Lincoln Electric Idealarc Sp 255 Users Manual Im533

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IDEALARC SP-255

OPERATOR’S MANUAL

IM533

June, 1998

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.

For use with machine Code Numbers 10164, 10165

• 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 Premier Manufacturer of Industrial Motors

RETURN TO MAIN MENU

FOR ENGINE

powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes

outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.

Stop the engine and allow it to cool before

refueling to prevent spilled fuel from vaporiz-

ing on contact with hot engine parts and

igniting. Do not spill fuel when filling tank. If

fuel is spilled, wipe it up and do not start

engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing and

tools away from V-belts, gears, fans and all other moving

parts when starting, operating or repairing equipment.

____________________________________________________

1.e. 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.

Always use the greatest care when working near moving

parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or

idler by pushing on the throttle control rods

while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenance

work, disconnect the spark plug wires, distributor cap or

magneto wire as appropriate.

SAFETY

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.

KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you

purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box

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.

WARNING

Mar ‘95

ELECTRIC AND

MAGNETIC FIELDS

may be dangerous

2.a. Electric current flowing through any conductor causes

localized Electric and Magnetic Fields (EMF). Welding

current creates EMF fields around welding cables and

welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right

side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is

hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

are known to the State of California to cause can-

cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

SAFETY

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks and

the rays of the arc when welding or observing

open arc welding. Headshield and filter lens

should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from

the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

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.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of

electrode holders connected to two welders because voltage

between the two can be the total of the open circuit voltage

of both welders.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASES

can be dangerous.

5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases.When welding, keep

your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) or on lead or

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon

vapors

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors

form phosgene, a highly toxic gas, and other irritating

products.

5.c. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,

especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.e. Also see item 1.b. Mar ‘95

FOR ELECTRICALLY

powered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturer’s

recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the

process used and properly operating

regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for

the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely

chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand

tight except when the cylinder is in use or connected for

use.

7.g. Read and follow the instructions on compressed gas

cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association

1235 Jefferson Davis Highway, Arlington, VA 22202.

iii

SAFETY

iii

Mar ‘95

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. Avoid welding near

hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,

special precautions should be used to prevent hazardous

situations. Refer to “Safety in Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the

equipment being used.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact

can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances

inside. They can cause an explosion even

though

they have

been “cleaned”. For information, purchase “Recommended

Safe Practices for the

Preparation

for Welding and Cutting of

Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil

free protective garments such as leather gloves, heavy shirt,

cuffless trousers, high shoes and a cap over your hair. Wear

ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a

welding area.

6.g. Connect the work cable to the work as close to the welding

area as practical. Work cables connected to the building

framework or other locations away from the welding area

increase the possibility of the welding current passing

through lifting chains, crane cables or other alternate cir-

cuits. This can create fire hazards or overheat lifting chains

or cables until they fail.

6.h. Also see item 1.c.

SAFETY

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. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher

metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état

defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder

parce que la tension entre les deux pinces peut être le

total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-électrode s’applicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie

du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray-

onnement de l’arc et des projections quand on soude ou

quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de

soudage. Se protéger avec des vêtements de protection libres

de l’huile, tels que les gants en cuir, chemise épaisse, pan-

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible

de la zone de travail qu’il est pratique de le faire. Si on place

la masse sur la charpente de la construction ou d’autres

endroits éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,

voir le code “Code for safety in welding and cutting” CSA

Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de

l’électricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branché à une

bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-

er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

place.

Mar. ‘93

Thank You 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!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.

The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or

loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to

this equipment.

CAUTION

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.

Please record your equipment identification information below for future reference. This information can be

found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information

you have recorded above.

APR96 IDEALARC SP-255

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1

Safety Precautions.................................................................................................A-2

Uncrating the SP-255 ............................................................................................A-2

Location .................................................................................................................A-2

Input Power, Grounding and Connection Diagrams ..............................................A-2

Output Polarity Connections..................................................................................A-3

Gun and Cable Installation ....................................................................................A-3

Shielding Gas .......................................................................................................A-4

Operation .........................................................................................................Section B

Safety Precautions ................................................................................................B-1

Product Description ...............................................................................................B-2

Recommended Processes and Equipment ...........................................................B-2

Welding Capability.................................................................................................B-2

Limitations..............................................................................................................B-2

Description of Controls and Keys ..........................................................................B-2

Gun Switches.......................................................................................................B-10

Wire Drive Roll.....................................................................................................B-10

Procedure for Changing Drive Roll......................................................................B-10

Wire Reel Loading ...............................................................................................B-10

Mounting of 10 to 44 lbs. Spools .........................................................................B-11

To Start the Welder..............................................................................................B-11

Feeding Electrode................................................................................................B-11

Idle Roll Pressure Setting ....................................................................................B-11

Making a Auto Mode Weld...................................................................................B-12

Spot Weld Mode ..................................................................................................B-13

Stitch Weld Mode.................................................................................................B-13

Avoiding Wire Feeding Problems ........................................................................B-13

Fan Control..........................................................................................................B-13

Input Line Voltage Protection...............................................................................B-13

Wire Feed Overload Protection ...........................................................................B-13

Welding Thermal Overload Protection.................................................................B-14

Overcurrent Protection.........................................................................................B-14

Explanation of Prompting and Error Messages ...................................................B-14

Accessories.....................................................................................................Section C

Drive Roll Kits........................................................................................................C-1

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

(continued)

vii

IDEALARC SP-255

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

General Maintenance ............................................................................................D-1

Drive Rolls and Guide Tubes.................................................................................D-1

Gun Tubes and Nozzles........................................................................................D-1

Cable Cleaning......................................................................................................D-1

Contact Tip and Gas Nozzle Installation ...............................................................D-1

Liner Removal and Replacement ..........................................................................D-2

Gun Handle Disassembly......................................................................................D-3

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

A-1

INSTALLATION

AUG 95 IDEALARC SP-255

75C Copper Wire 75C Copper Wire

in Conduit in Conduit

Input Fuse or Input Ampere AWG (IEC) AWG (IEC)

Voltage/ Breaker Size Rating on Sizes Sizes

Frequency (Super Lag) Nameplate For lengths For lengths Ground Wire

up to 100 ft. exceeding 100 ft.

208 60 53 8 (10 mm2) 6 (16 mm2) #10 (6 mm2)

230 60 50 10 (6 mm2) 8 (10 mm2) #10 (6 mm2)

460 30 25 14 (2.5 mm2) 12 (4 mm2) #10 (6 mm2)

575 25 20 14 (2.5 mm2) 12 (4 mm2) #10 (6 mm2)

TECHNICAL SPECIFICATIONS – IDEALARC®SP-255

INPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

RECOMMENDED INPUT CABLE AND FUSE SIZES

Height Width Depth Weight

28.2 in 18.8 in 40.1 in 222 Ibs

719 mm 480 mm 1019 mm 101 kg

PHYSICAL DIMENSIONS

-20° C TO 40°C ±40°C

OPERATING TEMPERATURE STORAGE TEMPERATURE

Standard Voltage/Frequency Input Current (@ Max Rated Output)

208/230/60 Hz 53/49 Amps

230/460/575 Hz 50/25/20 Amps

Duty Cycle Amps Volts at Rated Amperes

35% 250 Amps 26 Volts

60% 200 Amps 28 Volts

100% 145 Amps 26 Volts

Welding Current Range Maximum Open Circuit Voltage Wire Speed Range

30-250 Amps 40 Volts 50-600 IMP (1.27-15.2 m/min)

A-2 INSTALLATION

IDEALARC SP-255 OCT94

Read entire Installation section before starting

installation.

SAFETY PRECAUTIONS

UNCRATING THE SP-255

Remove the staples from the bottom edge of the car-

ton and lift off. Cut the tape securing the two rear

wheels to the wooden shipping pallet. Using a 1/2 inch

(or 13 mm) wrench or socket, remove the two screws

which attach the pallet to the bottom of the 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

smoke and dirt drawn into the rear louvers reduces

the chance of dirt accumulation that can block air pas-

sages and cause overheating.

INPUT POWER AND GROUNDING

CONNECTIONS

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform

this installation.

• Only personnel that have read and under-

stood the SP-255 Operating Manual should

install and operate this equipment.

• Machine must be plugged into a receptacle

which is grounded per any national, local

or other applicable electrical codes.

• Turn the power switch on the SP-255 “off”

before connecting or disconnecting gun

and cable, output cables or other equip-

ment.

WARNING

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such as

output terminals or internal wiring

•All input power must be electri-

cally disconnected before

proceeding.

WARNING

1. Before starting the installation, check with the local

power company if there is any question about

whether your power supply is adequate for the volt-

age, amperes, phase, and frequency specified on

the welder nameplate. Also, be sure the planned

installation will meet the U.S. National Electrical

Code and local code requirements. This welder

may be operated from a single phase line or from

one phase of a two or three phase line.

2. Models that have multiple input voltages specified

on the nameplate (e.g., 208/230) are shipped con-

nected for the higher voltage. If the welder is to be

operated on lower voltage, it must be reconnected

according to the instructions on the inside of the

removable panel near the top left side of the rear

panel. These instructions are repeated below:

Make certain that the input power is electrically

disconnected before removing the screw that

holds the removable rear panel in place.

3. The 208/230 volt 60 Hz model SP-255 is shipped

with a 10 ft. (3.0 m) input cable and plug connected

to the welder. A matching receptacle is supplied

with the machine. Mount the receptacle in a suit-

able location using the screws provided. Be sure it

can be reached by the plug on the input cable

attached to the welder. Mount with the grounding

terminal at the top to allow the power cable to hang

down without bending.

WARNING

The 230/460/575 volt 60 Hz model is not equipped

with a plug, input cable or receptacle.

4. Using the following instructions have a qualified

electrician connect the receptacle or cable to the

input power lines and the system ground per the

U.S. National Electrical Code and any applicable

local codes. See the “Technical Specifications”

page at the beginning of this chapter for proper

wire sizes. For long runs over 100 feet (30 m), larg-

er copper wires should be used. Fuse the two hot

lines with super lag type fuses as shown in the fol-

lowing diagram. The center contact in the recepta-

cle is for the grounding connection. A green wire in

the input cable connects this contact to the frame

of the welder.

This ensures proper grounding of the welder frame

when the welder plug is inserted into the

receptacle.

CONNECT TO A SYSTEM GROUND-

ING WIRE. SEE THE UNITED STATES

NATIONAL. ELECTRICAL CODE

AND/OR LOCAL CODES FOR OTHER

DETAILS AND MEANS FOR PROPER

GROUNDING.

