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IM402-B
IDEALARC AC/DC 250 August, 2007
For use with machines having Code Number 9491 thru 11104.
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.
OPERATOR鈥橲 MANUAL
Copyright 漏 2007 Lincoln Global Inc.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
i i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
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 鈥淪afety in Welding & Cutting - ANSI Standard Z49.1鈥? from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of 鈥淎rc Welding Safety鈥? 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.
FOR ENGINE 1.h. To avoid scalding, do not remove the
powered equipment. radiator pressure cap when the engine is
hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
____________________________________________________
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 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. 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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
Mar 驶95
magneto wire as appropriate.
SAFETY
ii ii
ARC RAYS can burn.
ELECTRIC SHOCK can
kill. 4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing
are electrically 鈥渉ot鈥? when the welder is on. open arc welding. Headshield and filter lens
Do not touch these 鈥渉ot鈥? parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
4.c. Protect other nearby personnel with suitable, non-flammable
area of physical contact with work and ground.
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
FUMES AND GASES
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
can be dangerous.
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 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
鈥? Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
鈥? DC Manual (Stick) Welder. your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
鈥? AC Welder with Reduced Voltage Control.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
3.c. In semiautomatic or automatic wire welding, the electrode,
ventilation such as stainless or hard facing (see
electrode reel, welding head, nozzle or semiautomatic
instructions on container or MSDS) or on lead or
welding gun are also electrically 鈥渉ot鈥?.
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
3.d. Always be sure the work cable makes a good electrical
low as possible and below Threshold Limit Values (TLV)
connection with the metal being welded. The connection
using local exhaust or mechanical ventilation. In
should be as close as possible to the area being welded.
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.e. Ground the work or metal to be welded to a good electrical
also required when welding on galvanized steel.
(earth) ground.
5. b. The operation of welding fume control equipment is affected
3.f. Maintain the electrode holder, work clamp, welding cable and
by various factors including proper use and positioning of
welding machine in good, safe operating condition. Replace
the equipment, maintenance of the equipment and the spe-
damaged insulation.
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.g. Never dip the electrode in water for cooling.
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
3.h. Never simultaneously touch electrically 鈥渉ot鈥? parts of
electrode holders connected to two welders because voltage
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
between the two can be the total of the open circuit voltage
coming from degreasing, cleaning or spraying operations.
of both welders.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.i. When working above floor level, use a safety belt to protect
ucts.
yourself from a fall should you get a shock.
5.d. Shielding gases used for arc welding can displace air and
3.j. Also see Items 6.c. and 8.
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer始s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer始s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
SAFETY
iii iii
WELDING and CUTTING CYLINDER may explode
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to 鈥淪afety in Welding and Cutting鈥? (ANSI 鈥? Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
鈥? A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically 鈥渉ot鈥? parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been 鈥渃leaned鈥?. For information, purchase 鈥淩ecommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances鈥?, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or 鈥淧recautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,鈥? available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
FOR ELECTRICALLY
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
powered equipment.
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
8.b. Install equipment in accordance with the U.S. National
increase the possibility of the welding current passing
Electrical Code, all local codes and the manufacturer始s
through lifting chains, crane cables or other alternate cir-
recommendations.
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer始s recommendations.
6.h. Also see item 1.c.
Jan, 07
6.I. Read and follow NFPA 51B 鈥? Standard for Fire Prevention
During Welding, Cutting and Other Hot Work鈥?, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
SAFETY iv
iv
PR脡CAUTIONS DE S脹RET脡 6. Eloigner les mat茅riaux inflammables ou les recouvrir afin de
pr茅venir tout risque d始incendie d没 aux 茅tincelles.
Pour votre propre protection lire et observer toutes les instructions
et les pr茅cautions de s没ret茅 specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince 脿 une endroit isol茅 de
manuel aussi bien que les pr茅cautions de s没ret茅 g茅n茅rales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
茅chauffement et un risque d始incendie.
