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WELDMARK 225
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.
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 10992
R
OPERATOR'S MANUAL
• Manufactured by Lincoln Electric Company •
IM806
September, 2005
Copyright © 2005 Lincoln Global Inc.
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Summary of Contents for Lincoln Electric WELDMARK IM806
- Page 1 PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful. 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 IM806 September, 2005...
- 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.
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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.
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Page 7: Table Of Contents
Operation Section B General Description ...B-1 Design Features ...B-1 Other Features...B-1 Engine Features ...B-1 Fuel Consumption...B-2 Controls and Settings ...B-2 Welder / Generator Controls...B-2 Engine Operation...B-3 Starting the Engine ...B-3 Safety Precautions...B-3 Stopping the Engine ...B-3 Break-In Period...B-3 Welding Process...B-4 Duty Cycle ...B-4... -
Page 8: Installation
3600 RPM (Kohler) Full Load 3500 Low Idle 2200 RATED OUTPUT - WELDER Welding Output * AC Constant Current 225A / 25V / 100% DC Constant Current 210A / 25V / 100% DC Constant Voltage 200A / 20V / 100%... -
Page 9: Specifications
SPECIFICATIONS INSTALLATION 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
• Do not ground the machine to a pipe that carries explosive or combustible material. ------------------------------------------------------------------------ When this welder is mounted on a truck or trailer, its frame must be securely connected to the metal frame of the vehicle. Use a #8 or larger copper wire connected between the machine grounding stud and the 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 volt- age drop. -
Page 12: Angle Of Operation
Also, locate the welder so that engine exhaust fumes are properly vented to an outside area. -
Page 13: Connection Of Tig Module
- order kit T12246. INSTRUCTIONS ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the roof and case sides in place as this provides maximum protection from moving parts and assures proper cooling air flow. -
Page 14: Motor Starting
*Current Sensing for Automatic Idle. (Receptacle viewed from front of Machine) 115 V DUPLEX RECEPTACLES The 115V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current load through the associated receptacle (Refer to Table I ). -
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
AUXILIARY POWER WHILE WELDING It must be noted that the above auxiliary power ratings are with no welding load. Simultaneous welding and power loads are permitted by following Table III. The permissible currents shown assume that current is being drawn from either the 115V or 230V supply (not both at the same time). -
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 VOLT PLUG NEMA TYPE 14-50 50 AMP, 115/230 VOLT... -
Page 18: General Description
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
(4.5 Liters/Hour) Auxiliary Power 1.4 Gallons/Hour 8000 Watts (5.3 Liters/Hour) Welder Controls - Function and Operation Explanation of Symbols that Appear on this Equipment Low Idle ENGINE “ON-OFF” Switch When placed in the “ON” position, this switch energizes the engine ignition circuit. When placed in the “OFF”... -
Page 20: Starting The Engine
Starting/Shutdown Instructions Starting the Engine WARNING • Do not touch electrically live parts of electrode with skin or wet clothing. • Keep flammable material away. • Insulate yourself from work and ground. Wear eye, ear, and body protection. • Keep your head out of the fumes. •... -
Page 21: Welding Process
WELDING PROCESS DUTY CYCLE Duty Cycle is the the percentage of time the load is being applied in a 10 minute period. For example, a 60% duty cycle reresents 6 minutes of load and 4 min- utes of no load in a 10 minute period. STICK (CONSTANT CURRENT) WELDING Connect welding cables to the "TO WORK”... -
Page 22: Summary Of Welding Processes
CONTROL PROCESS STICK TIG/K7930-1/K938-1, K936-( ) /K892-1 (WITH AMPTROL) WIRE FEED, LN-25 WITH INTERNAL CONTACTOR WIRE FEED, LN-7 WITH K240 CONTACTOR KIT OPERATION SUMMARY OF WELDING PROCESSES ELECTRODE CABLE IDLE WHEN NOT USED MODE WELDING AUTO HIGH Cold AUTO Cold HIGH Cold WELDMARK 225... -
Page 23: Accessories
K857 25 ft (7.5m) or K857-1 100 ft. (30.4m) REMOTE CON- TROL - Portable control provides same dial range as the output control on the welder. Has a convenient 6 pin plug for easy connection to the welder. K894-1 Spark Arrester Kit - Includes a heavy gauge steel, approved spark arrester and clamp for easy mounting to muffler exhaust pipe. -
Page 24: Recommended Equipment/ Accessories
RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield K892-1 Remote Control Receptacle Kit and K857 Remote Control Kit are optional for remote current control. Magnum™ TIG Torch Magnum Parts Kit and Argon Gas K930-2 TIG Module (requires K938-1 Contactor Kit) K939-3 Control Cable (see Optional Equipment) Optional:... -
Page 25: Maintenance
SAFETY PRECAUTIONS WARNING Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. -
Page 26: Oil Filter Change
Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SG or SH. Always check the API SERVICE label on the oil con- tainer to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for general, all-temper- ature use, -5 F to 104 F (-20 C to 40 C). -
Page 27: 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 28: Gfci Receptacle Testing And Resetting Procedure
GFCI RECEPTACLE TESTING AND RESET- TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage. -
Page 29: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. - Page 30 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) No welder or output power. Engine will not idle down to low speed. Engine will not go to high idle when attempting to weld. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 31 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine will not go to high idle when using auxiliary power. Engine will not crank or is hard to crank. Engine shuts down. Engine does not develop full power. Engine is hard to start. No auxiliary power.
- Page 32 DIAGRAMS 201A 200B WELDMARK 225...
- Page 33 N.B. 3 conductor #16 power cord physically suitable for the installation and plug rated at 115 volts 15 amperes AC. N.C. Plug into 115 volt AC receptacle on welder control panel or other 115 volt AC supply rated at a minimum of 500 volt- amperes.
- Page 34 DIAGRAMS WELDMARK 225...
- Page 35 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 36 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 37 •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...