Lincoln Electric WELDMARK 225 Operator's Manual
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Lincoln Electric WELDMARK 225 Operator's Manual

Lincoln Electric WELDMARK 225 Operator's Manual

Lincoln electric welder user manual
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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
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN MENU
WELDMARK 225
For Machines with Code Number 10946
THIS
OPERATOR'S MANUAL
• Manufactured by Lincoln Electric Company •
R
IM766
April, 2002
Copyright © 2002 Lincoln Global Inc.

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Summary of Contents for Lincoln Electric WELDMARK 225

  • Page 1 Serial Number: Code Number: Model: Where Purchased: OPERATOR’S MANUAL • Manufactured by Lincoln Electric Company • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com RETURN TO MAIN MENU For Machines with Code Number 10946 IM766 April, 2002...
  • 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

    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 Thank You Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

  • Page 7: Table Of Contents

    Connection of Wire Feeders ...A-5,A-6 Connection of Tig Module ...A-6 Additional Safety Precautions ...A-6 Auxiliary Power Receptacles, and Plugs ...A-6,A-7 Motor Starting ...A-7 Electrical Device Used with the WELDMARK 225 ...A-8 Auxiliary Power While Welding...A-9 Premises Wiring ...A-10 Operation...Section B General Description...B-1 Design Features ...B-1...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - WELDMARK 225 WEM 2239-1 Make/Model Description 2 cylinder 4 Cycle Kohler CH20S Air-Cooled (WEM 2239-1) Gasoline Engine. Aluminum Alloy with Cast Iron Liners, Electrical Ignition HEIGHT WIDTH 30.3 in. 19.2 in. 770 mm 488 mm Based on a 10 min. period.

  • Page 9: Specifications

    AC STICK / TIG (CC) OUTPUT A 225 OUTPUT RANGE B 50 OUTPUT RANGE OUTPUT AMPS DC STICK / TIG (CC) OUTPUT A 210 OUTPUT RANGE B 50 OUTPUT RANGE OUTPUT AMPS DC WIRE FEED (CV) OUTPUT CV OUTPUT RANGE OUTPUT AMPS WELDMARK 225...

  • Page 10: Installation Instructions

    To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must: • be grounded to the frame of the welder using a grounded type plug, or • be double insulated. INSTALLATION When this welder is mounted on a truck or trailer, it’s frame must be securely connected to the metal frame of the vehicle.

  • Page 11: Pre-Operation Engine Service

    Listed below are copper cable sizes recommended for the rated current and duty cycle. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop.

  • Page 12: Angle Of Operation

    3.5% per 1000 feet for altitudes above 377 feet. CAUTION Do not operate a Weldmark 225 with a high alti- tude jet installed at altitudes below 5000 ft. This will result in the engine running too lean and result in higher engine operating temperatures which can shorten engine life.

  • Page 13: Additional Safety Precautions

    TIG Module for installation instructions. NOTE: The TIG Module does not require the use of a high frequency bypass capacitor. However, if the Weldmark 225 is used with any other high frequency equipment, the bypass capacitor must be installed - order kit T12246.

  • Page 14: Motor Starting

    Larger motors through 2 hp can be 230 V run provided the receptacle rating as previously stated is not exceeded. This may necessitate 230V operation only. 115 V* Total From Both 115V Duplexes Total From Both 115V Duplex WELDMARK 225...

  • Page 15: Electrical Device Used With The Weldmark 225

    ELECTRICAL DEVICE USE WITH THE WELDMARK 225 Type Resistive Capacitive Inductive Capacitive/Inductive IWDC is not responsible for any damage to electrical components improperly connected to the Weldmark 225. INSTALLATION TABLE lll Common Electrical Devices Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker.

  • Page 16: Auxiliary Power While Welding

    Standby Power Connections The Weldmark 225 is suitable for temporary, standby, or emergency power using the engine manufacturer’s recommended maintenance schedule. The Weldmark 225 can be permanently installed as a standby power unit for 230V-3 wire, single phase 35 ampere service. WARNING...

  • Page 17: Premises Wiring

    A-10 CONNECTION OF WELDMARK 225 TO PREMISES WIRING 230 VOLT POWER 230 Volt 60 Hz. COMPANY 3-Wire Service METER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. 50 AMP, 115/230...