CONNECT TO HOT WIRES OF A

THREE-WIRE, SINGLE PHASE SYS-

TEM OR TO ONE PHASE OF A TWO

OR THREE PHASE SYSTEM.

A-3

INSTALLATION

IDEALARC SP-255

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. The electrode

cable, which is attached to the wire drive, is to be con-

nected to the negative (–) labeled terminal and the

work lead, which is attached to the work clamp, is to

be connected to the positive (+) labeled terminal.

GUN AND CABLE INSTALLATION

The Magnum™ 250SP gun and cable provided with

the SP-255 is factory installed with a liner for .035-

.045" (0.9-1.2 mm) electrode and an .035" (0.9 mm)

contact tip. Install the .045 tip (also provided) if this

wire size is being used. For other wire sizes, see Gun

and Cable Maintenance.

Turn the welder power switch off before installing

gun and cable.

1. Lay the cable out straight.

2. Make sure all pins on the gun cable connector are

aligned with the proper mating sockets on the front

panel gun connector and then join the connectors

and tighten the hand nut on the gun cable connec-

tor.

NOTE: If a gun and cable other than the Magnum

250SP is to be used, it must conform to standard

European-style connector (Magnum Fast-Mate™)

specifications. See diagram below.

SINGLE PHASE INPUT SUPPLY RECONNECT DIAGRAM FOR 230/460/575 60 HZ MACHINES

TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE INSTALLING

OR SERVICING THIS MACHINE.

DO NOT TOUCH ELECTRICALLY "HOT" PARTS SUCH AS OUTPUT TERMINALS

OR INTERNAL WINDINGS.

GROUNDING SCREW MUST BE CONNECTED TO A GOOD EARTH GROUND PER

NATIONAL ELECTRICAL CODE.

DO NOT OPERATE WITH COVERS REMOVED.

ONLY QUALIFIED PERSONNEL SHOULD INSTALL OR SERVICE THIS EQUIPMENT.

WARNING

HIGH VOLTAGE

can kill

1. ALL MACHINES ARE SHIPPED FROM THE FACTORY CONNECTED FOR THE HIGHEST NAMEPLATED SINGLE PHASE

INPUT VOLTAGE. TO CHANGE CONNECTIONS FOR A DIFFERENT INPUT VOLTAGE. RECONNECT BOTH COPPER

JUMPERS PER DIAGRAM BELOW. ALWAYS CONNECT JUMPERS BETWEEN OUTER STEEL NUT AND

INNER BRASS NUT ON TERMINAL STUDS.

2. CONNECT THE INPUT POWER TO THE INPUT TERMINAL BLOCK, L1 AND L2 AT THE UPPER LEFT CORNER OF

THE PANEL. TORQUE TO 16 IN-LBS.

3. CONNECT A GROUNDING LEAD TO THE GROUND STUD ON THE MACHINE NEAR THE INPUT TERMINAL BLOCK.

SINGLE PHASE

VOLTAGE

JUMPER

CONNECTION

DIAGRAMS

230V / 60HZ. 460V. / 60HZ. 575V. / 60HZ.

BOTH

JUMPERS

TO GROUND PER NATIONAL ELECTRICAL CODE

SINGLE PHASE INPUT POWER SUPPLY LINES

S21531-1

L1 L2 L1 L2 L1 L2

WARNING

A-4 INSTALLATION

IDEALARC SP-255 OCT94

However, the thumbswitch functions available on

the Magnum 250SP gun will only be operable from

the front panel keypad. The gun trigger switch must

be capable of switching 5 milliamps at 15 volts

DC– resistive.

The gun trigger switch connected to the gun trig-

ger control cable must be a normally open,

momentary switch. The terminals of the switch

must be insulated from the welding circuit.

Improper operation of or damage to the SP-255

might result if this switch is common to an electri-

cal circuit other than the SP-255 trigger circuit.

SHIELDING GAS

(For Gas Metal Arc Welding Processes)

Customer must provide cylinder of appropriate type

shielding gas for the process being used.

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. Remove dust and dirt with a clean cloth.

DO NOT ATTACH THE REGULATOR IF OIL,

GREASE OR DAMAGE IS PRESENT! Inform your

gas supplier of this condition. Oil or grease in the

presence of high pressure oxygen is explosive.

3. Stand to one side away from the outlet and open

the cylinder valve for an instant. This blows away

any dust or dirt which may have accumulated in the

valve outlet.

Be sure to keep your face away from the valve

outlet when “cracking” the valve.

4. Inspect the regulator for damaged threads, dirt,

dust, oil or grease. Remove dust and dirt with a

clean cloth.

DO NOT USE THE REGULATOR IF OIL,

GREASE OR DAMAGE IS PRESENT! Have an

authorized repair station clean the regulator or

repair any damage.

5. Attach the flow regulator to the cylinder valve and

tighten the union nut(s) securely with a wrench.

NOTE: If connecting to 100% CO2cylinder, insert

regulator adapter provided between regulator and

cylinder valve. If adapter is equipped with a plastic

washer, be sure it is seated for connection to the

CO2cylinder.

6. Attach one end of the inlet gas hose to the outlet

fitting of the flow regulator, the other end to the SP-

255 rear fitting, and tighten the union nuts securely

with a wrench.

7. Before opening the cylinder valve, turn the regula-

tor adjusting knob counter-clockwise until the

adjusting spring pressure is released.

8. Open the cylinder valve slowly a fraction of a turn.

When the cylinder pressure gauge pointer stops

moving, open the valve fully.

Never stand directly in front of or behind the flow

regulator when opening the cylinder valve. Always

stand to one side.

9. The flow regulator is adjustable. Set it for the flow

rate recommended for the procedure and process

being used before making the weld.

CAUTION

CYLINDER may explode if

damaged.

Gas under pressure is explosive.

Always keep gas cylinders in an

upright position and always keep

chained to undercarriage or stationary support.

See American national Standard Z49.1, “Safety in

Welding and Cutting” published by the American

Welding Society.

WARNING

Gun - END VIEW

IDEALARC SP-255

B-1

OPERATION

Read entire Operation section before

operating the SP-255.

ELECTRIC SHOCK can kill.

• Do not touch electrically live

parts or electrode with skin or

wet clothing. Insulate yourself

from work and ground.

• Always wear dry insulating

gloves.

FUMES AND GASES can be

dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to

remove fumes from breathing

zone.

WELDING SPARKS can

cause fire or explosion.

• 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.

WARNING

IDEALARC SP-255

B-2 OPERATION

PRODUCT DESCRIPTION

The SP-255 is a complete semiautomatic constant

voltage DC arc welding machine built to meet NEMA

specifications. It combines a constant voltage power

source and a constant speed wire feeder with a micro-

computer-based controller. This forms an intelligent

welding system that really puts the automatic in semi-

automatic. A touch key entry system with audible

feedback, along with a two-line, 32 character alphanu-

meric display provide user friendly control of the sys-

tem.

Multilingual display capability allows the SP-255 to

communicate with the user in any of the following lan-

guages: English, German, French, Spanish, or

Japanese (Katakana).

RECOMMENDED PROCESSES AND

EQUIPMENT

The SP-255 is recommended for GMA welding

processes using 10 to 44 lb. (4.5 to 20 kg) 2" (51 mm)

I.D. spools or Readi-Reel®coils of .025 through .045

(0.6-1.2 mm) solid steel using CO2, ArCO2, or ArO2

shielding gas, .035" (0.9 mm) stainless steel using

ArO2or HeArCO2shielding gas, 3/64" (1.2 mm) alu-

minum using Ar shielding gas, and .045" (1.2 mm)

Outershield®electrodes using CO2or ArCO2shielding

gas, as well as .035" (0.9 mm) and .045" (1.2 mm)

Innershield®self-shielded electrodes.

The SP-255 is factory equipped to feed .035" (0.9

mm) and .045" (1.2 mm) electrodes and includes a

200A, 60% duty cycle rated, 12.5 ft. (3.8 m) GMA gun

and cable assembly equipped for these wire sizes.

The SP-255 is factory equipped with an adjustable

CO2and Argon blend flow regulator. A supply of

shielding gas is required for GMAW processes.

WELDING CAPABILITY

The SP-255 is rated at 250 amps @ 26 volts at a 35%

duty cycle on a ten minute basis. 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.

DESCRIPTION OF CONTROLS AND

KEYS

POWER SWITCH

Place the lever in the “ON” position to turn the SP-255

on. When the power is on, the red LED backlighting of

the LCD display will be lit, and the screen will contain

a readable display. The welding setup present when

the power was shut off or disconnected will be

restored when the power is restored.

SETUP KEYS

DISPLAY LANGUAGE SELECTION

The SP-255 has multilingual display capability permit-

ting the SP-255 prompts, messages, and other display

information to be in any of five languages: English,

German, French, Spanish, and Japanese (Katakana).

The user may select the chosen language by simulta-

neously pressing the PROCESS Key and the appro-

priate Number Key per the instructions given in the

appropriate language on the Keypad Instruction Decal

inside the SP-255 door, also shown below:

ARROW KEYS

There are three pairs of arrow keys: left, center, and

right. The up arrow keys increase the selection dis-

played directly above them. The down arrow keys

decrease the selection displayed directly above them.

All of the arrow keys have a repeat function when they

B-3

OPERATION

JAN96 IDEALARC SP-255

are held closed. The left pair will automatically contin-

ue to increment or decrement the selection above it at

a slow, steady rate as long as the key is pressed. The

center and right pairs will continue to increment and

decrement the selections above them at a slow rate,

but then the rate will gradually increase until it

becomes very rapid. This allows rapid setting from a

small quantity to a large quantity or vice versa while

maintaining an excellent resolution (i.e., 50 IPM to 600

IPM). However, when the trigger is closed, the

changes will be at a steady, moderate rate to allow for

proper “on the fly” control.

START MODE SELECTIONS

The SP-255 permits selection of Fast/Slow Run-In

wire feed speed as well as adjustment of the start

striking voltage, to optimize arc starting, using the

starting screen display.

The starting screen (see Figures below) is

displayed by pressing and holding both the

PROCESS key and the TIMERS OFF key at

the same time.

FIGURE 1

1. Run-In Speed

The SP-255 is factory set for FAST run-in

(Figure 1) where the wire feed will accelerate

directly to the preset speed. SLOW run-in will

initially feed at 50 IPM until welding current is

sensed, or for 2 seconds if feeding without

welding (loading wire).

