Lincoln Electric AC-235 Manual
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Lincoln Electric AC-235 Manual

Lincoln Electric AC-235 Manual

Welding power source
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AC-235
WELDING POWER SOURCE
by
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
Contents
Safety Precautions ...............................................................................................2
Installation and Operating Instructions
for AC-235 ...................................................................................................7
Includes safety, installation, operating instructions
and parts lists.
Learning to Weld ...............................................................................................11
Using the Carbon Arc Torch..............................................................................18
Includes for heating metal, welding aluminum or
brazing with an arc torch.
Selecting Electrodes ..........................................................................................23
Brief descriptions of the types and operating
data for all Lincoln electrodes.
Welding Books and Teaching Aids ...................................................................25
• 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 •
Page
Copyright © 2004 Lincoln Global Inc.
IM556
May, 2004

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Summary of Contents for Lincoln Electric AC-235

  • Page 1 AC-235 IM556 May, 2004 WELDING POWER SOURCE This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci cations and availability of optional features may have changed. Contents Page Safety Precautions ....................2 Installation and Operating Instructions for AC-235 ....................7...

  • Page 2: Electric Shock Can Kill

    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 PER- FORMED ONLY BY QUALIFIED INDIVIDUALS.
  • Page 3 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 4.a. Remove fire hazards from the welding area. 5.a. Use only compressed cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
  • Page 4 SAFETY ELECTRIC AND MAGNETIC FOR ENGINE powered equipment. FIELDS may be dangerous 7.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 8.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF).
  • Page 5 SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté...
  • Page 6 The code number is especially important when identifying the correct replacement parts. On-Line Product Registration - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

  • Page 7: Operating Instructions

    These installation instructions apply to the input wiring 4. Remove cable connecting clamp from holder jaws. Place and overload protection installed to supply one AC-235 clamp over bare end of electrode cable and insert into and comply with the United States National Electrical holder with clamp centered against connecting screw.

  • Page 8: Duty Cycle

    Duty Cycle ing screw in until it is tight. The threaded end of the The AC-235 is rated for 20% duty cycle on all switch posi- screw will then pass against the inside of the handle and tions except maximum (235 amps). At 235 amps the duty the head of the screw will be completely inside the han- cycle is 18%.
  • Page 9 NOTES –9 –...
  • Page 10 4. Get the welder code number found on the nameplate. 5. Order the part from The Lincoln Electric Company, or from a Lincoln Field Service Shop. Be sure to give the Parts List number, item number, part name and description, number required, the welder name, model number and code number.

  • Page 11: Learning To Weld

    Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying this type of information. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements.

  • Page 12: The Correct Welding Position

    If you are using a hand shield, hold the electrode holder in your right hand and the hand shield in your left. (For weld- ing left-handed it is the opposite.) FIGURE 2—The welding arc. The function of the covered electrode is much more than simply to carry current to the arc.

  • Page 13: The Correct Welding Speed

    4. Run beads on a flat plate. Run them parallel to the top 4. The Correct Welding Speed edge (the edge farthest away from you). This gives you The important thing to watch while welding is the puddle practice in running straight welds, and also, it gives you of molten metal right behind the arc.

  • Page 14: Welding In The Vertical Position

    Tack the plates at both ends, otherwise the heat will cause the plates to move apart. (See drawing): Fillet Welds Now weld the two plates together. Weld from left to right When welding fillet welds, it is very important to hold the (if right-handed).

  • Page 15: Overhead Welding

    nique has to be followed: 1. Use 1/8 (3.2mm) or 3/32" (2.4mm) Fleetweld 180 electrode. 2. On thin metal, use 60-75 amps. (14 ga 75 amps — 16 ga 60 amps.) 3. Hold the electrode in a 30-45° angle with the tip of the electrode pointing upwards.

  • Page 16: Welding Sheet Metal

    Welding Sheet Metal Welding sheet metal presents an additional problem. The thinness of the metal makes it very easy to burn through. Follow these few simple rules: 1. Hold a very short arc. (This prevents burn through, since (12.7 to 19 mm) beginners seem to hold too long an arc.) 5.

  • Page 17: Cast Iron Plate Preparation

    In this way no large amount of heat is put into the mass. NOTE: The quenching of the roller (or idler) has another purpose: It increases the hardness — and thus the service Most inexperienced welders will probably use the second life —...

  • Page 18: Required Equipment

    If a lot of cutting is to be done, USING THE CARBON ARC TORCH soak each electrode in water . . . Welding Aluminum and Copper Alloys for a minute or two. It keeps . . . Brazing and Soldering them cooler, and the electrodes .
  • Page 19 WARNING ARC RAYS can burn. The carbon arc torch rays will cause severe arc burns to exposed skin. Therefore, a pair of work gloves, long sleeved shirt or sleevelets, and an apron are recommended. Use an arc welding headshield or hand shield with a No. 11 2.00"...
  • Page 20 Heating Heavy Parts Welding Procedures 1. Use the recommended AC currents and carbon sizes list- Heavy metal can be heated more rapidly by connecting the ed in the Table on page 19. A headshield is required. work lead to the work so the arc is between the carbons and the work as well as between the two carbons.
  • Page 21 LH-73 grease and work the grease well into the threaded jaw. is recommended with the AC-235. Normally, DC(+) is pre- ferred for these electrodes. SELECTING ELECTRODES Which electrode is best for the particular job .
  • Page 22 Motions Manipulation depends on the joint. Some of the common motions are shown above. Motion “A” is a straight whipping motion used with fast- freeze electrodes to make stringer beads in all positions and on all types of joints. It keeps the molten pool small and lets it freeze quickly so the weld metal doesn’t spill down or through the joint.
  • Page 23 NOTE: The AC-235 is an AC welder. DC electrodes have been included in the chart below for referance only. ELECTRODE IDENTIFICATION AND OPERATION DATA Electrode Conforms to Test Polarity Sizes and Current Ranges (Amps.) Coating Requirements of Electrode (+) = “Reverse”...
  • Page 24 – 24 –...
  • Page 26 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
  • Page 27 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
  • Page 28 • World's Leader in Welding and Cutting Products • • 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...

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