S没ret茅 Pour Soudage A L始Arc
8. S始assurer que la masse est connect茅e le plus pr茅s possible
1. Protegez-vous contre la secousse 茅lectrique:
de la zone de travail qu始il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d始autres
a. Les circuits 脿 l始茅lectrode et 脿 la pi茅ce sont sous tension
endroits 茅loign茅s de la zone de travail, on augmente le risque
quand la machine 脿 souder est en marche. Eviter toujours
de voir passer le courant de soudage par les chaines de lev-
tout contact entre les parties sous tension et la peau nue
age, c芒bles de grue, ou autres circuits. Cela peut provoquer
ou les v茅tements mouill茅s. Porter des gants secs et sans
des risques d始incendie ou d始echauffement des chaines et des
trous pour isoler les mains.
c芒bles jusqu始脿 ce qu始ils se rompent.
b. Faire tr茅s attention de bien s始isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
9. Assurer une ventilation suffisante dans la zone de soudage.
metallique ou des grilles metalliques, principalement dans
Ceci est particuli茅rement important pour le soudage de t么les
les positions assis ou couch茅 pour lesquelles une grande
galvanis茅es plomb茅es, ou cadmi茅es ou tout autre m茅tal qui
partie du corps peut 锚tre en contact avec la masse.
produit des fume茅s toxiques.
c. Maintenir le porte-茅lectrode, la pince de masse, le c芒ble
de soudage et la machine 脿 souder en bon et s没r 茅tat
10. Ne pas souder en pr茅sence de vapeurs de chlore provenant
defonctionnement.
d始op茅rations de d茅graissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-茅lectrode dans l始eau pour le
chaleur ou les rayons de l始arc peuvent r茅agir avec les vapeurs
refroidir.
du solvant pour produire du phosg茅ne (gas fortement toxique)
e. Ne jamais toucher simultan茅ment les parties sous tension
ou autres produits irritants.
des porte-茅lectrodes connect茅s 脿 deux machines 脿 souder
parce que la tension entre les deux pinces peut 锚tre le
11. Pour obtenir de plus amples renseignements sur la s没ret茅,
total de la tension 脿 vide des deux machines.
voir le code 鈥淐ode for safety in welding and cutting鈥? CSA
f. Si on utilise la machine 脿 souder comme une source de
Standard W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-茅lectrode s始applicuent aussi au pistolet de
soudage.
PR脡CAUTIONS DE S脹RET脡 POUR
2. Dans le cas de travail au dessus du niveau du sol, se prot茅ger
LES MACHINES 脌 SOUDER 脌
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le c芒ble-茅lectrode autour de n始importe quelle partie
TRANSFORMATEUR ET 脌
du corps.
REDRESSEUR
3. Un coup d始arc peut 锚tre plus s茅v猫re qu始un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant appropri茅 1. Relier 脿 la terre le chassis du poste conformement au code de
ainsi qu始un verre blanc afin de se prot茅ger les yeux du ray- l始茅lectricit茅 et aux recommendations du fabricant. Le dispositif
onnement de l始arc et des projections quand on soude ou de montage ou la piece 脿 souder doit 锚tre branch茅 脿 une
quand on regarde l始arc. bonne mise 脿 la terre.
b. Porter des v锚tements convenables afin de prot茅ger la
peau de soudeur et des aides contre le rayonnement de 2. Autant que possible, I始installation et l始entretien du poste seront
l驶arc. effectu茅s par un 茅lectricien qualifi茅.
c. Prot茅ger l始autre personnel travaillant 脿 proximit茅 au
soudage 脿 l始aide d始茅crans appropri茅s et non-inflammables. 3. Avant de faires des travaux 脿 l始interieur de poste, la debranch-
er 脿 l始interrupteur 脿 la boite de fusibles.
4. Des gouttes de laitier en fusion sont 茅mises de l始arc de
soudage. Se prot茅ger avec des v锚tements de protection libres 4. Garder tous les couvercles et dispositifs de s没ret茅 脿 leur
de l始huile, tels que les gants en cuir, chemise 茅paisse, pan- place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de s茅curit茅 dans la zone de
soudage. Utiliser des lunettes avec 茅crans lateraux dans les
zones o霉 l始on pique le laitier.
Mar. 驶93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
Thank You 鈥⑩?⑩?? as much pride as we have in bringing this product to you!
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer始s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change 鈥? This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
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.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
鈥? For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
鈥? For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose 鈥淨uick Links鈥? and then
鈥淧roduct Registration鈥?. Please complete the form and submit your registration.