SLOW run-in may be selected using the left

arrow keys which will toggle the starting screen

display to SLOW (Figure 2) or back to FAST

(Figure 1).

FIGURE 2

2. Start Voltage

The START voltage setting (Figure 1 or 2) may

be offset from the factory programmed level

(00%) by up to ±30% above or below pro-

grammed level using the right arrow keys, or

from the gun thumbswitch by positioning the

screen cursor beneath the START display using

the IPM-VOLTS key. (see “Gun Switch Keys” in

this section).

3. Spool Gun Start Mode

If using optional spool gun mode (see “Making

a Weld with the Spool Gun” in Accessories sec-

tion), the RUN-IN portion of the starting screen

is not functional and will not be displayed. The

START voltage is adjusted as described above

(Figure 3).

FIGURE 3

The starting screen is exited by pressing any

key on the keypad except TIMERS OFF, IPM-

VOLTS or any Arrow key. Closing Gun Trigger

will also not clear the starting screen.

NOTE: It is not necessary to repeat the above

procedure each time the unit is powered up.

That is, the unit will remember the start mode

settings from the previous power down and

return you to that same state upon your next

power up. thus, you need only perform the

above procedure when you want to change the

start mode settings.

When saving to Memory locations 1-5, the start

mode at the time of saving will be saved into

the memory location as well. Thus, the operator

should be aware that when recalling a memo-

rized procedure, he is also recalling particular

start mode which will override any present start

mode setting and remain in effect until either

the mode is changed using the above proce-

dure or until a memorized procedure containing

another start mode is recalled.

PROCESS (WIRE/GAS) KEY

This key is used to display the Wire Type, Wire

Diameter, and Welding Gas. Each combination of wire

and gas dictates a unique relationship between the

wire feed speed and the arc voltage. The SP-255

uses this unique relationship, along with the metal

thickness, to set the proper values of wire feed speed

and arc voltage. 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

B-4 OPERATION

IDEALARC SP-255

Center arrow keys—set Wire Diameter

Right arrow keys—set Welding Gas

The following 16 processes are programmed into the

SP-255:

PROCEDURE KEYS

AUTO KEY

Pressing the Auto Key once places the SP-255 into

the automatic mode of operation. Auto mode provides

automatic setup of the recommended wire feed speed

and arc voltage based on the metal thickness selected

and the process being used. The Auto mode screen

displays metal thickness, set wire feed speed, the set

arc voltage, and a cursor that indicates which parame-

ter, wire feed speed, or arc voltage is being controlled

by the thumbswitch on the SP-255 gun (see Gun

Switches section).

Left arrow keys — Increases (up arrow) or

decreases (down arrow) metal thickness setting.

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

available sizes. (NOTE: If the spot or stitch timers are

on, metal thickness is not displayed and, therefore,

the left arrow keys will not function. Also, the left arrow

keys do not function when the trigger is closed. (See

Figures I and 2 following.)

Center arrow keys — Increases (up arrow) or

decreases (down arrow) wire feed speed setting.

Increasing or decreasing wire feed speed will

simultaneously cause an increase or decrease in

the arc voltage and can change the metal thick-

ness setting.

Right arrow keys — Increases (up arrow) or

decreases (down arrow) arc voltage setting. An up

arrow indicator appears below the V in VOLTS if

the arc voltage has been set higher than the rec-

ommended value, and a down arrow indicator

appears below the V in VOLTS if the arc voltage is

below the recommended value. No arrow indicates

that you are set to the recommended value. (See

Figures 4 and 5 following.)

Repressing the Auto key resets the wire feed speed

and arc voltage settings to the recommended values

for the metal thickness displayed. (NOTE: If the spot

or stitch timers are on, metal thickness is not dis-

played and, therefore, the repress function does not

work.)

TYPICAL AUTO KEY PRESS SEQUENCES

Process screen is being displayed prior to pressing

Auto key. The Auto key is pressed, the Auto screen is

now displayed.

If the unit was in a Manual configuration (see Manual

Key) when the Auto key was pressed, the audio alarm

will beep three times and a message (see below) will

be displayed for 2.5 seconds reminding you that the

process entered into the SP-255 (see Process Key)

must match the wire and gas being used. After the 2.5

second period is over, the Auto screen will be dis-

played with the same procedure that was in Manual.

Wire Type Wire Diameter Welding Gas

Solid Steel

Stainless

Aluminum (5356)

Outershield®

Outershield

Innershield®

Innershield

.025 (0.6mm)

.030 (0.8mm)

.035 (0.9mm)

.045 (1.2mm)

.035 (0.9mm)

3/64” (1.2mm)

.045 (1.2mm)

.035 (0.9mm)

.045 (1.2mm)

CO2

ArCO2

CO2

ArCO2

CO2

ArCO2

ArO2

CO2

ArCO2

ArO2

HeArCO2

Argon

CO2

Ar/CO2

None

Because design, fabrication, assembly and

welding variables affect the results obtained in

applying recommended procedure information,

the serviceability of a product or assembly is

the responsibility of the builder/user.

Figure 4 Figure 5

B-5

OPERATION

IDEALARC SP-255

Repressing the Auto Key sets the recommended pro-

cedure for the metal thickness displayed.

MANUAL KEY

Permits individual setting of wire feed speed and arc

voltage for manual procedure setup. The manual

screen displays wire feed speed, arc voltage, and a

cursor that indicates which parameter, wire feed

speed, or arc voltage is being controlled by the thumb-

switch on the SP-255 gun (see “Gun Switches” in

operation section).

Left arrow keys — Do not function in Manual mode.

Center arrow keys — Increase (up arrow) or

decrease (down arrow) wire feed speed.

Right arrow keys — Increase (up arrow) or

decrease (down arrow) arc voltage.

If the spot or stitch timers are on it will be indicated in

the bottom left corner of the display. (See Figures 6

and 7 below.)

TYPICAL MANUAL KEY PRESS SEQUENCE

Auto screen is being displayed prior to pressing

Manual key. The Manual key is pressed, the Manual

screen is now displayed. The procedure is the same

that was in Auto.

MEMORY KEYS

SAVE KEY

Saves present setup (including process, procedure,

and timer functions, if used) to one of five memories

chosen by pressing the desired memory number key.

When the Save key is pressed, a prompting message

instructing the operator to “PRESS MEMORY 1-5 TO

SAVE SETUP” is displayed. This message will stay on

the display until a memory number key is selected or

one of the other keys, such as Auto, Manual, or

Process, is pressed. If a memory number key is

selected, a message will be displayed for 2.5 seconds

that confirms that the setup was saved to that memory

number (see Key Press Sequence following).

The six arrow keys perform no function when saving a

setup.

NOTE: When a setup is saved to a memory, the previ-

ous content of that memory is lost because it is

replaced by the present setup. Removing input power

does not affect setups In memory.

TYPICAL SAVE KEY PRESS SEQUENCE

Auto screen displayed prior to pressing Save key.

Save key is pressed, and display changes to prompt-

ing message. Memory 1 key is pressed, and the dis-

play changes to a message that confirms the setup

was saved to memory 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).

Figure 6 Figure 7

B-6 OPERATION

IDEALARC SP-255 OCT94

The six arrow keys perform no function during a recall.

NOTE: The presently displayed setup is lost because

it is replaced by the setup recalled from memory. If

you wish to save the present setup, save it to an

unused memory first (see Save key), and then recall

the memory required.

TYPICAL MEMORY NUMBER KEY PRESS

SEQUENCE

Manual screen displayed prior to pressing Memory

Number key. Memory Number key is pressed, the dis-

play changes to the Auto setup that was in memory 1.

If the memory is empty (contains no setup yet), then a

message indicating that (see below) will be displayed

when the Memory Number key is pressed. The mes-

sage will be displayed for 2.5 seconds, and then the

display will change to the original display before the

Memory Number key was pressed.

If the setup in memory is an Auto mode type and it

requires a different wire type, wire size, or welding

gas, the display will alternate messages (see below),

once the Memory Number is pressed. The first mes-

sage will tell you what process is required, and the

second message will tell you to press the Process key

once you have installed the process required into the

SP-255. Once the required process has been

installed, press the 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.

TIMER KEYS

SPOT KEY

Turns on the Spot weld timer and displays selection of

the spot ON time. Pressing the Spot key a second

time returns the screen to the previous display without

turning off the spot timer Any time the Spot weld timer

is on and the display is in the Auto or Manual mode,

the word SPOT will appear in the bottom left corner of

the display.

Left arrow keys — Do not function.

Center arrow keys — Increase (up arrow) or

decrease (down arrow) Spot ON time in seconds

(0.20 to 2.50s).

Right arrow keys — Do not function.

TYPICAL SPOT KEY PRESS SEQUENCE

Auto screen is displayed prior to pressing Spot key.

Spot key is pressed, Spot On timer is activated and

the display changes to Spot screen. Spot ON timer

can now be adjusted using the center arrow keys.

Once the timer has been set, pressing the Spot key

again returns the display to the original Auto screen

with the Spot timer status indicated in the bottom left

corner.

B-7

OPERATION

IDEALARC SP-255

STITCH KEY

Turns on the Stitch weld timers and displays selec-

tions of the stitch ON and OFF times. Pressing the

Stitch key a second time returns the screen to the

previous display without turning off the stitch timers.

Any time the Stitch weld timers are on and the display

is in the Auto or Manual mode, the abbreviation STCH

will appear in the bottom left corner of the display.

Left arrow keys — Do not function.

Center arrow keys — Increase (up arrow) or

decrease (down arrow) Stitch ON time in seconds

(0.20 to 2.50s).

Right arrow keys — Increase (up arrow) or

decrease (down arrow) Stitch OFF time in seconds

(0.20 to 2.50s).

TYPICAL STITCH KEY PRESS SEQUENCE

Auto screen is displayed prior to pressing Stitch key.

Stitch key is pressed, Stitch timers are activated and

the display changes to Stitch screen. Stitch ON and

OFF timers can now be adjusted using the center and

right arrow keys. Once the timers have been set,

pressing the Stitch key again returns the display to

the original Auto screen with the Stitch timer status

indicated in the bottom left corner.

TIMERS OFF KEY

Turns off both Spot and Stitch timers and removes

their indicating letters from the bottom left corner of

the Auto and Manual mode displays.

The six arrow keys do not function with this key.

TYPICAL TIMERS OFF KEY PRESS SEQUENCE

Auto screen is displayed prior to pressing Timers Off

key. Timers Off key is pressed, all timers are turned

off, and the display no longer indicates in the bottom

left-hand corner that any timers are on. (Timer status

is replaced by gauge in the Auto mode.)

