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IM533
IDEALARC SP-255 June, 1998

For use with machine Code Numbers 10164, 10165

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’S MANUAL

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
�? 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
i i
SAFETY
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 “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.

FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. 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.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
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
magneto wire as appropriate. Mar �?95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. 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 “hot�? when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot�? 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
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
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
�? Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
�? DC Manual (Stick) Welder. your head out of the fume. Use enough
�? AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�?. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.

5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot�? parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.

5.e. Also see item 1.b.
Mar �?95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.

7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting�? (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
�? Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
�? A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.

7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot�? parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�?. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�?, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,�? available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.

6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar �?95
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
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
a. Les circuits à l’électrode et à la piéce sont sous tension
la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours
endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue
de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans
age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains.
des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’�? ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble
produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de
voir le code “Code for safety in welding and cutting�? CSA
courant pour soudage semi-automatique, ces precautions
Standard W 117.2-1974.
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
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
du corps.

TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:

a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �?93
v v

for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•�?��?? as much pride as we have in bringing this product to you!

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

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.

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.
vi

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)

APR96 IDEALARC SP-255
vii

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

IDEALARC SP-255
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS �? IDEALARC® SP-255
INPUT �? SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current (@ Max Rated Output)
208/230/60 Hz 53/49 Amps
230/460/575 Hz 50/25/20 Amps

RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
35% 250 Amps 26 Volts
60% 200 Amps 28 Volts
100% 145 Amps 26 Volts

OUTPUT
Welding Current Range Maximum Open Circuit Voltage Wire Speed Range
30-250 Amps 40 Volts 50-600 IMP (1.27-15.2 m/min)

RECOMMENDED INPUT CABLE AND FUSE SIZES
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.

8 (10 mm2) 6 (16 mm2) #10 (6 mm2)
208 60 53
10 (6 mm2) 8 (10 mm2) #10 (6 mm2)
230 60 50
14 (2.5 mm2) 12 (4 mm2) #10 (6 mm2)
460 30 25
14 (2.5 mm2) 12 (4 mm2) #10 (6 mm2)
575 25 20

PHYSICAL DIMENSIONS
Height Width Depth Weight
28.2 in 18.8 in 40.1 in 222 Ibs
719 mm 480 mm 1019 mm 101 kg

OPERATING TEMPERATURE STORAGE TEMPERATURE
-20° C TO 40°C ±40°C

AUG 95 IDEALARC SP-255
A-2 INSTALLATION
1. Before starting the installation, check with the local
Read entire Installation section before starting
power company if there is any question about
installation.
whether your power supply is adequate for the volt-
SAFETY PRECAUTIONS 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
WARNING may be operated from a single phase line or from
one phase of a two or three phase line.
ELECTRIC SHOCK can kill.
2. Models that have multiple input voltages specified
�? Only qualified personnel should perform
this installation. on the nameplate (e.g., 208/230) are shipped con-
nected for the higher voltage. If the welder is to be
�? Only personnel that have read and under-
stood the SP-255 Operating Manual should operated on lower voltage, it must be reconnected
install and operate this equipment.
according to the instructions on the inside of the
�? Machine must be plugged into a receptacle removable panel near the top left side of the rear
which is grounded per any national, local
panel. These instructions are repeated below:
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.

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.

WARNING
INPUT POWER AND GROUNDING
CONNECTIONS Make certain that the input power is electrically
disconnected before removing the screw that
WARNING holds the removable rear panel in place.

ELECTRIC SHOCK can kill.
3. The 208/230 volt 60 Hz model SP-255 is shipped
�? Do not touch electrically live parts such as
output terminals or internal wiring with a 10 ft. (3.0 m) input cable and plug connected
to the welder. A matching receptacle is supplied
�? Allinput power must be electri-
cally disconnected before with the machine. Mount the receptacle in a suit-
proceeding. 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.

IDEALARC SP-255 OCT94
A-3
INSTALLATION

The 230/460/575 volt 60 Hz model is not equipped OUTPUT POLARITY CONNECTION
with a plug, input cable or receptacle.
WARNING
4. Using the following instructions have a qualified
electrician connect the receptacle or cable to the Turn the welder power switch off before changing
input power lines and the system ground per the output connection.
U.S. National Electrical Code and any applicable
local codes. See the “Technical Specifications�?
The welder, as shipped from the factory, is connected
page at the beginning of this chapter for proper
for electrode positive (+) polarity. This is the normal
wire sizes. For long runs over 100 feet (30 m), larg-
polarity for GMA welding.
er copper wires should be used. Fuse the two hot
lines with super lag type fuses as shown in the fol-
If negative (�?) polarity is required, interchange the
lowing diagram. The center contact in the recepta-
connections of the two cables located in the wire drive
cle is for the grounding connection. A green wire in
compartment near the front panel. The electrode
the input cable connects this contact to the frame
cable, which is attached to the wire drive, is to be con-
of the welder.
nected to the negative (�?) labeled terminal and the
work lead, which is attached to the work clamp, is to
This ensures proper grounding of the welder frame
be connected to the positive (+) labeled terminal.
when the welder plug is inserted into the
receptacle.

GUN AND CABLE INSTALLATION
SINGLE PHASE INPUT SUPPLY RECONNECT DIAGRAM FOR 230/460/575 60 HZ MACHINES
TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH BEFORE INSTALLING
WARNING
OR SERVICING THIS MACHINE.
The Magnum�? 250SP gun and cable provided with
DO NOT TOUCH ELECTRICALLY "HOT" PARTS SUCH AS OUTPUT TERMINALS
OR INTERNAL WINDINGS.

the SP-255 is factory installed with a liner for .035-
GROUNDING SCREW MUST BE CONNECTED TO A GOOD EARTH GROUND PER
NATIONAL ELECTRICAL CODE.