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.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
鈥?6鈥?
TABLE OF CONTENTS
Page
GENERAL DESCRIPTION..................................................................................................8
RECOMMENDED PROCESSES & EQUIPMENT...............................................................8
AC and DC Constant Current Welding .............................................................................8
TIG Welding ......................................................................................................................8
DESIGN FEATURES...........................................................................................................8
OPTIONS/ACCESSORIES & COMPATIBLE LINCOLN EQUIPMENT..............................8
Power Factor Capacitors ...........................................................................................8
Undercarriage ............................................................................................................8
Hi-Freq .......................................................................................................................8
Standard Accessory Set ............................................................................................8
TECHNICAL SPECIFICATIONS .........................................................................................9
INSTALLATION ...............................................................................................................10-11
Safety Precautions ...........................................................................................................10
Machine Installation .........................................................................................................10
Location ....................................................................................................................10
Input Connections.....................................................................................................10
Stacking ....................................................................................................................11
Installation of Field Installed Options ...............................................................................11
Output Cable Size and Connection..................................................................................11
OPERATION.......................................................................................................................12
Safety Precautions ...........................................................................................................12
Duty Cycle ................................................................................................................12
Control Operation .....................................................................................................12
MAINTENANCE .................................................................................................................13
Safety Precautions ...........................................................................................................13
General Maintenance.......................................................................................................13
TROUBLESHOOTING.....................................................................................................13-15
Rectifier Troubleshooting .................................................................................................13
Troubleshooting Procedures .........................................................................................14-15
WIRING DIAGRAMS .......................................................................................................16-17
PARTS LIST ...............................................................................................................P200 Series
鈥?7鈥?
GENERAL DESCRIPTION 鈥? Recessed front panel protects controls.
鈥? Large safety margins and protective circuits protect
The Idealarc庐 250 is a single phase constant current rectifiers from transient voltages and high currents.
arc welding power source available in an AC/DC
model only. Designed for stick welding, it may also be 鈥? Submersion dipping of assembled transformer and
used for TIG welding when used with the K799 Hi- choke in special sealing/insulating material gives
Freq unit. extra protection against moisture and corrosive
atmosphere.
鈥? Stackability - Machines can be stacked up to three
RECOMMENDED PROCESSES AND high.
EQUIPMENT 鈥? Outstanding Arc Stability - Transformer design and
built-in stabilizer provide pop-out-resistant welding
AC and DC Constant Current Welding with all electrodes, including those which normally
require an industrial type AC welder.
AC 35-300 Amps 60 Hz 35-250 Amps 50 Hz 鈥? Reconnect panel is provided to permit changing
DC 40-250 Amps 50/60 Hz from one input voltage to another without reconnect-
ing transformer leads.
Duty Cycle 60 Hz 50 Hz
100%-140 Amps 100%-140 Amps
50%-200 Amps 60%-180 Amps
30%-250 Amps 30%-250 Amps
OPTIONS / ACCESSORIES
20%-300 Amps
AND COMPATIBLE LINCOLN
EQUIPMENT
TIG Welding
Factory Installed Options/Accessories
The K799 can be used with this machine to provide
high frequency stabilization and a gas valve for TIG
welding. It operates on 115V 50/60 Hz power. A
鈥? Power Factor Capacitors
water valve (for water cooled TIG torches) is available
(Reduce input amps by 30% at rated load.)
as an option.
When TIG welding, AC or DC may be used but when
Field Installed Options
AC TIG welding, the duty cycle must be decreased by
one-half.
鈥? Power Factor Capacitors
(Reduce input amps by 30% at rated load.)
鈥? Undercarriage (K866)
DESIGN FEATURES Consists of a handle, axle, wheels, front bracket and
mounting hardware. Overall width 24.56 inches
(624 mm).
鈥? Power On/Off switch.
鈥? Hi Freq Kit (K799)
鈥? Polarity switch selects AC, DC+ or DC- . Converts Idealarc 250 into a TIG welder.
Request Bulletin E385 for full details.
鈥? Continuous current control dials with exact welding
current needed for each job. Settings are precise 鈥? Standard Accessory Kit (K710)
and free from creep. Includes electrode holder, work clamp, electrode,
work cables, and headshield with lens and
鈥? Spring loaded knob on the continuous current coverplate
control crank pulls out for easy adjustment and
snaps back out of the way when released.