GUN SWITCH KEYS

IPM VOLTS KEY

Sets the gun thumbswitch to control IPM or VOLTS.

Pushing the gun thumbswitch forward (toward the tip)

increases and pulling it back decreases IPM or

VOLTS. The underlining cursor always indicates the

selection being controlled by the gun thumbswitch. If

the cursor is not present, the gun thumbswitch will not

be functional which prevents any inadvertent actua-

tions. Each time this key is pressed, it causes the cur-

sor to go to the next step in the following sequence

IPM to VOLTS to no cursor to IPM to VOLTS, etc.

NOTE: In Auto mode, changing IPM will change arc

voltage also and can cause a change in metal thick-

ness as well.

TYPICAL IPM VOLTS KEY PRESS SEQUENCE

Auto screen is displayed prior to pressing IPM VOLTS

key. IPM VOLTS key is pressed, cursor moves from

under 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

B-8 OPERATION

IDEALARC SP-255

The first time this key is pressed it turns on toggle

mode and recalls the setup in memory 4. This mode

allows you to toggle between the setups in memory 4

and memory 5. Each time the key is pressed, it alter-

nates between the two memories. The toggle screen

displays the memory number the current setup was

recalled from, indicates automatic (AUTO:) or manual

(MAN:) mode, displays gauge if in Auto mode, set

wire feed speed, and set arc voltage. The cursor

underlines the memory number currently selected.

If in AUTO mode, an up or down arrow which shows

whether the arc voltage has been adjusted above or

below the recommended level can also be on the dis-

play (see “Procedure Keys” in operation section). Also

Spot or Stitch timer status will be displayed in the

lower left-hand corner if either timer is active.

The gun thumbswitch functions as a Toggle key in

Toggle mode. Pushing the gun thumbswitch forward

(toward the tip) selects the setup in memory 5, and

pulling it back selects the setup in memory 4 (see

Gun Thumbswitch Section). The gun thumbswitch

also functions with the trigger closed for “on the fly”

changes during a weld.

To turn toggle mode off, press Auto, Manual, or any

Memory Number key.

Any changes made to settings in toggle mode are

not automatically saved when power is removed,

or if toggle mode is turned off. To save these

changes, press the Save key and then the memo-

ry number key that was currently displayed on the

toggle screen (4 or 5), “toggle” then press the

Save key and then the other Memory Number key

that was displayed after the toggle (5 or 4). When

power is returned, the machine will not be in tog-

gle mode, but will contain the settings present

when power was removed so you may continue to

weld right where you left off or press Toggle key

to return to toggle mode.

Left arrow keys — If metal thickness is displayed,

these keys will increase (up arrow) or decrease

(down arrow) it; otherwise, they perform no func-

tion.

Center arrow keys — Increases (up arrow) or

decreases (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

metal thickness setting.

Right arrow keys — Increases (up arrow) or

decreases (down arrow) arc voltage setting. If in

Auto mode, an up arrow indicator appears below

the V in VOLTS if the arc voltage has been set

higher than the recommended value, and a down

arrow indicator appears below the V in VOLTS if

the arc voltage is below the recommended value.

No arrow indicates that you are set to the recom-

mended value.

TYPICAL TOGGLE KEY PRESS SEQUENCE

Auto screen is displayed prior to pressing Toggle key.

Toggle key is pressed, memory 4 is recalled and

appears on the display. The unit is now in toggle

mode. Pressing the Toggle key again or pushing the

gun thumbswitch forward (toward the gun tip) “tog-

gles” the unit, and memory 5 is recalled and appears

on the display. Pressing the Toggle key again or

pulling the gun thumbswitch back (toward the gun

cable) “toggles” the unit, and memory 4 is recalled

and appears on the display. This whole cycle is

repeatable as long as the unit remains in Toggle

mode.

When the Toggle key is pressed and the setup in

memory 4 or 5 is an Auto mode type and it requires a

different wire type, wire diameter, or welding gas, a

message (see below) will be displayed for 2.5 sec-

onds telling you which memory does not match the

process set in the machine, and then the screen will

return to the previous display. In order to see what

process is required, press the Memory Number key of

CAUTION

B-9

OPERATION

IDEALARC SP-255

the one that did not match (see Memory Number Key

Section).

4-STEP TRIGGER INTERLOCK KEYS

Pressing and

Controls whether 4-step trigger interlock is activated

or deactivated. (See “Using 4-Step Trigger Interlock

Function” section.)

NOTE: 4-Step Trigger is automatically deactivated if

either the spot or stitch timer mode is being used.

TYPICAL ACTIVATE KEY PRESS SEQUENCE

Auto screen is displayed prior to pressing keys.

Process key is pressed and held, then Toggle key is

pressed. The auto screen now displays the 4T symbol

in the upper left corner indicating that the 4-step trig-

ger interlock is now active.

TYPICAL DEACTIVE KEY PRESS SEQUENCE

Auto screen is displayed prior to pressing keys.

Process key is pressed and held, then Toggle key is

pressed. The 4T symbol is no longer displayed in the

upper left corner indicating that the 4-step trigger

interlock no longer functions.

USING 4-STEP TRIGGER INTERLOCK

FUNCTION

When the function is deactivated, the trigger will func-

tion in the normal mode which welds only when the

trigger is closed.

When activated, the trigger will function as follows:

Once the arc has been struck, the gun trigger may

be released and the welding will continue until

welding is stopped by either of two methods:

1. The arc is extinguished by manually jerking the

gun away from the work.

2. The gun trigger is depressed before the end of

the weld returning the trigger function to normal

mode so the weld will be stopped when the trig-

ger is released. Releasing the trigger reinstates

the trigger interlock function for the next weld.

The second trigger interlock stopping method per-

mits the user better control at the finish of the weld

and allows automatic burnback to prevent exces-

sive wire feed speed overrun.

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.)

B-10 OPERATION

IDEALARC SP-255

GUN SWITCHES

Gun Trigger Switch — Turns on arc voltage, wire

feeder, and gas solenoid (except with Innershield)

when closed. Also causes the screen to display the

Auto or Manual screens (depending on which mode it

is in), when the trigger is pulled. Turns off arc voltage,

wire feeder, and gas solenoid when opened.

NOTE: If using Slow Run-In, when the trigger is

pulled, the wire feeder feeds wire a low speed regard-

less of the set wire feed speed until the welding arc

starts or 2 seconds has elapsed. This feature

enhances starting and makes it easier to set the stick-

out. The 2 second limit permits high speed loading of

the gun and cable. To change Run-In mode, see

“Start Mode Selections” in this section.

Gun Thumbswitch (Magnum™ 250SP Only) —

Used to control wire feed speed, arc voltage, or selec-

tion of toggle memories 4 and 5. See IPM VOLTS key

and Toggle key for control details. The increase or

decrease function of the thumbswitch is the same as

the center and right arrow key pairs for IPM or VOLTS

setting. (See Arrow keys in “Setup Keys” section

for details.)

WIRE DRIVE ROLL

The drive roll provided with the SP-255 has two

grooves, one for .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. If .045" (1.2 mm) electrode is to be used or

one of the optional drive rolls is required (see

Accessories section). The drive roll must be reversed

or changed.

PROCEDURE FOR CHANGING

DRIVE ROLL

Different wire sizes may require changing the drive

roll. The applicable wire sizes are stamped on the

drive roll. Dual groove rolls must be installed so the

side with the proper wire size stamp faces out.

1 Turn off the power source.

2. Release the pressure on the idle roll by swinging

the pressure arm off the idle roll arm.

3. Remove the wire from the drive system.

4. Remove the thumbscrew from the drive roll. Turn

the drive roll over or change to another roll as

required. Reinstall the thumbscrew.

5. Be sure the gun liner and contact tip are properly

sized for wire being used. (See Gun and Cable

Maintenance section.)

WIRE REEL LOADING

MOUNTING OF 22 TO 30 LB. READI-

REELS

To mount a 22-30 Ib. (10-14 kg) Readi-Reel®pack-

age using the optional Readi-Reel Adapter

(K363P).

1. Remove the locking collar from the 2" O.D. spindle

and mount the K363P Adapter so the spindle pin

engages the hole provided in the Adapter. Replace

and tighten the locking collar.

2. Rotate the spindle and adapter so the retaining

spring is at the 12 o’clock position.

3. Position the Readi-Reel so that it will rotate in a

counterclockwise direction (as viewed from

retaining spring side of Adapter) when wire is

dereeled from the top of the coil as shown below:

4. Set one of the Readi-Reel inside cage wires on the

slot in the retaining spring tab.

5. Lower the Readi-Reel to depress the retaining

spring and align the other inside cage wires with

the grooves in the molded adapter.

6. Slide cage all the way onto the adapter until the

retain spring “pops up” fully.

MOLDED ADAPTER

RETAINING SPRING

BRAKE TENSION

ADJUSTING SCREW

2" O.D. SPINDLE LOCKING COLLAR

READI-REEL

INSIDE CAGE WIRES

WIRE DEREELING

DIRECTION

B-11

OPERATION

IDEALARC SP-255

Check to be sure the retaining spring has fully

returned to the locking position and has

securely

locked the Readi-Reel cage in place. Retaining

spring must rest on the cage not the welding elec-

trode.

To remove Readi-Reel from Adapter, depress retain-

ing spring tab with thumb while pulling the Readi-Reel

cage from the molded adapter with both hands. It is

not necessary to remove adapter from spindle.

MOUNTING OF 10 TO 44 LBS. SPOOLS

To mount 10 to 44 lb. spools (8" and 12" diame-

ter): (For 8" spools a K468 adapter must be used.)

1. Remove the locking collar and the Readi-Reel

adapter (if installed) from the 2" dia. spindle.

2. If using an 8" spool, place the K468 adapter on the

spindle first. The hole in the adapter arm is to

engage the pin on the spindle.

3. Place the spool on the spindle making certain the

brake driving pin enters one of the holes in the

back side of the spool. Be certain the wire comes

off the reel in a clockwise direction when dereeled

from the top of the coil.

4. Replace and tighten the locking collar for several

seconds.

TO START THE WELDER

Turn the “Power” switch to “ON” This lights the red

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

When inching, the electrode and drive mechanism

are always “hot” to work and ground and remain

“hot” several seconds after the gun trigger is

released.

NOTE: Check that drive rolls and gun parts are proper

for the wire size and type being used. (Refer to

Accessories section.)

1. Turn the Readi-Reel or spool until the free end of

the electrode is accessible.