.045" (0.9-1.2 mm) electrode and an .035" (0.9 mm)
DO NOT OPERATE WITH COVERS REMOVED.
HIGH VOLTAGE
ONLY QUALIFIED PERSONNEL SHOULD INSTALL OR SERVICE THIS EQUIPMENT.
can kill
contact tip. Install the .045 tip (also provided) if this
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
wire size is being used. For other wire sizes, see Gun
JUMPERS PER DIAGRAM BELOW. ALWAYS CONNECT JUMPERS BETWEEN OUTER STEEL NUT AND
INNER BRASS NUT ON TERMINAL STUDS.

and Cable Maintenance.
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
230V / 60HZ. 460V. / 60HZ. 575V. / 60HZ.
WARNING
VOLTAGE
L1
L1 L2
L2
L1 L2 5 5 5
JUMPER
2
4 2
4 2
4
Turn the welder power switch off before installing
CONNECTION
1 3 1
1 3
3
DIAGRAMS
gun and cable.
BOTH
JUMPERS

1. Lay the cable out straight.
TO GROUND PER NATIONAL ELECTRICAL CODE
SINGLE PHASE INPUT POWER SUPPLY LINES

2. Make sure all pins on the gun cable connector are
S21531-1

aligned with the proper mating sockets on the front
CONNECT TO A SYSTEM GROUND-
panel gun connector and then join the connectors
ING WIRE. SEE THE UNITED STATES
NATIONAL. ELECTRICAL CODE
and tighten the hand nut on the gun cable connec-
AND/OR LOCAL CODES FOR OTHER
tor.
DETAILS AND MEANS FOR PROPER
GROUNDING.
NOTE: If a gun and cable other than the Magnum
CONNECT TO HOT WIRES OF A
250SP is to be used, it must conform to standard
THREE-WIRE, SINGLE PHASE SYS-
European-style connector (Magnum Fast-Mate�?)
TEM OR TO ONE PHASE OF A TWO
OR THREE PHASE SYSTEM.
specifications. See diagram below.

IDEALARC SP-255
A-4 INSTALLATION
Gun - END VIEW 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.

WARNING
Be sure to keep your face away from the valve
outlet when “cracking�? the valve.
However, the thumbswitch functions available on
the Magnum 250SP gun will only be operable from
the front panel keypad. The gun trigger switch must 4. Inspect the regulator for damaged threads, dirt,
be capable of switching 5 milliamps at 15 volts dust, oil or grease. Remove dust and dirt with a
DC�? resistive. clean cloth.

CAUTION DO NOT USE THE REGULATOR IF OIL,
GREASE OR DAMAGE IS PRESENT! Have an
The gun trigger switch connected to the gun trig- authorized repair station clean the regulator or
ger control cable must be a normally open, repair any damage.
momentary switch. The terminals of the switch
must be insulated from the welding circuit. 5. Attach the flow regulator to the cylinder valve and
Improper operation of or damage to the SP-255 tighten the union nut(s) securely with a wrench.
might result if this switch is common to an electri-
cal circuit other than the SP-255 trigger circuit. NOTE: If connecting to 100% CO2 cylinder, insert
regulator adapter provided between regulator and
cylinder valve. If adapter is equipped with a plastic
SHIELDING GAS washer, be sure it is seated for connection to the
(For Gas Metal Arc Welding Processes) CO2 cylinder.

Customer must provide cylinder of appropriate type 6. Attach one end of the inlet gas hose to the outlet
shielding gas for the process being used. fitting of the flow regulator, the other end to the SP-
255 rear fitting, and tighten the union nuts securely
with a wrench.
WARNING
7. Before opening the cylinder valve, turn the regula-
CYLINDER may explode if
tor adjusting knob counter-clockwise until the
damaged.
adjusting spring pressure is released.
Gas under pressure is explosive.
Always keep gas cylinders in an 8. Open the cylinder valve slowly a fraction of a turn.
upright position and always keep When the cylinder pressure gauge pointer stops
chained to undercarriage or stationary support. moving, open the valve fully.
See American national Standard Z49.1, “Safety in
Welding and Cutting�? published by the American
WARNING
Welding Society.
Never stand directly in front of or behind the flow
regulator when opening the cylinder valve. Always
1. Set gas cylinder in rear platform of SP-255. Hook stand to one side.
chain in place to secure cylinder to rear of welder.

2. Remove the cylinder cap. Inspect the cylinder 9. The flow regulator is adjustable. Set it for the flow
valves for damaged threads, dirt, dust, oil or rate recommended for the procedure and process
grease. Remove dust and dirt with a clean cloth. being used before making the weld.

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.

IDEALARC SP-255 OCT94
B-1
OPERATION
Read entire Operation section before
operating the SP-255.

WARNING
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.

IDEALARC SP-255
B-2 OPERATION
PRODUCT DESCRIPTION DESCRIPTION OF CONTROLS AND
KEYS
The SP-255 is a complete semiautomatic constant
voltage DC arc welding machine built to meet NEMA POWER SWITCH
specifications. It combines a constant voltage power
source and a constant speed wire feeder with a micro- Place the lever in the “ON�? position to turn the SP-255
computer-based controller. This forms an intelligent on. When the power is on, the red LED backlighting of
welding system that really puts the automatic in semi- the LCD display will be lit, and the screen will contain
automatic. A touch key entry system with audible a readable display. The welding setup present when
feedback, along with a two-line, 32 character alphanu- the power was shut off or disconnected will be
meric display provide user friendly control of the sys- restored when the power is restored.
tem.
SETUP KEYS
Multilingual display capability allows the SP-255 to
communicate with the user in any of the following lan- DISPLAY LANGUAGE SELECTION
guages: English, German, French, Spanish, or
Japanese (Katakana). 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,
RECOMMENDED PROCESSES AND German, French, Spanish, and Japanese (Katakana).
EQUIPMENT 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
The SP-255 is recommended for GMA welding
appropriate language on the Keypad Instruction Decal
processes using 10 to 44 lb. (4.5 to 20 kg) 2" (51 mm)
inside the SP-255 door, also shown below:
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
ArO2 or HeArCO2 shielding gas, 3/64" (1.2 mm) alu-
minum using Ar shielding gas, and .045" (1.2 mm)
Outershield® electrodes using CO2 or ArCO2 shielding
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
CO 2 and Argon blend flow regulator. A supply of
shielding gas is required for GMAW processes.