鈥? Meets NEMA Class II specifications.
鈥?8鈥?
TECHNICAL SPECIFICATIONS: IDEALARC AC/DC 250
INPUT - OUTPUT RATINGS
Model AC/DC 250 AC/DC 250
Type K1053 K1054
AC Input Frequency 60 50
Output Rating NEMA CLASS II (60) IEC 974
AC DC AC DC
Amperes 300 250 250 250
Volts 32 30 30 30
Duty Cycle 20 30 30 30
Current Range 35-300 40-250 35-250 40-250
Max. O.C.V. 72 70 72 70
Input Power
Standard Voltages 208/230/460 220/380/440
230/460/575 380/415/500
Rated Input Current
(230V 60Hz, 220V 50Hz)
With Condensers 68 68
Without Condensers 86 86
Idle Input Current (230V)
With Condensers 23 23
Without Condensers 6.2 6.2
Power Factor (200 Amp Load)
With Condensers 83.3 83.3
Without Condensers 69.0 69.0
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
27.00 in. 19.00 in. 21.50 in. 350 lbs.
159 kg
686 mm 483 mm 546 mm
鈥?9鈥?
INSTALLATION Location
Safety Precautions The machine should be located in a clean, dry place
WARNING where there is free circulation of clean air such that air
movement in the back and along the sides will not be
ELECTRIC SHOCK can kill. restricted. Dirt and dust that can be drawn into the
鈥? Do not touch electrically live parts or machine should be kept to a minimum. Failure to
electrode with skin or wet clothing. observe the precautions can result in excessive
鈥? Insulate yourself from work and operating temperatures and nuisance shutdown of the
ground. machine.
鈥? Always wear dry insulating gloves.
Input Connections
------------------------------------------------------------------------
FUMES AND GASES can be dangerous.
鈥? Keep your head out of fumes. Be sure the voltage, phase and frequency of the input
鈥? Use ventilation or exhaust to remove power is as specified on the welder rating plate locat-
fumes from breathing zone. ed on the rear panel of the machine. Either a single
phase or one phase of a three phase line can be
------------------------------------------------------------------------ used.
WELDING SPARKS can cause fire or
Have a qualified electrician install the machine per the
explosion.
following instructions:
鈥? Keep flammable material away.
鈥? Do not weld on closed containers.
Remove the left side panel (viewed from the front).
Route the input power lines through the hole in the
------------------------------------------------------------------------
rear panel and center baffle. Lug the input leads with
ARC RAYS can burn eyes and skin.
a ring terminal for a 1/4鈥? (6mm) screw. Connect
鈥? Wear eye, ear and body
lugged leads to L1 and L2 of the reconnect panel per
protection.
the wiring diagram pasted to m inside of the side
panel. Input connection must conform to the U.S.
------------------------------------------------------------ National Electrical Code and all local codes.
See additional warning information at the Models designed for two or three input voltages are
front of this operator始s manual. shipped connected for the highest voltage.
----------------------------------------------------------- Reconnect instructions are on the diagram pasted to
the inside of the side panel. Consult rating plate on
the rear panel for machine input voltage rating.
鈥? Connect the Idealarc 250 grounding terminal located
under the reconnect panel (marked ) to a good
The welder frame must be grounded. A stud marked
electrical ground per the U.S. National Electrical
with the symbol located under the reconnect
Code and any applicable local codes.
panel is provided for this purpose. See the U.S.
National Electrical Code for details on proper ground-
鈥? Turn the power switch on the Idealarc 250 鈥淥FF鈥?
ing methods.
before connecting or disconnecting output cables or
other equipment.
Fuse the input circuit with the recommended super lag
鈥? Only qualified personnel should perform this installa- fuses. Choose an input and grounding wire size accord-
tion. ing to local codes or use the following table. 鈥淒elay type鈥?
circuit breakers may be used in place of fuses. Using
Undercarriages: If the optional K866 undercarriage
fuses or circuit breakers smaller than recommended may
is to be installed, it should be done before connecting
result in 鈥渘uisance鈥? tripping from welder inrush currents
the welder to power lines. Instructions are included
even if not welding at high currents.
with the undercarriage.