2. While securely holding the electrode, cut off the

bent end and straighten the first six inches (152

mm). Cut off the first inch (25 mm). (If the electrode

is not properly straightened, it may not feed or may

not go into the outgoing guide tube causing a

“birdnest”)

3. Push the wire through the guide tubes and close

the idle roll assembly. For idle roll pressure set-

tings, see Idle Roll Pressure Setting Section below.

4. Turn “OFF” weld timers by pressing TIMERS OFF

key. Press the gun trigger and push the electrode

into the drive roll. If the electrode fails to thread

itself into the outgoing guide tube of the wire drive,

open the quick release idle roll arm, thread the

electrode manually, and reclose the arm.

5. Inch the electrode through the gun.

NOTE: If using the low speed starting feature of

the SP-255, the wire will feed at low speed for 2

seconds while inching, then come up to the set

speed.

6. Check that the welding process is set for the wire

type, diameter, and gas per instructions on name-

plate.

IDLE ROLL PRESSURE SETTING

The idle roll pressure thumbscrew is set at the factory

backed out 2-1/2 turns from full pressure. This is an

approximate setting. The optimum idle roll pressure

varies with type of wire, wire diameter, surface condi-

tion, lubrication, and hardness. As a general rule, hard

wires may require greater pressure, and soft, or alu-

minum wire, may require less pressure than the facto-

ry setting. The optimum idle roll setting can be deter-

mined as follows:

1. Press end of gun against a solid object that is elec-

trically isolated from the welder output and press

the gun trigger for several seconds.

2. If the wire “birdnests,” jams or breaks at the drive

roll, the idle roll pressure is too great. Back the

thumbscrew out 1/2 turn, run new wire through

gun, and repeat above steps.

WARNING

B-12 OPERATION

IDEALARC SP-255 OCT94

3. If the only result was drive roll slippage, loosen the

gun cable Fast-Mate™ connection nut from the

front of the SP-255 and pull the gun cable forward

about 6” (152 mm). There should be a slight wavi-

ness in the exposed wire. If there is no waviness,

the pressure is too low. Tighten the thumbscrew

1/4 turn, lock the gun cable in place and repeat the

above steps.

MAKING AN AUTO MODE WELD

1. Check that the polarity is correct for the process

being used, then turn power switch ON.

2. Press then select:

3. Press then select:

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:

Press again to return to previous

display.

4.b.Press then select:

Press again to return to previous

display.

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

inch (19 mm) for Outershield®electrodes].

6. If welding gas is to be used, turn on the gas sup-

ply and set the required flow rate [typically 25-35

CFH (12-16.5 I/min)].

7. When using Innershield®electrode, the gas noz-

zle may be removed from the insulation on the

end of the gun and replaced with the gasless noz-

zle. This will give improved visibility and eliminate

the possibility of the gas nozzle overheating.

8. Connect work clamp to metal to be welded. Work

clamp must make good electrical contact to the

work. The work must also be grounded as stated

in “Arc Welding Safety Precautions”.

When using an open arc process, it is necessary

to use correct eye, head, and body protection.

9. Position electrode over joint. End of electrode

may be lightly touching the work.

10. Lower welding helmet, close gun trigger, and

begin welding. Hold the gun so the contact tip to

work distance is about 3/8 inch (9.5 mm), [3/4

inch (19 mm) for Outershield electrodes].

11. To stop welding, release the gun trigger and then

pull the gun away from the work after the arc goes

out.

WARNING

B-13

OPERATION

IDEALARC SP-255

12. When no more welding is to be done, close valve

on gas cylinder (if used), momentarily operate

gun trigger to release gas pressure, and turn off

SP-255.

SPOT WELD MODE

Arc spot plug welds are used when continuous welds

are not needed or to hold thin sheet metal together

prior to stitch welding or continuous welding. Plug

welds are made by using a punch to make a 3/16 inch

(4.8 mm) diameter hole in the top sheet and arc weld-

ing through the hole into the back sheet.

Spot On Time sets welding time. Start with a dial set-

ting of about 1.2 seconds.

To make an arc spot plug weld, punch 3/16 inch (4.8

mm) holes in top sheet. Set the procedure for the

metal thickness to be welded. Install spot weld nozzle

(if available) on gun and press it against the top sheet

so the top and bottom sheets are tight together. Close

trigger and hold it closed until the arc goes out. If a

spot weld nozzle is not used, smoother welds will

result by moving the welding wire in a small circle dur-

ing the weld.

STITCH WELD MODE

Used to weld thin material where warpage and burn-

through are a problem. Proper adjustment of ON and

OFF times and arc travel speed permits welding thin

sheet metal with small welds, minimum distortion, and

no burnthrough.

Stitch On Time sets welding time. Start with a dial set-

ting of 0.5 seconds. Raise setting to increase penetra-

tion and weld size; lower setting to reduce burn-

through and distortion.

Stitch Off Time sets off time. Start with a dial setting

of 0.5 seconds. Raise setting to reduce burnthrough;

lower setting to make weld flatter and smoother.

To weld, set the procedure for the metal thickness to

be welded. Close trigger and hold it closed for length

of seam. Hold gun in one place during ON time and

move gun just beyond edge of molten metal during

OFF time.

NOTE: For smoothest welds on thinner metal, point

gun slightly toward direction of travel.

AVOIDING WIRE FEEDING

PROBLEMS

Wire feeding problems can be avoided by observing

the following gun handling procedures:

a. Do not kink or pull cable around sharp corners.

b. Keep the electrode cable as straight as possible

when welding or loading electrode through cable.

c. Do not allow dolly wheels or trunks to run over

cables.

d. Keep cable clean by following maintenance

instructions.

e. Use only clean, rust-free electrode. The Lincoln

electrodes have proper surface lubrication.

f. Replace contact tip when the arc starts to become

unstable or the contact tip end is fused or

deformed.

g. Keep wire reel spindle brake tension to minimum

required to prevent excess reel over-travel which

may cause wire “loop-offs” from coil.

h. Use proper drive rolls and wire drive idle roll pres-

sure for wire size and type being used. (See Drive

Roll Kits in Accessories section.)

FAN CONTROL

The fan motor is thermostatically controlled to provide

cooling for the transformer and other components

only when required. Even though the power switch is

on, the fan motor will not run when the machine does

not require fan cooling, such as when first turned on,

or when welding at low current or duty cycle proce-

dures.

INPUT LINE VOLTAGE

PROTECTION

HIGH LINE VOLTAGE—If the line voltage exceeds

121% of rated input voltage, the output will be

reduced to the lower level to protect voltage rating of

the capacitor bank. A HIGH LINE message will be dis-

played if the output has been reduced (see Section on

Explanation of Prompting and Error Messages).

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

EXPLANATION OF PROMPTING AND ERROR MESSAGES

On Screen Error Message Message Explanation

PROCESS MUST

MATCH WIRE & GAS

ONLY SET UP FOR

.035 STAINLESS

ONLY ARGON USED

WITH ALUMINUM

ONLY SET UP FOR

.045 OUTERSHIELD

NO GAS REQUIRED

WITH INNERSHIELD

MEMORY 1 NOW

CONTAINS SETUP

MEMORY 2

IS EMPTY

MEMORY 4 DOESN’T

MATCH WIRE & GAS

Reminder that in Auto mode the process entered with the Process key must match

the process installed in the machine.

Unit is only programmed for .035 (0.9 mm) diameter in stainless steel wire. Other

wire diameters can be accommodated by using the Manual mode.

Unit is programmed to use only argon gas with aluminum electrodes. Other gases

can be accommodated by using the Manual mode.

Unit is only programmed for .045 (1.1 mm) diameter in Outershield®electrode wire.

Other wire diameters within the SP-255 rating can be accommodated by using the

Manual mode.

Innershield®electrode wire does not require a shielding gas. In the Auto mode the

SP-255 automatically leaves the solenoid de-energized even when the trigger is

closed.

Verifies that the setup was saved to memory number 1. The actual memory num-

ber is determined by the memory number key that was pressed following Save.

An attempt was made to recall a setup from a memory that does not contain one.

The actual memory number is determined by the memory number key that was

just pressed.

An attempt was made to enter Toggle mode and the process of the Auto setup in

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.

B-14 OPERATION

IDEALARC SP-255

LINE message will be displayed (see Section on

Explanation of Prompting and Error Messages). The

unit will continue to weld, but the output will be less

than what is set.

WIRE FEED OVERLOAD

PROTECTION

The SP-255 has solid state overload protection of the

wire drive motor. If the motor becomes overloaded,

the protection circuitry turns off the arc voltage, wire

feed speed and gas solenoid and then causes the

alarm to beep 3 times. The screen displays a mes-

sage for 2.5 seconds stating that the motor is being

overloaded and the gun and wire drive should be

checked. Check for proper size tip, liner, and drive

rolls, for any obstructions or bends in the gun cable,

and any other factors that would impede the wire

feeding. To resume welding, simply pull the trigger.

WELDING THERMAL OVERLOAD

PROTECTION

The SP-255 has built-in protective thermostats that

respond to excessive temperature. they open the wire

feed and welder output circuits if the machine

exceeds the maximum safe operating temperature

because of a frequent overload, or high ambient tem-

perature plus overload. The thermostats automatically

reset when the temperature reaches a safe operating

level.

OVERCURRENT PROTECTION

The machine will automatically reduce the output if

the load on the machine exceeds 260 to 280

amperes. This protects the welding power SCR’s from

excessive short circuit currents and from exceeding

their temperature rating before the thermostats can

react. A CURRENT OVERLOAD message is dis-

played when the overcurrent protection is active (see

Section on Explanation of Prompting and Error

Messages).

REQ’S: STAINLESS

WIRE .035 Ar02

PRESS PROCESS

WHEN INSTALLED

DATA ***ERROR***

CHECK SETTINGS

PRESS PROCESS TO

CHECK SETTINGS

MOTOR OVERLOADED

CHECK GUN, DRIVE

XXXX ***ERROR***

CHECK SETTINGS

PRESS PROCESS TO

CHECK SETTINGS

GUN SWITCH BEING

USED FOR TOGGLE

CONNECT FOR

NEG. POLARITY

LOW LINE: CHECK

RECONNECT PANEL

PRESS ANY KEY

TO STOP MESSAGE

An attempt was made to recall from memory an Auto setup whose process doesn’t

match the process in the machine. This message indicates the process required

and alternates with the second message until the Process key is pressed.