WELDING CAPABILITY ARROW KEYS

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
There are three pairs of arrow keys: left, center, and
The SP-255 may not operate as designed if powered
right. The up arrow keys increase the selection dis-
with a portable or in-plant generator.
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

IDEALARC SP-255
B-3
OPERATION
are held closed. The left pair will automatically contin-
ue to increment or decrement the selection above it at 3. Spool Gun Start Mode
a slow, steady rate as long as the key is pressed. The If using optional spool gun mode (see “Making
center and right pairs will continue to increment and a Weld with the Spool Gun�? in Accessories sec-
decrement the selections above them at a slow rate, tion), the RUN-IN portion of the starting screen
but then the rate will gradually increase until it is not functional and will not be displayed. The
becomes very rapid. This allows rapid setting from a START voltage is adjusted as described above
small quantity to a large quantity or vice versa while (Figure 3).
maintaining an excellent resolution (i.e., 50 IPM to 600 FIGURE 3
IPM). However, when the trigger is closed, the
changes will be at a steady, moderate rate to allow for
proper “on the fly�? control.

The starting screen is exited by pressing any
START MODE SELECTIONS key on the keypad except TIMERS OFF, IPM-
VOLTS or any Arrow key. Closing Gun Trigger
The SP-255 permits selection of Fast/Slow Run-In will also not clear the starting screen.
wire feed speed as well as adjustment of the start
striking voltage, to optimize arc starting, using the NOTE: It is not necessary to repeat the above
starting screen display. procedure each time the unit is powered up.
That is, the unit will remember the start mode
The starting screen (see Figures below) is settings from the previous power down and
displayed by pressing and holding both the return you to that same state upon your next
PROCESS key and the TIMERS OFF key at power up. thus, you need only perform the
the same time. 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
FIGURE 1 should be aware that when recalling a memo-
rized procedure, he is also recalling particular
1. Run-In Speed start mode which will override any present start
The SP-255 is factory set for FAST run-in mode setting and remain in effect until either
(Figure 1) where the wire feed will accelerate the mode is changed using the above proce-
directly to the preset speed. SLOW run-in will dure or until a memorized procedure containing
initially feed at 50 IPM until welding current is another start mode is recalled.
sensed, or for 2 seconds if feeding without
welding (loading wire).
PROCESS (WIRE/GAS) KEY
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).

This key is used to display the Wire Type, Wire
Diameter, and Welding Gas. Each combination of wire
FIGURE 2 and gas dictates a unique relationship between the
wire feed speed and the arc voltage. The SP-255
2. Start Voltage uses this unique relationship, along with the metal
The START voltage setting (Figure 1 or 2) may thickness, to set the proper values of wire feed speed
be offset from the factory programmed level and arc voltage. Therefore, it is very important that
(00%) by up to ±30% above or below pro- the wire type, wire diameter, and welding gas on
grammed level using the right arrow keys, or the display match the actual wire type, wire diame-
from the gun thumbswitch by positioning the ter, and welding gas being used for the weld.
screen cursor beneath the START display using
the IPM-VOLTS key. (see “Gun Switch Keys�? in Left arrow keys—set Wire Type
this section).

JAN96 IDEALARC SP-255
B-4 OPERATION
Center arrow keys—set Wire Diameter available sizes. (NOTE: If the spot or stitch timers are
on, metal thickness is not displayed and, therefore,
Right arrow keys—set Welding Gas the left arrow keys will not function. Also, the left arrow
keys do not function when the trigger is closed. (See
The following 16 processes are programmed into the Figures I and 2 following.)
SP-255:
Center arrow keys �? Increases (up arrow) or
Wire Type Wire Diameter Welding Gas decreases (down arrow) wire feed speed setting.
Increasing or decreasing wire feed speed will
Solid Steel .025 (0.6mm) CO2
Solid Steel .025 (0.6mm) ArCO2 simultaneously cause an increase or decrease in
Solid Steel .030 (0.8mm) CO2
the arc voltage and can change the metal thick-
Solid Steel .030 (0.8mm) ArCO2
ness setting.
Solid Steel .035 (0.9mm) CO2
Solid Steel .035 (0.9mm) ArCO2
Solid Steel .035 (0.9mm) ArO2
Right arrow keys �? Increases (up arrow) or
Solid Steel .045 (1.2mm) CO2
decreases (down arrow) arc voltage setting. An up
Solid Steel .045 (1.2mm) ArCO2
arrow indicator appears below the V in VOLTS if
Stainless .035 (0.9mm) ArO2
Stainless .035 (0.9mm) HeArCO2 the arc voltage has been set higher than the rec-
ommended value, and a down arrow indicator
Aluminum (5356) 3/64�? (1.2mm) Argon
appears below the V in VOLTS if the arc voltage is
Outershield® .045 (1.2mm) CO2
Outershield .045 (1.2mm) Ar/CO2 below the recommended value. No arrow indicates
Innershield® that you are set to the recommended value. (See
.035 (0.9mm) None
Innershield .045 (1.2mm) None Figures 4 and 5 following.)

PROCEDURE KEYS 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
Because design, fabrication, assembly and
or stitch timers are on, metal thickness is not dis-
welding variables affect the results obtained in
played and, therefore, the repress function does not
applying recommended procedure information,
work.)
the serviceability of a product or assembly is
the responsibility of the builder/user.

AUTO KEY

Figure 4 Figure 5

Pressing the Auto Key once places the SP-255 into TYPICAL AUTO KEY PRESS SEQUENCES
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- Process screen is being displayed prior to pressing
ter, wire feed speed, or arc voltage is being controlled Auto key. The Auto key is pressed, the Auto screen is
by the thumbswitch on the SP-255 gun (see Gun now displayed.
Switches section).
If the unit was in a Manual configuration (see Manual
Left arrow keys �? Increases (up arrow) or Key) when the Auto key was pressed, the audio alarm
decreases (down arrow) metal thickness setting. will beep three times and a message (see below) will
Increasing or decreasing metal thickness automati- be displayed for 2.5 seconds reminding you that the
cally increases or decreases both wire feed speed process entered into the SP-255 (see Process Key)
and arc voltage simultaneously. See gauge chart must match the wire and gas being used. After the 2.5
on instruction label on inside of SP-255 door for second period is over, the Auto screen will be dis-
played with the same procedure that was in Manual.