RECOMMENDED INPUT WIRE, GROUND WIRE AND FUSE SIZES 200 Amp Output and 50% Duty Cycle
Copper Wire Sizes Fuse Size
75掳C in Conduit (Super Lag)
Input Amps
With Without With Without
P.F. P.F. With Without Grounding P.F. P.F.
Input Freq.
Cap Cap Cap Cap Conductor Cap Cap
Volts
200 50/60 58 81 #8 #6 #8 70 100
208 60 55 77 #8 #6 #8 70 100
220/230 50/60 50 70 #8 #6 #8 70 90
380 50 29 41 #10 #8 #10 40 50
400 50/60 29 40 #10 #8 #10 40 50
440/460 50/60 25 35 #12 #10 #10 35 45
500 50 22 31 #14 #12 #10 30 40
鈥? 10 鈥?
575 60 20 28 #14 #12 #10 25 40
STACKING CABLE SIZES FOR COMBINED LENGTHS OF
WARNING COPPER ELECTRODE AND WORK CABLES
FALLING EQUIPMENT can cause 200 Amps 250 Amps
50% Duty Cycle 30% Duty Cycle
injury.
鈥? Do not lift this machine using lift bale if
0-100 Ft. 3 (30mm2) 3 (30mm2)
it is equipped with a heavy accessory
such as undercarriage or gas cylinder.
100-150 Ft. 2 (35mm2) 2 (35mm2)
鈥? Lift only with equipment of adequate lifting capacity.
鈥? Be sure machine is stable when lifting. 150-200 Ft. 1 (45mm2) 1 (45mm2)
鈥? Do not stack more than three high.
鈥? Do not stack on top of any other type machine. 200-250 Ft. 1/0 (55mm2) 1/0 (55mm2)
---------------------------------------------------------------------
A. Make sure the first or bottom unit is setting on a
level, well supported surface.
B. The units must be stacked with their front flush,
making sure the two holes in the base rails of
the unit being stacked on top are over the two
holes located on the top front corners of the unit
being stacked on. Fasten the units together
with 5/16 (8 mm) bolts, nuts and lockwashers
through these holes.
C. Remote fastening bolts before lifting unit off
stacks.
Installation of Field Installed Options
For installation of compatible field installed options,
see Field Installed Options section, and refer to the
instructions included with those options.
Output Cable Size and Connection
WARNING
ELECTRIC SHOCK can kill.
鈥? Turn the power switch of the
welding power source 鈥淥FF鈥?
before connecting or disconnect-
ing output cables.
------------------------------------------------------------
The output leads are connected to the output termi-
nals marked 鈥淲ORK鈥? and 鈥淓LECTRODE鈥?. They are
located at the lower right and lower left corners of the
front panel. The 60 Hz Idealarc 250 provides 1/2鈥?
studs for weld cable connections. The 50 Hz Idealarc
250 provides European weld cable connector recepta-
cles. Minimum cable sizes recommended are listed in
the table below.
鈥? 11 鈥?
OPERATION CONTROL OPERATION
Safety Precautions A. Current Control Handle
WARNING Rotating the hand wheel raises and lowers the
ELECTRIC SHOCK can kill. output current allowing the operator to dial the
鈥? Do not touch electrically live parts or desired current. Clockwise rotation reduces
electrode with skin or wet clothing. the current while counter-clockwise rotation
鈥? Insulate yourself from work and increases the current. Turning the current
ground. control handle also drives the output pointer at
鈥? Always wear dry insulating gloves. the bottom of the nameplate which indicates
------------------------------------------------------------------------ the stick welding current at NEMA arc volts.
FUMES AND GASES can be dangerous.
鈥? Keep your head out of fumes. B. Polarity Switch
鈥? Use ventilation or exhaust to remove
fumes from breathing zone. Turn the arc polarity switch in the upper right
hand corner of the case front to AC, DC(-) or
------------------------------------------------------------------------ DC(+) as required for the particular application.
WELDING SPARKS can cause fire or DO NOT CHANGE POLARITY SWITCH
explosion. WHILE WELDING. Doing this can seriously
鈥? Keep flammable material away. damage the switch.
鈥? Do not weld on closed containers.