An attempt was made to recall a setup from memory that has improper settings

due to excessive electrical interference. The SP-255 will recall the setup and reset

the improper data to within machine limits. However, all settings should be

checked, properly set if needed, and then resaved to that memory. This message

alternates with the second message until the Process key is pressed.

Unit shut down even though trigger was closed. There is an excessive current

draw on the motor. Check for proper size tip, liner, and drive rolls, for any obstruc-

tions or bends in the gun cable, and any other factors that would impede the wire

feeding. To resume welding, simply pull the trigger.

Indicates that an error has occurred due to excessive electrical interference. All of

these error types turn off the arc voltage, wire feed speed, and solenoid. Press the

Process key, per second message, and check all settings before continuing to

weld.

XXXX

IC31

RTI

SWI

IOT

XIRQ

PWOF

DATA

Reminds the operator that the gun switch is being used to toggle between memory

4 and memory 5 and, therefore, is not able to control IPM or arc VOLTS.

Reminds the operator to change the electrode polarity to negative when

Innershield wire type is selected.

Indicates to operator that the input line voltage is too low to obtain the output set

on the machine. The operator can continue to weld, but the voltage will be less

than what is set on the machine. This message occurs when the line voltage is

less than 75% of nominal line or if the voltage level set on the machine is not

obtainable at that line voltage and load current. The operator should check if the

reconnect panel is wired properly. Lowering the set VOLTS and/or IPM can elimi-

nate the message. Pressing any key or gun switch when the operator is not weld-

ing will stop the message from being displayed. Pressing any increment or decre-

ment arrow keys or gun switch while welding will temporarily stop the message

from being displayed (approximately 1.3 sec.) allowing the operator to view the

increase or decrease in that setting.

B-15

IDEALARC SP-255

OPERATION

On Screen Error Message Message Explanation

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-16

IDEALARC SP-255 OCT94

OPERATION

On Screen Error Message Message Explanation

HIGH LINE: CHECK

RECONNECT PANEL

PRESS ANY KEY

TO STOP MESSAGE

CURRENT OVERLOAD

REDUCE OUTPUT

PRESS ANY KEY

TO STOP MESSAGE

SXXXXX-X

ROM ASSEMBLY

C SXXXXX-X

ROM ASSEMBLY

SPOOL GUN HAS

BEEN CONNECTED

PRESS MANUAL

TO ENTER SETTINGS

SPOOL GUN HAS

BEEN REMOVED

PRESS PROCESS TO

ENTER SETTINGS

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. This

message occurs when the line voltage is greater than 121% of nominal line. The

operator should check if the reconnect panel is wired properly. Pressing any key or

gun switch when the operator is not welding will stop the message from being dis-

played. Pressing any increment or decrement arrow keys or gun switch while weld-

ing will temporarily stop the message from being displayed (approximately 1.3

sec.) allowing the operator to view the increase or decrease in that setting.

Indicates to operator that too much current is being drawn from the machine, and

the output has been reduced to prevent the current from exceeding safe levels.

This will typically occur in Manual mode using .045 (1.2mm) wire and WFS greater

than 275 IPM (7.0m/min.). Lowering the WFS will reduce the output requirement

and allow operation within the machine ratings. Pressing any key or gun switch

when the operator is not welding will stop the message from being displayed.

Pressing any increment or decrement arrow keys or gun switch while welding will

temporarily stop the message from being displayed (approximately 1.3 sec.) allow-

ing the operator to view the increase or decrease in that setting.

Only displayed at power-up. Displays the part number of the ROM ASSEMBLY

currently on the PC board.

Indicates a checksum error in the software. Turn power off and back on again. If

this message persists, then replace the ROM assembly on the PC board.

Indicates a fault in system RAM. Turn power off and back on again. If this mes-

sage persists, then replace the control PC board assembly.

Reminder that the Spool gun has been connected and the Manual key must be

pressed to enter any Spool gun welding procedures.

Reminder that the Spool gun has been removed and the Process key must be

pressed to enter SP-255 weld settings. This message may also be displayed if

there is an open lead in the spool gun 6 pin plug assembly.

for use of the K487 Spool Gun (with remote

speed control), or the K469 Spool Gun

(requires K518 Connection Adapter).

It also provides single switch transfer of

Trigger and Wire Speed Controls between

the 250SP gun or the spool gun for same

polarity welding with different wire and gas

processes.

The kit includes a spool gun adapter mod-

ule assembly with plug for front installation

and connects to the machine. Also includes

a rear gas inlet fitting with hose, a gun and

cable holder, mounting hardware, and

installation and operation instructions.

(L-9696).

For spool gun installation refer to L9696

instructions included with spool gun adapter

kit (K672-1).

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™ Spool Gun.

MAKING A WELD WITH THE

SPOOL GUN ADAPTER AND

SPOOL GUN INSTALLED

The toggle switch on the front of the spool

gun adapter box permits quick transfer

between the use of the SP-255 with its

feeder gun and the connected spool gun for

same polarity electrodes.

In either transfer switch position, closing

the gun trigger will cause the electrode

of both guns to be electrically “HOT”. Be

sure unused gun is positioned so that

electrode or tip will not contact metal

case or other metal common to work.

1. Transfer switch in FEEDER position:

a. Disables spool gun trigger, wire feed

and gas output.

C-1

ACCESSORIES

OCT94 IDEALARC SP-255

3/64" (1.2 mm) ALUMINUM

FEEDING KIT (K673-1)

The kit provides gun and wire drive conver-

sion parts to weld with 3/64" (1.2 mm) alu-

minum wire. 5356 alloy aluminum wire is

recommended for best push feeding perfor-

mance.

Kit includes drive roll and incoming guide

tube for the wire drive, and a 45° gun tube,

liner and two contact tips for the gun. Install

per the S21529 Installation Instructions pro-

vided with the kit.

8" SPOOL ADAPTER (K468)

Permits use of 8" (200 mm) spools on the

SP-255 spindle.

DUAL CYLINDER MOUNTING

KIT (K671-1)

Permits stable side-by-side mounting of two

full size (9" dia. x 5' high) gas cylinders, with

“no-lift” loading. Simple installation with

installation kick stand and easy instructions.

Includes upper and lower cylinder supports,

wheel axles and mounting hardware.

SPOOL GUN DESCRIPTION

The optional Magnum SG Spool gun is a

lightweight, well-balanced, hand held semi-

automatic wire feeder. It is available in two

models, the K469-25 and the K487-25 with

remote wire speed control.

SPOOL GUN ADAPTER KIT

(OPTIONAL K672-1)

The K672-1 Spool Gun Adapter Kit provides

recessed panel “up front” direct connection

DRIVE ROLL KITS

Drive Rolls available to feed different sizes

and types of electrode:

Drive Roll

Drive Rolls Part No.

Steel Wire Sizes:

.025-.035" (0.6-0.9 mm) KP674-035S

.030-.045" (0.8-1.2 mm) KP674-045S

.045" Cored (1.2 mm) KP674-045C

Aluminum Wire Sizes:

3/64" (1.2 mm) KP674-3/64A

CAUTION

C-2 ACCESSORIES

IDEALARC SP-255 OCT94

d. Procedure settings may be stored in

memory for later recall. (See

“Memory Keys” in Operation section.)

4. The following procedure settings can be

used as initial settings for making test

welds to determine final settings:

SPOT KEY

Anytime the Spot weld timer is on and the

display is in Spool mode, the word SPOT

will appear in the bottom left corner of the

display.

TYPICAL SPOT KEY PRESS SEQUENCE

Spool screen is displayed prior to pressing

Spot key. Spot key is pressed, Spot On

timer is activated and the display changes

to Spot screen. Spot On timer can now be

adjusted using the center arrow keys. Once

the timer has been set, pressing the Spot

key again returns the display to the original

Spool screen with the Spot timer status indi-

cated in the bottom left corner.

STITCH KEY

Anytime the Stitch weld timers are on and

the display is in Spool mode, the abbrevia-

tion STCH will appear in the bottom left cor-

ner of the display.

b. Closing feeder gun trigger starts feed-

er gun welding and makes both elec-

trodes electrically “HOT”.

2. Transfer switch in SPOOL position:

a. Disables feeder gun wire feed and

gas output. However, closing feeder

gun trigger will make both electrodes

electrically “HOT” and activate spool

gun gas output.

b. Closing spool gun trigger starts spool

gun welding and makes both elec-

trodes electrically “HOT”.

3. Operation with SP-255:

a. Turn the input power ON. With the

transfer switch in SPOOL gun posi-

tion, the display will flash the mes-

sages:

b. Pressing the Manual key will change

the display to the spool screen.

c. Pressing the up or down arrow keys

under volts on the display will

increase or decrease your welding

voltage.

The 1-99% on the display represents

a percentage of wire feed speed. This

is the set speed for the K469 spool

gun and the maximum set speed for

the K487 spool gun (with the remote

control in gun handle at maximum).

The remote control turned to mini-

mum will give you approximately 50%

of the maximum set WFS.

Left arrow keys — Do not function.

Center arrow keys — Increase (up

arrow) or decrease (down arrow) per-

cent of wire feed speed.

Right arrow keys — Increase (up

arrow) or decrease (down arrow) arc

voltage.

Wire Diamter Arc Voltage

In. (mm) WFS Setting Setting

.030 (0.8) 42% 15V

.035 (0.9 39% 16V

3/64 (1.2) 32% 21V

C-3

ACCESSORIES

IDEALARC SP-255

memory 4 is recalled and appears on the

display. This whole cycle is repeatable as

long as the unit remains in Toggle mode.

DISABLING SPOOL GUN

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.

TYPICAL STITCH KEY PRESS

SEQUENCE

Spool screen is displayed prior to pressing

Stitch key. Stitch key is pressed, Stitch

timers are activated and the display

changes to Stitch screen. Stitch ON and

OFF timers can now be adjusted using the

center and right arrow keys. Once the

timers have been set, pressing the Stitch

key again returns the display to the original

Spool screen with the Stitch timer status

indicated in the bottom left corner.

TOGGLE KEY

The first time this key is pressed it turns on

toggle mode and recalls the setup in memo-

ry 4. This mode allows you to toggle

between the setups in memory 4 and mem-

ory 5. Each time the key is pressed, it alter-

nates between the two memories. The tog-

gle screen displays the memory number the

current setup was recalled from, indicates

spool (SPOL:) mode, displays percentage

of wire feed speed, and set arc voltage. The

cursor underlines the memory number cur-

rently selected.

TYPICAL TOGGLE KEY PRESS

SEQUENCE

Spool screen is displayed prior to pressing

Toggle key. Toggle key is pressed, memory

4 is recalled and appears on the display.