IDEALARC SP-255
B-5
OPERATION
Repressing the Auto Key sets the recommended pro-
cedure for the metal thickness displayed.

MEMORY KEYS

SAVE KEY

Saves present setup (including process, procedure,
and timer functions, if used) to one of five memories
MANUAL KEY 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
Permits individual setting of wire feed speed and arc number (see Key Press Sequence following).
voltage for manual procedure setup. The manual
screen displays wire feed speed, arc voltage, and a The six arrow keys perform no function when saving a
cursor that indicates which parameter, wire feed setup.
speed, or arc voltage is being controlled by the thumb-
switch on the SP-255 gun (see “Gun Switches�? in NOTE: When a setup is saved to a memory, the previ-
operation section). ous content of that memory is lost because it is
replaced by the present setup. Removing input power
Left arrow keys �? Do not function in Manual mode. does not affect setups In memory.
Center arrow keys �? Increase (up arrow) or
decrease (down arrow) wire feed speed. TYPICAL SAVE KEY PRESS SEQUENCE
Right arrow keys �? Increase (up arrow) or Auto screen displayed prior to pressing Save key.
decrease (down arrow) arc voltage. Save key is pressed, and display changes to prompt-
ing message. Memory 1 key is pressed, and the dis-
If the spot or stitch timers are on it will be indicated in play changes to a message that confirms the setup
the bottom left corner of the display. (See Figures 6 was saved to memory 1. The message is displayed
and 7 below.) for 2.5 seconds, and then the original Auto screen is
displayed.
TYPICAL MANUAL KEY PRESS SEQUENCE

Figure 6 Figure 7

MEMORY NUMBER KEY
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 Pressing the desired Memory Number key recalls the
that was in Auto. setup saved in that memory (including process, proce-
dure, and timer functions if used).

IDEALARC SP-255
B-6 OPERATION
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.

TIMER KEYS

SPOT KEY

If the memory is empty (contains no setup yet), then a
message indicating that (see below) will be displayed
Turns on the Spot weld timer and displays selection of
when the Memory Number key is pressed. The mes-
the spot ON time. Pressing the Spot key a second
sage will be displayed for 2.5 seconds, and then the
time returns the screen to the previous display without
display will change to the original display before the
turning off the spot timer Any time the Spot weld timer
Memory Number key was pressed.
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
If the setup in memory is an Auto mode type and it
(0.20 to 2.50s).
requires a different wire type, wire size, or welding
gas, the display will alternate messages (see below),
Right arrow keys �? Do not function.
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
TYPICAL SPOT KEY PRESS SEQUENCE
once you have installed the process required into the
SP-255. Once the required process has been
Auto screen is displayed prior to pressing Spot key.
installed, press the Process key and the setup will be
Spot key is pressed, Spot On timer is activated and
recalled from memory 1 and the display will show the
the display changes to Spot screen. Spot ON timer
required process. Press Auto key or close the gun trig-
can now be adjusted using the center arrow keys.
ger to display the procedure stored in memory 1.
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.

IDEALARC SP-255 OCT94
B-7
OPERATION
STITCH KEY 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.)

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.
GUN SWITCH KEYS
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. IPM VOLTS KEY

Left arrow keys �? Do not function.
Sets the gun thumbswitch to control IPM or VOLTS.
Center arrow keys �? Increase (up arrow) or Pushing the gun thumbswitch forward (toward the tip)
decrease (down arrow) Stitch ON time in seconds increases and pulling it back decreases IPM or
(0.20 to 2.50s). VOLTS. The underlining cursor always indicates the
selection being controlled by the gun thumbswitch. If
Right arrow keys �? Increase (up arrow) or the cursor is not present, the gun thumbswitch will not
decrease (down arrow) Stitch OFF time in seconds be functional which prevents any inadvertent actua-
(0.20 to 2.50s). 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.
TYPICAL STITCH KEY PRESS SEQUENCE
NOTE: In Auto mode, changing IPM will change arc
Auto screen is displayed prior to pressing Stitch key. voltage also and can cause a change in metal thick-
Stitch key is pressed, Stitch timers are activated and ness as well.
the display changes to Stitch screen. Stitch ON and
OFF timers can now be adjusted using the center and TYPICAL IPM VOLTS KEY PRESS SEQUENCE
right arrow keys. Once the timers have been set,
pressing the Stitch key again returns the display to Auto screen is displayed prior to pressing IPM VOLTS
the original Auto screen with the Stitch timer status key. IPM VOLTS key is pressed, cursor moves from
indicated in the bottom left corner. 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.

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.
TOGGLE 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

IDEALARC SP-255
B-8 OPERATION
The first time this key is pressed it turns on toggle metal thickness setting.
mode and recalls the setup in memory 4. This mode
allows you to toggle between the setups in memory 4 Right arrow keys �? Increases (up arrow) or
and memory 5. Each time the key is pressed, it alter- decreases (down arrow) arc voltage setting. If in
nates between the two memories. The toggle screen Auto mode, an up arrow indicator appears below
displays the memory number the current setup was the V in VOLTS if the arc voltage has been set
recalled from, indicates automatic (AUTO:) or manual higher than the recommended value, and a down
(MAN:) mode, displays gauge if in Auto mode, set arrow indicator appears below the V in VOLTS if
wire feed speed, and set arc voltage. The cursor the arc voltage is below the recommended value.
underlines the memory number currently selected. No arrow indicates that you are set to the recom-
mended value.
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- TYPICAL TOGGLE KEY PRESS SEQUENCE
play (see “Procedure Keys�? in operation section). Also
Spot or Stitch timer status will be displayed in the Auto screen is displayed prior to pressing Toggle key.
lower left-hand corner if either timer is active. Toggle key is pressed, memory 4 is recalled and
appears on the display. The unit is now in toggle
The gun thumbswitch functions as a Toggle key in mode. Pressing the Toggle key again or pushing the
Toggle mode. Pushing the gun thumbswitch forward gun thumbswitch forward (toward the gun tip) “tog-
(toward the tip) selects the setup in memory 5, and gles�? the unit, and memory 5 is recalled and appears
pulling it back selects the setup in memory 4 (see on the display. Pressing the Toggle key again or
Gun Thumbswitch Section). The gun thumbswitch pulling the gun thumbswitch back (toward the gun
also functions with the trigger closed for “on the fly�? cable) “toggles�? the unit, and memory 4 is recalled
changes during a weld. and appears on the display. This whole cycle is
repeatable as long as the unit remains in Toggle
To turn toggle mode off, press Auto, Manual, or any mode.
Memory Number key.