C. TIG Welding
------------------------------------------------------------------------
ARC RAYS can burn eyes and skin. The Idealarc 250 with the optional Hi-Freq is an
鈥? Wear eye, ear and body inexpensive equipment combination for part-
protection. time production or repair TIG welding of alu-
minum, magnesium, thin stainless steel and
------------------------------------------------------------ many space-age metals. The Idealarc 250 can
be used for normal stick electrode welding with
See additional warning information at the the Hi-Freq attached.
front of this operator始s manual.
CAUTION
-----------------------------------------------------------
Reduce the Idealarc 250 duty cycle by 50%
Be sure the Idealarc 250 is properly installed, and that when AC TIG welding, i.e., the welder should be
all accessories are properly hooked up before operated for only two and one half minutes out
attempting operation. of every ten at rated current of 200 amperes.
The Hi-Freq includes high frequency generator,
gas valve and needed controls. It operates on
115V, 50/60 Hz AC power.
DUTY CYCLE NOTE: The Hi-Freq unit includes an R.F.
bypass capacitor kit for power source protec-
This machine is rated at a 30% duty cycle at 250 tion. Installation instructions are in the kit.
amps or 50% duty cycle at 200 amp output. Duty (When using the Idealarc 250 with any other
cycle is based on a 10 minute period. Therefore, high frequency equipment, an R.F. bypass
the welder can be loaded at 200 amperes for 5 capacitor must be installed. Order Kit T12246.)
minutes out of each 10 minute period. Higher duty To provide protection, the welder grounding
cycles can be used at lower currents; see rating stud or frame must be connected to ground
plate information. (see instructions on grounding in Machine
Installation section). Also follow the grounding
instructions given in the Hi-Freq Instruction
manual.
鈥? 12 鈥?
MAINTENANCE TROUBLESHOOTING
Safety Precautions Safety Precautions
WARNING WARNING
ELECTRIC SHOCK can kill. ELECTRIC SHOCK can kill.
鈥? Have a qualified individual install and 鈥? Have a qualified individual install and
service this equipment. service this equipment.
鈥? Turn the input power off at the fuse 鈥? Turn the input power off at the fuse
box before working on equipment. box before working on equipment.
鈥? Do not touch electrically hot parts. 鈥? Do not touch electrically hot parts.
--------------------------------------------------------------------- ---------------------------------------------------------------------
General Maintenance Rectifier Troubleshooting
1. The fan motor has sealed ball bearings which 1. Turn the input power off.
requires no service.
2. Disconnect all input and output leads from the
2. In dusty locations dirt may clog the air channels rectifier bridge.
causing the welder to run hot. Under these
conditions carefully blow out the welder at regular 3. Connect an ohmmeter between the DC positive
intervals. (red) terminal and one of the AC (yellow) termi-
nals. Note the ohmmeter reading using the 10 to
3. Keep the electrode and work cable connection 100 scale.
tight.
4. Reverse the ohmmeter leads. Note the readings.
5. The reading taken in steps 3 and 4 should be
4. Every twelve months or at the first indication of a different. If the readings are the same and
binding current pointer, turn the input power off near zero, the rectifier has shorted. IF the
and remove the left case side. Wipe the pointer readings are the same and near full scale, the
guide bar clean and lubricate with graphite rectifier has failed open.
grease.
6. Repeat steps 3, 4 and 5 between the DC posi-
5. When cleaning the current pointer, clean the tive (red) terminal and each of the AC (yellow)
reactor quadrant teeth, drive gear and pinion. terminals.
Lubricate with graphite grease.
7. Repeat steps 3, 4 and 5 between the DC nega-
tive (black) terminal and each of the AC (yel-
low) terminals.
NOTE: Since it is unlikely that all rectifiers of a
full wave bridge would fail simultaneously,
check the test method and the ohmmeter if the
checking indicates that all rectifiers have failed.
鈥? 13 鈥?
TROUBLESHOOTING
WHAT TO DO
TROUBLE CAUSE
1. Place line switch in 鈥淥n鈥? posi-
A. Welder will not weld. 1. Line switch not turned 鈥淥n鈥?.
tion. Replace. (Look for reason
Supply line fuse blown.
for blown fuse first).