  • Page 18: Operation

    GENERAL DESCRIPTION The Weldmark 225 is a twin-cylinder, gasoline driven, multiprocess arc welder and AC power generator. It is built in a heavy gauge steel case for durability on the job site. DESIGN FEATURES AC/DC STICK WELDING (Constant Current) • AC 40 - 225 Amps •...

  • Page 19: Fuel Consumption

    WELDMARK 225 Approximate Fuel Consumption KOHLER CH20S 20 H.P. COMMAND Low Idle - No Load .4 Gallons/Hour 2200 RPM (1.5 Liters/Hour) High Idle - No Load .9 Gallons/Hour 3700 RPM (3.5 Liters/Hour) AC CC Weld Output 1.3 Gallons/Hour 225 Amps @ 25 Volts (5.0 Liters/Hour)

  • Page 20: Starting/Shutdown Instructions

    The engine manufacturer’s recommendation for the running time until the first oil change is ( 5 ) HRS: The oil filter is to be changed at the second oil change. Refer to the Engine Owner’s Manual for more information. WELDMARK 225...

  • Page 21: Welding Process

    “CONTROL” or remote control. For best arc stability, use settings 5 through 10. The Weldmark 225 can be used with a broad range of AC and DC stick electrodes. See “Welding Tips 1” included with the WELDMARK 225 for electrodes within the rating of this unit and recommended weld- ing currents of each.

  • Page 22: Summary Of Welding Processes

    WHEN NOT USED MODE WELDING AUTO HIGH Cold AUTO Cold HIGH Cold WELDMARK 225 TO START WELDING Touch electrode to work. Welding starts immediately and engine goes to high idle. Press Amptrol, contactor closes, welding starts immediately. Press gun trigger, LN-25 contactor closes.

  • Page 23: Optional Equipment

    K936-3 Remote Control Cable - Control cable for connect- ing the K930-2 TIG Module to a Weldmark 225 equipped with a K892-1 Remote Kit. 9-Socket to a grounded 115 V plug and a 6 pin MS-connector. (Contains circuits 2, 4, 31,...

  • Page 24: Recommended Equipment/ Accessories

    K892-1 Remote control Receptacle Kit and K444-1 Remote voltage Control Kit are required for voltage control at the feeder. LN7-K240 Contactor Kit is required. Magnum Gun is required for gas-shielded welding. Innershield Gun is required for gasless welding. ACCESSORIES WELDMARK 225...

  • Page 25: Maintenance

    • Output Selector and Polarity Switch contacts should not be greased. To keep contacts clean, rotate the switch through its entire range frequently. A good practice is to turn the handle from maximum to minimum setting twice each morning before starting to weld. WELDMARK 225 CAUTION...

  • Page 26: Engine Adjustments

    • CONNECTING A BATTERY CHARGER - Remove bat- tery from welder by disconnecting negative cable first, then positive cable and battery clamp. When rein- stalling, connect negative cable last. Keep well venti- lated.

  • Page 27: Troubleshooting

    This column provides a course of action for the Possible Cause, generally it states to contact your local Authorized Field Service Facility. If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Authorized Field Service Facility. CAUTION WELDMARK 225...
  • Page 28 No voltage signal from the current sensor. No open circuit voltage on output studs. Faulty P.C. Board. CAUTION WELDMARK 225 RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Authorized Field...
  • Page 29 Fuel filter clogged. Air filter clogged. Spark plugs do not have specified gap. Spark plugs are fouled. CAUTION WELDMARK 225 RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Authorized Field...
  • Page 30 201A 200B DIAGRAMS WELDMARK 225...
  • Page 31 IN "OUTPUT CONTROL REMOTE" POSITION. CONNECTION OF WELDMARK 225 TO LN-7 & K240 CONTACTOR KIT C O N N E C T I O N O F L N - 7 & K 2 4 0 C O N T A C T O R K I T W I T H 1 1 5 V O L T A C A U X I L I A R Y P O W E R A N D C V O U T P U T C O N T R O L C A B L E N .
  • Page 32 DIAGRAMS WELDMARK 225...
  • Page 33 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 34 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● German ● WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 35 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 36 •Manufactured by Livcoln Electric Company • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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