CAUTION
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.
When the Toggle key is pressed and the setup in
Center arrow keys �? Increases (up arrow) or memory 4 or 5 is an Auto mode type and it requires a
decreases (down arrow) wire feed speed setting. If different wire type, wire diameter, or welding gas, a
in Auto mode, increasing or decreasing wire feed message (see below) will be displayed for 2.5 sec-
speed will simultaneously cause an increase or onds telling you which memory does not match the
decrease in the arc voltage and can change 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

IDEALARC SP-255
B-9
OPERATION
the one that did not match (see Memory Number Key USING 4-STEP TRIGGER INTERLOCK
Section). 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
4-STEP TRIGGER INTERLOCK KEYS the weld returning the trigger function to normal
mode so the weld will be stopped when the trig-
Pressing and ger is released. Releasing the trigger reinstates
the trigger interlock function for the next weld.

Controls whether 4-step trigger interlock is activated The second trigger interlock stopping method per-
or deactivated. (See “Using 4-Step Trigger Interlock mits the user better control at the finish of the weld
Function�? section.) and allows automatic burnback to prevent exces-
sive wire feed speed overrun.
NOTE: 4-Step Trigger is automatically deactivated if
either the spot or stitch timer mode is being used. The 4-step trigger feature does not function when
using SPOT or STITCH timed welding modes.
TYPICAL ACTIVATE KEY PRESS SEQUENCE (See “Spot and Stitch Weld Modes�? in this section.)

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.

IDEALARC SP-255
B-10 OPERATION
GUN SWITCHES 4. Remove the thumbscrew from the drive roll. Turn
the drive roll over or change to another roll as
required. Reinstall the thumbscrew.
Gun Trigger Switch �? Turns on arc voltage, wire
feeder, and gas solenoid (except with Innershield)
5. Be sure the gun liner and contact tip are properly
when closed. Also causes the screen to display the
sized for wire being used. (See Gun and Cable
Auto or Manual screens (depending on which mode it
Maintenance section.)
is in), when the trigger is pulled. Turns off arc voltage,
wire feeder, and gas solenoid when opened.

WIRE REEL LOADING
NOTE: If using Slow Run-In, when the trigger is
pulled, the wire feeder feeds wire a low speed regard-
MOUNTING OF 22 TO 30 LB. READI-
less of the set wire feed speed until the welding arc
REELS
starts or 2 seconds has elapsed. This feature
enhances starting and makes it easier to set the stick-
To mount a 22-30 Ib. (10-14 kg) Readi-Reel® pack-
out. The 2 second limit permits high speed loading of
age using the optional Readi-Reel Adapter
the gun and cable. To change Run-In mode, see
(K363P).
“Start Mode Selections�? in this section.

1. Remove the locking collar from the 2" O.D. spindle
Gun Thumbswitch (Magnum�? 250SP Only) �?
and mount the K363P Adapter so the spindle pin
Used to control wire feed speed, arc voltage, or selec-
engages the hole provided in the Adapter. Replace
tion of toggle memories 4 and 5. See IPM VOLTS key
and tighten the locking collar.
and Toggle key for control details. The increase or
decrease function of the thumbswitch is the same as
2. Rotate the spindle and adapter so the retaining
the center and right arrow key pairs for IPM or VOLTS
spring is at the 12 o’clock position.
setting. (See Arrow keys in “Setup Keys�? section
for details.)
3. Position the Readi-Reel so that it will rotate in a
counterclockwise direction (as viewed from
WIRE DRIVE ROLL retaining spring side of Adapter) when wire is
dereeled from the top of the coil as shown below:
The drive roll provided with the SP-255 has two
grooves, one for .030-.035" (0.8-0.9 mm) solid steel MOLDED ADAPTER

electrode, and the other for .045" (1.2 mm) solid steel RETAINING SPRING

electrode. The welder is shipped with the drive roll
installed in the .030-.035" (0.8-0.9 mm) position as WIRE DEREELING
DIRECTION
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 2" O.D. SPINDLE LOCKING COLLAR

or changed. BRAKE TENSION
ADJUSTING SCREW

READI-REEL

PROCEDURE FOR CHANGING INSIDE CAGE WIRES
DRIVE ROLL 4. Set one of the Readi-Reel inside cage wires on the
slot in the retaining spring tab.
Different wire sizes may require changing the drive
roll. The applicable wire sizes are stamped on the
5. Lower the Readi-Reel to depress the retaining
drive roll. Dual groove rolls must be installed so the
spring and align the other inside cage wires with
side with the proper wire size stamp faces out.
the grooves in the molded adapter.
1 Turn off the power source.
6. Slide cage all the way onto the adapter until the
retain spring “pops up�? fully.
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.

IDEALARC SP-255
B-11
OPERATION
for the wire size and type being used. (Refer to
WARNING Accessories section.)

Check to be sure the retaining spring has fully 1. Turn the Readi-Reel or spool until the free end of
returned to the locking position and has securely the electrode is accessible.
locked the Readi-Reel cage in place. Retaining
spring must rest on the cage not the welding elec- 2. While securely holding the electrode, cut off the
trode. 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
To remove Readi-Reel from Adapter, depress retain- not go into the outgoing guide tube causing a
ing spring tab with thumb while pulling the Readi-Reel “birdnest�?)
cage from the molded adapter with both hands. It is
not necessary to remove adapter from spindle. 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.
MOUNTING OF 10 TO 44 LBS. SPOOLS
4. Turn “OFF�? weld timers by pressing TIMERS OFF
key. Press the gun trigger and push the electrode
To mount 10 to 44 lb. spools (8" and 12" diame-
into the drive roll. If the electrode fails to thread
ter): (For 8" spools a K468 adapter must be used.)
itself into the outgoing guide tube of the wire drive,
open the quick release idle roll arm, thread the
1. Remove the locking collar and the Readi-Reel
electrode manually, and reclose the arm.
adapter (if installed) from the 2" dia. spindle.