2. Check supply line voltage.
2. Power circuit dead.
3. Repair.
3. Broken power lead.
4. Check voltage against rating
4. Wrong voltage.
plate. Check reconnect panel
jumper.
5. Tighten and repair connections.
5. Electrode or work lead loose or
broken.
6. Send to repair shop to have coils
6. Open transformer circuit.
replaced.
7. Center switch handle on DC(+),
7. Polarity switch not centered.
DC(-), or AC.
1. Make sure all case openings are
B. Welder welds, but soon stops 1. Proper ventilation hindered.
free for proper circulation of air.
welding (DC only).
2. Operate at normal current and
2. Welder loaded beyond rating.
duty cycle consistent with rating.
3. Check leads and motor bear-
3. Fan motor inoperative.
ings. Fan motor can be tested
on 115V line; with welder on,
voltage across fan motor should
be approximately 115V.
4. Check for loose or hot connec-
4. Poor internal connections.
tions and tighten.
5. Blow out welder with low pres-
5. Excessive dust accumulation in
sure.
welder.
6. Carefully clean in naptha.
6. Bi-metallic thermostat dirty.
鈥? 14 鈥?
TROUBLESHOOTING (CONTINUED)
WHAT TO DO
TROUBLE CAUSE
1. Check and clean all connections.
C. Variable or sluggish welding. 1. Poor work or electrode terminal
connection.
2. Check recommended currents
2. Current too low.
for rod type and size.
3. Check with power company.
3. Low line voltage.
4. See Output Cable section.
4. Welding leads too small.
5. Replace.
5. Old and badly frayed welding
cables.
1. Replace switch.
D. Welder won始t shut off. 1. Line switch has failed
mechanically.
1. Replace switch.
E. Polarity switch won始t turn. 1. Contacts rough and pitted from
improper switching under load.
鈥? 15 鈥?
WIRING DIAGRAM - 250 AMP IDEALARC 60 HZ & 50 / 60 HZ
TURN THE INPUT POWER TO THE WELDER OFF USING THE DISCONNECT SWITCH
AT THE FUSE BOX 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
T HROUGH THE INPUT CABLE PER NATIONAL ELECTRICAL CODE .
DO NOT OPERATE WITH COVERS REMOVED .
HIGH VOLTAGE
can kill ONLY QUALIFIED PERSONNEL SHOULD INSTALL OR SERVICE THIS EQUIPMENT.
LINE OPTIONAL POWER
SWITCH FACTOR CAPACITORS
H1
X3
X4 ELECTRODE
H5
SEE TABL E
BELOW FOR
X1
CORRECT
CONNECTION
STABILIZER
FA N
MTR CIRCUI T
MOTOR
LOW H2
MED H3
L1
WORK
L2 X2
INPU T
H5
(- )
HIGH H4
LEAD S
RECTIFIE R
PANEL
RECONNECT
AC1
OVERLOAD
AC2
THERMOSTAT
鈥? 16 鈥?
TO GROUND PER NATIONAL
POWE R
ELECTRICAL CODE
RECTIFIE R
CHOKE
(+ )
RECONNECT PANEL LEAD POSITION
200/400 (50/60 HZ)
208/230/460 230/460/575 60 HZ
60 HZ
H5 H5 H5
INPUT VOLTS INPUT VOLTS
INPUT VOLTS
ARC POLARITY SWITCH
SUPPRESSOR
LOW LOW
LOW 230 200
208 (LOOKING FROM INSIDE MACHINE)
CIRCUI T
MED MED
230 460
MED
HIGH HIGH
575 400
460 HIGH
P.F. CAP LEAD -MED P.F. CAP LEAD -HIGH
P.F. CAP LEAD -HIGH
CONNECTIONS MUST BE TIGHTENED SECURELY.
M ACHINES ARE SHIPPED FROM FACTORY CONNECTED
ELECTRICAL SYMBOLS PER E1537.
FOR HIGHEST INPUT VOLTAGE.
8-2-90
S19343
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. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
WIRING DIAGRAM - 250 AMP IDEALARC 50 HZ
TURN THE INPUT POWER TO THE WELDER OFF USING THE DISCONNECT SWITCH
AT THE FUSE BOX 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
T HROUGH THE INPUT CABLE PER NATIONAL ELECTRICAL CODE .