The unit is now in toggle mode. Pressing

the Toggle key again “toggles” the unit, and

C-4 NOTES

IDEALARC SP-255

D-1

MAINTENANCE

IDEALARC SP-255

GUN TUBES AND NOZZLES

1. Replace worn contact tips as required.

2. Remove spatter from inside of gas noz-

zle and from tip after each 10 minutes of

arc time or as required.

CABLE CLEANING

Clean cable liner after using approximately

300 pounds (136 kg) of electrode. Remove

the cable from the wire feeder and lay it out

straight on the floor. Remove the contact tip

from the gun. Using an air hose and only

partial pressure, gently blow out the cable

liner from the gas diffuser end.

Excessive pressure at the start may

cause dirt to form a plug.

Flex the cable over its entire length and

gain blow out the cable. Repeat this proce-

dure until no further dirt comes out.

CONTACT TIP AND GAS

NOZZLE INSTALLATION

1. Choose the correct size contact tip for

the electrode being used (wire size is

stencilled on the side of the contact tip)

and screw it snugly into the gas diffuser.

2. Screw the appropriate fixed gas nozzle

fully onto the diffuser. Either the standard

.50" (12.7 mm) flush nozzle or other

optional flush or recessed (spray arc)

nozzle sizes may be used. (See

Accessories section.)

3. Be sure the nozzle insulator is fully

screwed onto the gun tube and does not

block the gas holes in the diffuser.

4. If using an optional adjustable slip on

nozzle, slip the appropriate gas nozzle

onto the nozzle insulator. Either a stan-

dard .40" (12.7 mm) or optional .62"

(15.9 mm) I.D. slip-on gas nozzle may be

used and should be selected based on

the welding application.

SAFETY PRECAUTIONS

ELECTRIC SHOCK can

kill.

• Have qualified person-

nel do the maintenance

and trouble shooting

work.

• Turn the input power off

at the fuse box before

working on equipment.

• Do not touch electrically

hot parts..

ROUTINE MAINTENANCE

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.

The fan motors have sealed ball bearings

which require no service.

DRIVE ROLLS AND GUIDE

TUBES

After every coil of wire, inspect the wire

drive mechanism. clean it as necessary by

blowing with low pressure compressed air.

Do not use solvents for cleaning the idle roll

because it may wash the lubricant out of the

bearing. All drive rolls are stamped with the

wire sizes they will feed. If a wire size other

than that stamped on the roll is used, the

drive roll must be changed.

For instructions on replacing or changing

drive roll, see “Wire Drive Roll” in Operation

section or instruction decal inside the SP-

255 door.

WARNING

CAUTION

D-2 MAINTENANCE

IDEALARC SP-255

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.

4. Insert a new untrimmed liner into the

connector end of the cable. Be sure the

liner busing is stencilled appropriately for

the wire size being used.

5. Fully seat the liner bushing into the con-

nector. finger tighten the liner nut onto

the cable connector. The gas diffuser, at

this time, should not be installed onto

the end of the gun tube.

6. With the gas diffuser still removed from

the gun tube, be sure the cable is

straight, and then trim the liner to the

length shown in Figure D.1. Remove any

burrs from the end of the liner.

7. Screw the diffuser onto the end of the

gun tube and securely tighten. Be sure

the gas diffuser is correct for the liner

being used. (see table left and diffuser

stencil.)

8. Tighten the set screw in the side of the

gas diffuser against the cable liner using

a 5/64" (2.0 mm) Allen wrench.

This screw should only be gently

tightened. Overtightening will split or

collapse the liner and cause poor wire

feeding.

5. Adjust the gas nozzle as appropriate for

the GMAW process to be used.

Typically, the contact tip end should be

flush to .12" (3.2 mm) extended for the

short-circuiting transfer process and .12"

(3.2 mm) recessed for spray transfer.

LINER REMOVAL AND

REPLACEMENT

NOTE: Changing the liner for a different

wire size requires replacement of the gas

diffuser per the table below to properly

secure the different liner.

LINER REMOVAL, INSTALLATION,

AND TRIMMING INSTRUCTIONS

FOR MAGNUM 250SP

NOTICE: The variation in cable lengths pre-

vents the interchangeability of liners

between guns. Once a liner has been cut

for a particular gun, it should not be

installed in another gun unless it can meet

the liner cutoff length requirement. Liners

are shipped with the jacket of the liner

extended the proper

amount.

1. Remove the gas nozzle

(and nozzle insulator, if

used) to locate the set

screw in the gas diffuser

which is used to hold the

old liner in place.

Loosen the set screw

with a 5/64" (2.0 mm)

Allen wrench.

2. Remove the gas diffuser

from the gun tube.

3. Lay the gun and cable

Fixed Adjustable

Nozzle Gas Nozzle Gas

Replacement Size Stencilled Diffuser Diffuser

Diameter of Liner Part on End of Part No. Part No.

Electrodes Used Number Liner Bushing (and Stencil) (and Stencil)

.025-.030" Steel M16087-2 .030" (0.8 mm) S19418-3 S19418-2

(0.6-0.8 mm)

.035-.045" Steel M16087-1 .045" (1.2 mm) S19418-3 S19418-1

(0.9-1.2 mm)

3/64" Aluminum M16107-1 (Plastic Liner) S19418-3 S19418-1

(1.2 mm)

CAUTION

FIGURE D.1

Liner trim length for the 250SP gun

D-3

MAINTENANCE

IDEALARC SP-255

GUN HANDLE

DISASSEMBLY

The internal parts of the gun handle may be

inspected or serviced if necessary.

The gun handle consists of two halves that

are held together with a collar on each end.

To open up the handle, turn the collars

approximately 60 degrees counterclockwise

(the same direction as removing a right

hand thread) until the collar reaches a stop.

Then pull the collar off the gun handle. If the

collars are difficult to turn, position the gun

handle against a corner, place a screwdriv-

er against the tab on the collar and give the

screwdriver a sharp blow to turn the collar

past an internal locking rib.

➣

Counter-clockwise

Description Part Number English Size Metric Size

CABLE LINER

For 15' (4.5 m) or shorter M16087-1 .025-.030" 0.6-0.8 mm

Cable M16087-1 * .035-.045" 0.9-1.2 mm

M17714-1 ❏3/64" 1.2 mm

(Alum. wire) (Alum. wire)

CONTACT TIPS

Standard Duty S19391-6 .025" 0.6 mm

S19391-7 .030" 0.8 mm

S19391-1 * .035" 0.9 mm

S19391-2 * .045" 1.2 mm

Heavy Duty S19392-1 .035" 0.9 mm

S19292-2 .045" 1.2 mm

Tapered S19393-5 .025" 0.6 mm

S19393-6 .030" 0.8 mm

S19393-1 .035" 0.9 mm

S19393-2 .045" 1.2 mm

Tab (For Aluminum) S18697-46 ❏3/64 (Alum Wire) 1.2 mm

GAS NOZZLES

Fixed (Flush) M16081-1 3/8" 9.5 mm

M16081-2 * 1/2" 12.7 mm

M16081-3 5/8" 15.9 mm

Fixed (Recessed) M16080-1 3/8" 9.5 mm

M16080-2 1/2" 12.7 mm

M16080-3 5/8" 15.9 mm

Requires:

Gas Diffuser As’bly S19418-3 .025-.045 0.6-1.2 mm

Adjustable Slip-On M16093-2 1/2" 12.7 mm

Requires:

Nozzle Insulator As’bly S19417-1

Requires:

Gas Diffuser As’bly S19418-2 .025-.030" 0.6-0.8 mm

S19418-1 .035-.045" 0.9-1.2 mm

Gasless Nozzle (For M16938 Δ

Innershield)

GUN TUBE ASSEMBLIES

Standard (60°) S18920 *

45° S19890 ❏

MAGNUM 250SP GUN PARTS AND

ACCESSORIES

* 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.

ΔRequires S19418-1 Gas Diffuser Assembly.

D-4 NOTES

IDEALARC SP-255

E-1

TROUBLESHOOTING

IDEALARC SP-255

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM

(SYMPTOMS)”. This column describes pos-

sible symptoms that the machine may

exhibit. Find the listing that best describes

the symptom that your machine is exhibit-

ing.

Step 2. PERFORM EXTERNAL RECOM-

MENDED TESTS.

The second column labeled “POSSIBLE

AREAS OF MISADJUSTMENT(S)” lists the

obvious external possibilities that may con-

tribute to the machine symptom. Perform

these tests/checks in the order listed. In

general, these tests can be conducted with-

out removing the case wrap-around cover.

Step 3. CONSULT LOCAL AUTHORIZED

FIELD SERVICE FACILITY.

If you have exhausted all of the recom-

mended tests in Step 2, consult your local

Authorized Field Service facility.

HOW TO USE TROUBLESHOOTING GUIDE

This Troubleshooting Guide is designed to be used by the machine Owner/Operator.

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, please observe

all safety notes and precautions detailed in the Safety Section of this manual to avoid electri-

cal shock or danger while troubleshooting this equipment.

__________________________________________________________________________

WARNING

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.

___________________________________________________________________

CAUTION

This Troubleshooting Guide is provided to

help you locate and correct possible

machine maladjustments. Simply follow the

three-step procedure listed below.

IDEALARC SP-255

E-2 TROUBLESHOOTING

Observe Safety Guidelines

detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS

(SYMPTOMS)

Major physical or electrical damage

is evident.

There is no wire feed or open

circuit voltage when the gun trigger

is pulled. The LCD display is “ON”

indicating input power to the

SP-255..

Output voltage and wire feed is

present when gun trigger is not

pulled (not activated).

POSSIBLE AREAS OF

MISADJUSTMENT(S)

Contact your LOCAL LINCOLN

AUTHORIZED FIELD SERVICE

FACILITY.

1. The gun trigger or cable may be

faulty. check or replace gun

assembly..

2. The thermal protection circuit

may be activated. Allow the

machine to cool and then reduce

the duty cycle and or wire feed

speed.

3. Make sure input voltage is

correct and matches nameplate

rating and reconnect panel

configuration.

1. Remove gun assembly from

machine. If problem is solved

gun assembly is faulty. Repair or

replace.

2. If problem persists when gun

assembly is removed from the

machine, then the problem is

within the SP-255.

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.

OUTPUT PROBLEMS

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.

CAUTION

IDEALARC SP-255

E-3

TROUBLESHOOTING

Observe Safety Guidelines

detailed in the beginning of this manual. 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.

CAUTION

PROBLEMS

(SYMPTOMS)

Machine does not put out full

power. Welds are “cold”.