5. Inch the electrode through the gun.
2. If using an 8" spool, place the K468 adapter on the
spindle first. The hole in the adapter arm is to
NOTE: If using the low speed starting feature of
engage the pin on the spindle.
the SP-255, the wire will feed at low speed for 2
seconds while inching, then come up to the set
3. Place the spool on the spindle making certain the
speed.
brake driving pin enters one of the holes in the
back side of the spool. Be certain the wire comes
6. Check that the welding process is set for the wire
off the reel in a clockwise direction when dereeled
type, diameter, and gas per instructions on name-
from the top of the coil.
plate.
4. Replace and tighten the locking collar for several
seconds.
IDLE ROLL PRESSURE SETTING
TO START THE WELDER 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
Turn the “Power�? switch to “ON�? This lights the red
varies with type of wire, wire diameter, surface condi-
LED back lighting of the LCD display and a readable
tion, lubrication, and hardness. As a general rule, hard
screen should be visible on the display. With the
wires may require greater pressure, and soft, or alu-
desired weld mode selected, operate the gun trigger
minum wire, may require less pressure than the facto-
for welder output and to energize the wire feed motor.
ry setting. The optimum idle roll setting can be deter-
mined as follows:
FEEDING ELECTRODE
1. Press end of gun against a solid object that is elec-
trically isolated from the welder output and press
WARNING
the gun trigger for several seconds.
When inching, the electrode and drive mechanism
2. If the wire “birdnests,�? jams or breaks at the drive
are always “hot�? to work and ground and remain
roll, the idle roll pressure is too great. Back the
“hot�? several seconds after the gun trigger is
thumbscrew out 1/2 turn, run new wire through
released.
gun, and repeat above steps.

NOTE: Check that drive rolls and gun parts are proper

IDEALARC SP-255
B-12 OPERATION
3. If the only result was drive roll slippage, loosen the Press again to return to previous
gun cable Fast-Mate�? connection nut from the display.
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, 4.b.Press then select:
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:

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-
3. Press then select:
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�?.

WARNING
When using an open arc process, it is necessary
4. If Spot or Stitch timing modes are required, per- to use correct eye, head, and body protection.
form either step 4.a. for Spot or step 4.b. for
Stitch; otherwise, go to step 5.
9. Position electrode over joint. End of electrode
4.a.Press then select: 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.

IDEALARC SP-255 OCT94
B-13
OPERATION
12. When no more welding is to be done, close valve AVOIDING WIRE FEEDING
on gas cylinder (if used), momentarily operate PROBLEMS
gun trigger to release gas pressure, and turn off
SP-255. Wire feeding problems can be avoided by observing
the following gun handling procedures:
SPOT WELD MODE a. Do not kink or pull cable around sharp corners.
Arc spot plug welds are used when continuous welds b. Keep the electrode cable as straight as possible
are not needed or to hold thin sheet metal together when welding or loading electrode through cable.
prior to stitch welding or continuous welding. Plug
welds are made by using a punch to make a 3/16 inch c. Do not allow dolly wheels or trunks to run over
(4.8 mm) diameter hole in the top sheet and arc weld- cables.
ing through the hole into the back sheet.
d. Keep cable clean by following maintenance
Spot On Time sets welding time. Start with a dial set- instructions.
ting of about 1.2 seconds.
e. Use only clean, rust-free electrode. The Lincoln
To make an arc spot plug weld, punch 3/16 inch (4.8 electrodes have proper surface lubrication.
mm) holes in top sheet. Set the procedure for the
metal thickness to be welded. Install spot weld nozzle f. Replace contact tip when the arc starts to become
(if available) on gun and press it against the top sheet unstable or the contact tip end is fused or
so the top and bottom sheets are tight together. Close deformed.
trigger and hold it closed until the arc goes out. If a
spot weld nozzle is not used, smoother welds will g. Keep wire reel spindle brake tension to minimum
result by moving the welding wire in a small circle dur- required to prevent excess reel over-travel which
ing the weld. may cause wire “loop-offs�? from coil.

h. Use proper drive rolls and wire drive idle roll pres-
STITCH WELD MODE sure for wire size and type being used. (See Drive
Roll Kits in Accessories section.)
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 FAN CONTROL
sheet metal with small welds, minimum distortion, and
no burnthrough. The fan motor is thermostatically controlled to provide
cooling for the transformer and other components
Stitch On Time sets welding time. Start with a dial set- only when required. Even though the power switch is
ting of 0.5 seconds. Raise setting to increase penetra- on, the fan motor will not run when the machine does
tion and weld size; lower setting to reduce burn- not require fan cooling, such as when first turned on,
through and distortion. or when welding at low current or duty cycle proce-
dures.
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.
INPUT LINE VOLTAGE
PROTECTION
To weld, set the procedure for the metal thickness to
be welded. Close trigger and hold it closed for length
HIGH LINE VOLTAGE—If the line voltage exceeds
of seam. Hold gun in one place during ON time and
121% of rated input voltage, the output will be
move gun just beyond edge of molten metal during
reduced to the lower level to protect voltage rating of
OFF time.
the capacitor bank. A HIGH LINE message will be dis-
played if the output has been reduced (see Section on
NOTE: For smoothest welds on thinner metal, point
Explanation of Prompting and Error Messages).
gun slightly toward direction of travel.

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

IDEALARC SP-255
B-14 OPERATION
LINE message will be displayed (see Section on WELDING THERMAL OVERLOAD
Explanation of Prompting and Error Messages). The PROTECTION
unit will continue to weld, but the output will be less
than what is set. 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
WIRE FEED OVERLOAD exceeds the maximum safe operating temperature
PROTECTION because of a frequent overload, or high ambient tem-
perature plus overload. The thermostats automatically
The SP-255 has solid state overload protection of the reset when the temperature reaches a safe operating
wire drive motor. If the motor becomes overloaded, level.
the protection circuitry turns off the arc voltage, wire
feed speed and gas solenoid and then causes the
OVERCURRENT PROTECTION
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 The machine will automatically reduce the output if
checked. Check for proper size tip, liner, and drive the load on the machine exceeds 260 to 280
rolls, for any obstructions or bends in the gun cable, amperes. This protects the welding power SCR’s from
and any other factors that would impede the wire excessive short circuit currents and from exceeding
feeding. To resume welding, simply pull the trigger. 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).

