: 18/12/03 WELDANPOWER 230+ Supercedes: 1/6/99 KA1409 DIESEL For Code: 1494 & 1531 KA1409-1 DIESEL For Code: 70027 & below Model Index DO NOT attempt to use this Parts List for machine if its code NUMBERS IN THE TABLE BELOW INDICATE WHICH number is not listed.
  • Page 32 Weldanpower 230+ Diesel AP-86C Operative: 18/12/03 General Assembly Supercedes: 1/6/99 SEE DETAIL AP-86E Ref: AG1368-6 (A16.5.99M) for Code 1562 Page 32 Weldanpower 230+ IMA 572F...
  • Page 33 Weldanpower 230+ Diesel General Assembly AP-86C1 Operative: 18/12/03 Supercedes: 1/6/99 # Indicates a change this printing. Use only the parts marked “X” in the column under the * Items not illustrated. heading number called for in the model index page. Recommended Spare Parts are highlighted in bold ITEM DESCRIPTION...
  • Page 34 Weldanpower 230+ Diesel AP-86C2 Operative: 18/12/03 General Assembly Supercedes: 1/6/99 SEE PRESSURE SWITCH DETAIL AP-86E SEE AP-86E SEE REGULATOR PLUG DETAIL AP-86F Ref: AG1368-6 (A16.5.99M) for Code 1562 Page 34 Weldanpower 230+ IMA 572F...
  • Page 35 Weldanpower 230+ Diesel AP-86C2 General Assembly Operative: 18/12/03 Supercedes: 1/6/99 # Indicates a change this printing. Use only the parts marked “X” in the column under the * Items not illustrated. heading number called for in the model index page. Recommended Spare Parts are highlighted in bold ITEM DESCRIPTION...
  • Page 36 Weldanpower 230+ Diesel AP-86D Front Panel Assembly Operative: 18/12/03 Supercedes: 14/2/97 Ref: AL2514-2 (7/19/96G) Page 36 Weldanpower 230+ IMA 572F...
  • Page 37 Weldanpower 230+ Diesel AP-86D1 Front Panel Assembly Operative: 18/12/03 Supercedes: 14/2/97 # Indicates a change this printing. Use only the parts marked “X” in the column under the * Items not illustrated. heading number called for in the model index page. Recommended Spare Parts are highlighted in bold ITEM DESCRIPTION...
  • Page 38 Weldanpower 230+ Diesel AP-86E Miscellaneous Details Operative: 18/12/03 Supercedes: 1/6/99 CONTROL IDLER CONTROL CONTROL BOX ASSEMBLY DETAIL ENGINE OIL PRESSURE SWITCH DETAIL ROTOR & BLOWER ATTACHMENT DETAIL SOLENOID ATTACHMENT DETAIL Page38 Weldanpower 230+ IMA 572F...
  • Page 39 Weldanpower 230+ Diesel AP-86E1 Miscellaneous Details Operative: 18/12/03 Supercedes: 1/6/99 # Indicates a change this printing. Use only the parts marked “X” in the column under the * Items not illustrated. heading number called for in the model index page. Recommended Spare Parts are highlighted in bold ITEM DESCRIPTION...
  • Page 40 WELDANPOWER 230+ WIRING DIAGRAM - DIESEL ENGINE Ref: AM3421-2 (A16.4.97M) for Codes 1494 & 1531 Page 40 Weldanpower 230+ IMA 572F...
  • Page 41 WELDANPOWER 230+ WIRING DIAGRAM - DIESEL ENGINE Ref: AM3421-6 (A17.3.99) for Code 1562 IMA 572F Weldanpower 230+ Page 41...
  • Page 42 WELDANPOWER 230+ WIRING DIAGRAM - DIESEL ENGINE Ref: AM3421-9 (A28-01-04M) for Code 700027 Page 42 Weldanpower 230+ IMA 572F...
  • Page 43 NOTES IMA572F Weldanpower 230+ Page 43...

  • Page 44: Limited Warranty

    We respond to our customers based on the best information in our One Year* possession at that time. Lincoln Electric is not in a position to warrant or guarantee Ruggerini Engines and Accessories such advice and assumes no liability, with respect to such information or advice. We...

This manual is also suitable for:

Weldanpower ka 1390Weldanpower ka 1409-1

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