Poor arc striking with electrode

sticking or blasting off.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

1. If “HIGH LINE” or “LOW LINE”

messages are displayed then

check the input voltage. Make

sure input voltage matches

nameplate rating and reconnect

panel configuration.

2. Make sure settings for wire feed

speed and voltage are correct

for process being used.

3. Make sure output polarity is cor-

rect for process being used.

4. Check welding cables and gun

assembly for loose or faulty con-

nections.

1. Make sure settings for wire

speed and voltage are correct

for process being used.

2. The Run-In (Fast or Slow) speed

may be wrong for process and

technique being used. See

Operation section.

3. The Start Voltage may be set

wrong for process and technique

being used. See Operation sec-

tion.

4. The gas shielding may be

improper for process.

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.

OUTPUT PROBLEMS

E-4 TROUBLESHOOTING

IDEALARC SP-255

PROBLEMS

(SYMPTOMS)

The welding arc is unstable or

“hunting”.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

1. Check the work cable for loose

or faulty connections.

2. Check the contact tip and

replace if worn or damaged.

3. Make sure the welding polarity is

correct for the process being

used.

4. Make sure the shielding gas is

correct for the process being

used.

5. The gun and cable assembly

may be faulty. Replace.

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.

OUTPUT PROBLEMS

Observe Safety Guidelines

detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

E-5

TROUBLESHOOTING

IDEALARC SP-255

Observe Safety Guidelines

detailed in the beginning of this manual. TROUBLESHOOTING GUIDE

PROBLEMS

(SYMPTOMS)

The SP-255 stops feeding wire

while welding and the MOTOR

OVERLOADED message appears

on the LCD display.

The voltage and/or wire feed speed

are being changed even though the

gun thumbswitch or front panel

arrow keys are not activated.

The LCD display is not readable

even though the backlighting is

functioning.

Error messages or alarm continu-

ously beeps in bursts of three.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

1. Check for any restriction in the

wire feeding path.

2. Make sure the correct size con-

tact tip, gun liner and drive rolls

are being used.

1. The thumbswitch circuit in the

gun and cable assembly may be

faulty. Repair or replace.

1. There may have been an inter-

nal system “fault”. Turn input

power off for a few seconds.

Turn power back on and check

for proper machine operation.

2. Check the input voltage. Make

sure the input voltage matches

the nameplate rating and the

reconnect panel configuration.

1. There may be an error in the

system or the keypad entry. 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.

FUNCTION PROBLEMS

IDEALARC SP-255

E-6 TROUBLESHOOTING

Observe Safety Guidelines

detailed in the beginning of this manual. 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.

CAUTION

PROBLEMS

(SYMPTOMS)

Rough wire feeding or wire will not

feed but drive rolls are turning.

There is no wire feed but arc

voltage is present.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

1. The gun cable may be kinked or

twisted.

2. The wire may be jammed in the

gun cable, or gun cable may

be dirty.

3. Check drive roll tension and

position of grooves.

4. Check for worn or loose

drive roll.

5. The electrode may be rusty or

dirty.

6. Check for damaged or incorrect

contact tip.

1. If the drive rolls are turning

check the drive roll tension.

Check for restrictions in the wire

feeding path.

2. If the drive rolls are not turning

when the gun trigger is pulled

there is a problem within the

SP-255.

3. If using a Spool Gun adapter kit,

make sure transfer switch is in

the correct position.

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.

FEEDING PROBLEMS

PROBLEMS

(SYMPTOMS)

Gas does not flow when gun trigger

is pulled.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

1. The Process gas type may be

set to NONE for Innershield.

Press Process key and enter

correct process including gas.

2. Make sure gas supply is con-

nected properly and turned “on”.

3. If the gas solenoid does actuate

when the gun trigger is pulled

there may be a restriction in the

gas supply line.

4. The gun cable assembly may be

faulty. Check or replace.

5. If using a Spool Gun adapter kit,

make sure transfer switch is in

the correct position.

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.

GAS FLOW PROBLEMS

F-1

WIRING DIAGRAMS

IDEALARC SP-255

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.

F-2 WIRING DIAGRAMS

IDEALARC SP-255

SP-255 WIRING DIAGRAM: L9689 (230/460/575V)

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.

F-3

DIMENSION PRINT

IDEALARC SP-255

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

Inches (Millimeters)

NOTES

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WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

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.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A

ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-

STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

●Do not touch electrically live parts or

electrode with skin or wet clothing.

●Insulate yourself from work and

ground.

●No toque las partes o los electrodos

bajo carga con la piel o ropa moja-

da.

●Aislese del trabajo y de la tierra.

●Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact

avec des pièces sous tension.

●Isolez-vous du travail et de la terre.

●Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem

Körper oder feuchter Kleidung!

●Isolieren Sie sich von den

Elektroden und dem Erdboden!

●Não toque partes elétricas e elec-

trodos com a pele ou roupa molha-

da.

●Isole-se da peça e terra.

●Keep flammable materials away.

●Mantenga el material combustible

fuera del área de trabajo.

●Gardez à l’écart de tout matériel

inflammable.

●Entfernen Sie brennbarres Material!

●Mantenha inflamáveis bem guarda-

dos.

●Wear eye, ear and body protection.

●Protéjase los ojos, los oídos y el

cuerpo.

●Protégez vos yeux, vos oreilles et

votre corps.

●Tragen Sie Augen-, Ohren- und Kör-

perschutz!

●Use proteção para a vista, ouvido e

corpo.

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS

PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

●Keep your head out of fumes.

●Use ventilation or exhaust to

remove fumes from breathing zone.

●Los humos fuera de la zona de res-

piración.

●Mantenga la cabeza fuera de los

humos. Utilice ventilación o

aspiración para gases.

●Gardez la tête à l’écart des fumées.

●Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones

de travail.

●Vermeiden Sie das Einatmen von

Schweibrauch!

●Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

●Mantenha seu rosto da fumaça.

●Use ventilação e exhaustão para

remover fumo da zona respiratória.

●Turn power off before servicing.

●Desconectar el cable de ali-

mentación de poder de la máquina

antes de iniciar cualquier servicio.

●Débranchez le courant avant l’entre-

tien.

●Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff-

nen; Maschine anhalten!)

●Não opere com as tampas removidas.

●Desligue a corrente antes de fazer

serviço.

●Não toque as partes elétricas nuas.

●Do not operate with panel open or

guards off.

●No operar con panel abierto o

guardas quitadas.

●N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de

protection enlevés.

●Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in

Betrieb setzen!

●Mantenha-se afastado das partes

moventes.

●Não opere com os paineis abertos

ou guardas removidas.

• 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 Premier Manufacturer of Industrial Motors

STATEMENT OF LIMITED WARRANTY

The Lincoln Electric Company (Lincoln) warrants to the

end user (purchaser) of all new welding and cutting equip-

ment, electrode and flux (collectively called the “Goods”)

that it will be free of defects in workmanship and material.

This warranty is void if Lincoln or its Authorized Service

Facility finds that the equipment has been subjected to

improper installation, improper care or abnormal opera-

tions.

WARRANTY PERIOD (1) (2) (3)

Lincoln will assume both the parts and labor expense of

correcting defects during the full warranty period. All war-

ranty periods date from the date of purchase to the original

end user and are as follows:

7 Years

• Main power rectifiers on all non-inverter low frequency

(50 and 60 Hz) type welders.

3 Years

• All Lincoln welding machines, wirefeeders and plasma

cutting machines unless listed below.

2 Years

• Power Arc 5000

Ranger 10, Ranger 10-LX

Weldanpower 125, Weldanpower 150

1 Year

• AC-100

Invertec V100-S, Invertec V130-S, Invertec V200-T

Power Arc 4000

Pro-Cut 20

• All water coolers (internal or external models)

• All stick electrode, welding wire and flux.

• Arc welding and cutting robots and robotic controllers

• All Environmental Systems equipment, including portable

units, central units, gun and cable assemblies and acces-

sories. (Does not include consumable items listed under

30 day warranty.)

• All welding and cutting accessories including gun and

cable assemblies, TIG and plasma torches, spool guns,

wire feed modules, undercarriages, field installed options

that are sold separately, unattached options, welding

supplies, standard accessory sets, replacement parts,

and Magnum products. (Does not include expendable

parts listed under 30 day warranty)

30 Days

• All consumable items that may be used with the environ-

mental systems described above. This includes hoses,

filters, belts and hose adapters.

• Expendable Parts - Lincoln is not responsible for the

replacement of any expendable part that is required due

to normal wear.

CONDITIONS OF WARRANTY

TO OBTAIN WARRANTY COVERAGE:

The purchaser must contact Lincoln or Lincoln’s Authorized

Service Facility about any defect claimed under Lincoln’s

warranty.

Determination of warranty on welding and cutting equip-

ment will be made by Lincoln or Lincoln’s Authorized

Service Facility.

WARRANTY REPAIR:

If Lincoln or Lincoln’s Authorized Service Facility confirms

the existence of a defect covered by this warranty, the

defect will be corrected by repair or replacement at

Lincoln’s option.

At Lincoln’s request, the purchaser must return, to Lincoln

or its Authorized Service Facility, any “Goods” claimed

defective under Lincoln’s warranty.

FREIGHT COSTS:

The purchaser is responsible for shipment to and from the

Lincoln Authorized Service Facility.

WARRANTY LIMITATIONS

Lincoln will not accept responsibility or liability for repairs

made outside of a Lincoln Authorized Service Facility.

Lincoln’s liability under this warranty shall not exceed the

cost of correcting the defect of the Lincoln product.

Lincoln will not be liable for incidental or consequential

damages (such as loss of business, etc.) caused by the

defect or the time involved to correct the defect.

This written warranty is the only express warranty provided

by Lincoln with respect to its products. Warranties implied

by law such as the warranty of merchantability are limited

to the duration of this limited warranty for the equipment

involved.

This warranty gives the purchaser specific legal rights. The

purchaser may also have other rights which vary from state

to state.

(1) Equipment manufactured for the Lincoln Electric Company is subject to

the warranty period of the original manufacturer.

(2) All engines and engine accessories are warranted by the engine or

engine accessory manufacturer and are not covered by this warranty.

(3) SAE400 WELD N’ AIR compressor is warranted by the compressor man-

ufacturer and not covered by this warranty.

LIMITED WARRANTY

Dec, ‘97

Lincoln Electric Idealarc Sp 255 Users Manual Im533

SP-255 to the manual 996eb798-f528-4cd3-aa38-f5b782fab06d

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