EXPLANATION OF PROMPTING AND ERROR MESSAGES
On Screen Error Message Message Explanation

PROCESS MUST Reminder that in Auto mode the process entered with the Process key must match
MATCH WIRE & GAS the process installed in the machine.

ONLY SET UP FOR Unit is only programmed for .035 (0.9 mm) diameter in stainless steel wire. Other
.035 STAINLESS wire diameters can be accommodated by using the Manual mode.

ONLY ARGON USED Unit is programmed to use only argon gas with aluminum electrodes. Other gases
WITH ALUMINUM can be accommodated by using the Manual mode.

ONLY SET UP FOR Unit is only programmed for .045 (1.1 mm) diameter in Outershield® electrode wire.
.045 OUTERSHIELD Other wire diameters within the SP-255 rating can be accommodated by using the
Manual mode.

NO GAS REQUIRED Innershield® electrode wire does not require a shielding gas. In the Auto mode the
WITH INNERSHIELD SP-255 automatically leaves the solenoid de-energized even when the trigger is
closed.

MEMORY 1 NOW Verifies that the setup was saved to memory number 1. The actual memory num-
CONTAINS SETUP ber is determined by the memory number key that was pressed following Save.

MEMORY 2 An attempt was made to recall a setup from a memory that does not contain one.
IS EMPTY The actual memory number is determined by the memory number key that was
just pressed.

MEMORY 4 DOESN’T An attempt was made to enter Toggle mode and the process of the Auto setup in
MATCH WIRE & GAS 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.

IDEALARC SP-255
B-15
OPERATION

On Screen Error Message Message Explanation

REQ’S: STAINLESS An attempt was made to recall from memory an Auto setup whose process doesn’t
WIRE .035 Ar02 match the process in the machine. This message indicates the process required
and alternates with the second message until the Process key is pressed.

PRESS PROCESS
WHEN INSTALLED

DATA ***ERROR*** An attempt was made to recall a setup from memory that has improper settings
CHECK 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
PRESS PROCESS TO alternates with the second message until the Process key is pressed.
CHECK SETTINGS

MOTOR OVERLOADED Unit shut down even though trigger was closed. There is an excessive current
CHECK GUN, DRIVE 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.

XXXX ***ERROR*** Indicates that an error has occurred due to excessive electrical interference. All of
CHECK SETTINGS 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.
PRESS PROCESS TO
CHECK SETTINGS XXXX This table shows all of the actual lettering which appears in place of
IC31 XXXX. There is no reason to note which of these occurred unless it
RTI occurs frequently.
SWI
IOT
XIRQ
PWOF
DATA

GUN SWITCH BEING Reminds the operator that the gun switch is being used to toggle between memory
USED FOR TOGGLE 4 and memory 5 and, therefore, is not able to control IPM or arc VOLTS.

CONNECT FOR Reminds the operator to change the electrode polarity to negative when
NEG. POLARITY Innershield wire type is selected.

LOW LINE: CHECK Indicates to operator that the input line voltage is too low to obtain the output set
RECONNECT PANEL 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
PRESS ANY KEY obtainable at that line voltage and load current. The operator should check if the
TO STOP MESSAGE 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.

IDEALARC SP-255
B-16 OPERATION

On Screen Error Message Message Explanation

HIGH LINE: CHECK Indicates to operator that the line voltage is too high, and the output voltage has
RECONNECT PANEL 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
PRESS ANY KEY operator should check if the reconnect panel is wired properly. Pressing any key or
TO STOP MESSAGE 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.

CURRENT OVERLOAD Indicates to operator that too much current is being drawn from the machine, and
REDUCE OUTPUT 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
PRESS ANY KEY and allow operation within the machine ratings. Pressing any key or gun switch
TO STOP MESSAGE 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.

SXXXXX-X Only displayed at power-up. Displays the part number of the ROM ASSEMBLY
ROM ASSEMBLY currently on the PC board.

C SXXXXX-X Indicates a checksum error in the software. Turn power off and back on again. If
ROM ASSEMBLY this message persists, then replace the ROM assembly on the PC board.

R 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.

SPOOL GUN HAS Reminder that the Spool gun has been connected and the Manual key must be
BEEN CONNECTED pressed to enter any Spool gun welding procedures.

PRESS MANUAL
TO ENTER SETTINGS

SPOOL GUN HAS Reminder that the Spool gun has been removed and the Process key must be
BEEN REMOVED 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.
PRESS PROCESS TO
ENTER SETTINGS

IDEALARC SP-255 OCT94
C-1
ACCESSORIES
for use of the K487 Spool Gun (with remote
DRIVE ROLL KITS
speed control), or the K469 Spool Gun
(requires K518 Connection Adapter).
Drive Rolls available to feed different sizes
and types of electrode:
It also provides single switch transfer of
Trigger and Wire Speed Controls between
Drive Roll
Drive Rolls Part No.
the 250SP gun or the spool gun for same
Steel Wire Sizes: polarity welding with different wire and gas
.025-.035" (0.6-0.9 mm) KP674-035S
processes.
.030-.045" (0.8-1.2 mm) KP674-045S
.045" Cored (1.2 mm) KP674-045C
The kit includes a spool gun adapter mod-
Aluminum Wire Sizes:
3/64" (1.2 mm) KP674-3/64A ule assembly with plug for front installation
and connects to the machine. Also includes
a rear gas inlet fitting with hose, a gun and
3/64" (1.2 mm) ALUMINUM cable holder, mounting hardware, and
FEEDING KIT (K673-1) installation and operation instructions.
(L-9696).
The kit provides gun and wire drive conver-
sion parts to weld with 3/64" (1.2 mm) alu- For spool gun installation refer to L9696
minum wire. 5356 alloy aluminum wire is instructions included with spool gun adapter
recommended for best push feeding perfor- kit (K672-1).
mance.
CAUTION
Kit includes drive roll and incoming guide
tube for the wire drive, and a 45° gun tube, The spool gun module is intended for
use with Lincoln Electric ® Magnum�?
liner and two contact tips for the gun. Install
per the S21529 Installation Instructions pro- Spool Guns only. Use with other units
vided with the kit. may cause damage to the equipment.
For Spool Gun operation, refer to the
instruction manual provided with the
8" SPOOL ADAPTER (K468) Magnum�? Spool Gun.