DO NOT OPERATE WITH COVERS REMOVED .
HIGH VOLTAGE
can kill ONLY QUALIFIED PERSONNEL SHOULD INSTALL OR SERVICE THIS EQUIPMENT.
LINE OPTIONAL POWER
SWITCH FACTOR CAPACITORS
H1
X3
V
ELECTRODE
X4
H5
1000
STABILIZER
X1 5W
SEE TABLE FAN
CIRCUI T
B ELOW FO R MOTOR
RECTIFIER
CORREC T
MTR OVERLOAD
CONNECTIO N
THERMOSTAT
150 /100W
LOW H2
WORK
H3
L1 ME D X2
L2
INPUT H5 N.A.
H4
HIGH (-)
LEADS
PANEL
RECONNECT
鈥? 17 鈥?
AC1 AC2
TO GROUND PER NATIONAL
POWER
ELECTRICAL CODE
RECTIFIER
CHOKE
(+ )
RECONNECT PANEL LEAD POSITIO N
380/500
220/380/440
H5 ARC POLARITY SWITCH
H5 INPUT VOLTS
INPUT VOLTS
SUPPRESSOR (LOOKING FROM INSIDE MACHINE)
LO W
LO W 380
220 CIRCUIT
380 ME D ME D
415
N.A. BOLTED CONNECTION ON MACHINES
HIGH
440 HIGH 500
WITH COPPER COILS.
P.F. CAP LEAD -ME D
P.F. CAP LEAD -HIG H
M ACHINES ARE SHIPPED FROM FACTORY CONNECTED CONNECTIONS MUST BE TIGHTENED SECURELY.
FOR HIGHEST INPUT VOLTAGE.
ELECTRICAL SYMBOLS PER E1537.
8-2-90
S19441
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. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
NOTES
WARNING
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
electrode with skin or wet clothing.
AVISO DE
G Insulate yourself from work and
ground.
Spanish
PRECAUCION
G No toque las partes o los electrodos G Mantenga el material combustible G Prot茅jase los ojos, los o铆dos y el
bajo carga con la piel o ropa moja- fuera del 谩rea de trabajo. cuerpo.
da.
G Aislese del trabajo y de la tierra.
ATTENTION
French G Ne laissez ni la peau ni des v锚te- G Gardez 脿 l鈥櫭ヽart de tout mat茅riel G Prot茅gez vos yeux, vos oreilles et
ments mouill茅s entrer en contact inflammable. votre corps.
avec des pi猫ces sous tension.
G Isolez-vous du travail et de la terre.
WARNUNG
German G Ber眉hren Sie keine stromf眉hrenden G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und K枚r-
Teile oder Elektroden mit Ihrem perschutz!
K枚rper oder feuchter Kleidung!
G Isolieren Sie sich von den
ATEN脟脙O
Portuguese
Elektroden und dem Erdboden!
G N茫o toque partes el茅tricas e elec- G Mantenha inflam谩veis bem guarda- G Use prote莽茫o para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
G Isole-se da pe莽a e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER鈥橲 INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER鈥橲 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 UNFALLVERH脺TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
WARNING
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to guards off.
AVISO DE
remove fumes from breathing zone.
Spanish
PRECAUCION
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
piraci贸n. mentaci贸n de poder de la m谩quina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilaci贸n o
ATTENTION
aspiraci贸n para gases.
French
G D茅branchez le courant avant l鈥檈ntre- G N鈥檕p茅rez pas avec les panneaux
G Gardez la t锚te 脿 l鈥櫭ヽart des fum茅es.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
protection enlev茅s.
teur pour 么ter les fum茅es des zones
WARNUNG
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgeh盲use
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom v枚llig 枚ff- oder Innenschutzverkleidung in
Schweibrauch!
G Sorgen Sie f眉r gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entl眉ftung des Arbeitsplatzes!
ATEN脟脙O
Portuguese
G N茫o opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fuma莽a.
G Desligue a corrente antes de fazer
G Use ventila莽茫o e exhaust茫o para moventes.
servi莽o. G N茫o opere com os paineis abertos
remover fumo da zona respirat贸ria.
G N茫o toque as partes el茅tricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRU脟脮ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PR脕TICAS DE SEGURAN脟A DO EMPREGADOR.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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