Permits use of 8" (200 mm) spools on the
MAKING A WELD WITH THE
SP-255 spindle.
SPOOL GUN ADAPTER AND
DUAL CYLINDER MOUNTING SPOOL GUN INSTALLED
KIT (K671-1)
The toggle switch on the front of the spool
Permits stable side-by-side mounting of two gun adapter box permits quick transfer
full size (9" dia. x 5' high) gas cylinders, with between the use of the SP-255 with its
“no-lift�? loading. Simple installation with feeder gun and the connected spool gun for
installation kick stand and easy instructions. same polarity electrodes.
Includes upper and lower cylinder supports,
wheel axles and mounting hardware. CAUTION
In either transfer switch position, closing
SPOOL GUN DESCRIPTION the gun trigger will cause the electrode
of both guns to be electrically “HOT�?. Be
The optional Magnum SG Spool gun is a sure unused gun is positioned so that
lightweight, well-balanced, hand held semi- electrode or tip will not contact metal
automatic wire feeder. It is available in two case or other metal common to work.
models, the K469-25 and the K487-25 with
remote wire speed control.
1. Transfer switch in FEEDER position:

SPOOL GUN ADAPTER KIT a. Disables spool gun trigger, wire feed
and gas output.
(OPTIONAL K672-1)
The K672-1 Spool Gun Adapter Kit provides
OCT94 IDEALARC SP-255
recessed panel “up front�? direct connection
C-2 ACCESSORIES
b. Closing feeder gun trigger starts feed- d. Procedure settings may be stored in
er gun welding and makes both elec- memory for later recall. (See
trodes electrically “HOT�?. “Memory Keys�? in Operation section.)

2. Transfer switch in SPOOL position: 4. The following procedure settings can be
used as initial settings for making test
a. Disables feeder gun wire feed and welds to determine final settings:
gas output. However, closing feeder
Wire Diamter Arc Voltage
gun trigger will make both electrodes
In. (mm) WFS Setting Setting
electrically “HOT�? and activate spool
.030 (0.8) 42% 15V
gun gas output.
.035 (0.9 39% 16V
3/64 (1.2) 32% 21V
b. Closing spool gun trigger starts spool
gun welding and makes both elec- SPOT KEY
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- Anytime the Spot weld timer is on and the
sages: display is in Spool mode, the word SPOT
will appear in the bottom left corner of the
display.

b. Pressing the Manual key will change TYPICAL SPOT KEY PRESS SEQUENCE
the display to the spool screen.
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
c. Pressing the up or down arrow keys key again returns the display to the original
under volts on the display will Spool screen with the Spot timer status indi-
increase or decrease your welding cated in the bottom left corner.
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% STITCH KEY
of the maximum set WFS.

Left arrow keys �? Do not function.

Center arrow keys �? Increase (up
arrow) or decrease (down arrow) per- Anytime the Stitch weld timers are on and
cent of wire feed speed. the display is in Spool mode, the abbrevia-
tion STCH will appear in the bottom left cor-
Right arrow keys �? Increase (up ner of the display.
arrow) or decrease (down arrow) arc
voltage.

IDEALARC SP-255 OCT94
C-3
ACCESSORIES
TYPICAL STITCH KEY PRESS memory 4 is recalled and appears on the
SEQUENCE display. This whole cycle is repeatable as
long as the unit remains in Toggle mode.
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.

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-
TOGGLE KEY sages:

Pressing the Process key will return you to
The first time this key is pressed it turns on the last process entered before the Spool
toggle mode and recalls the setup in memo- gun was attached.
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

IDEALARC SP-255
C-4 NOTES

IDEALARC SP-255
D-1
MAINTENANCE
SAFETY PRECAUTIONS GUN TUBES AND NOZZLES
WARNING 1. Replace worn contact tips as required.

ELECTRIC SHOCK can 2. Remove spatter from inside of gas noz-
kill. zle and from tip after each 10 minutes of
arc time or as required.
�? Have qualified person-
nel do the maintenance
and trouble shooting CABLE CLEANING
work.
Clean cable liner after using approximately
�? Turn the input power off
300 pounds (136 kg) of electrode. Remove
at the fuse box before
the cable from the wire feeder and lay it out
working on equipment.
straight on the floor. Remove the contact tip
from the gun. Using an air hose and only
�? Do not touch electrically
partial pressure, gently blow out the cable
hot parts..
liner from the gas diffuser end.

CAUTION
ROUTINE MAINTENANCE Excessive pressure at the start may
cause dirt to form a plug.
GENERAL MAINTENANCE
In extremely dusty locations, dirt may clog
the air passages causing the welder to run Flex the cable over its entire length and
hot. Blow dirt out of the welder with low- gain blow out the cable. Repeat this proce-
pressure air at regular intervals to eliminate dure until no further dirt comes out.
excessive dirt and dust build-up on internal
parts.
CONTACT TIP AND GAS
The fan motors have sealed ball bearings
NOZZLE INSTALLATION
which require no service.
1. Choose the correct size contact tip for
the electrode being used (wire size is
DRIVE ROLLS AND GUIDE stencilled on the side of the contact tip)
TUBES and screw it snugly into the gas diffuser.

After every coil of wire, inspect the wire 2. Screw the appropriate fixed gas nozzle
drive mechanism. clean it as necessary by fully onto the diffuser. Either the standard
blowing with low pressure compressed air. .50" (12.7 mm) flush nozzle or other
Do not use solvents for cleaning the idle roll optional flush or recessed (spray arc)
because it may wash the lubricant out of the nozzle sizes may be used. (See
bearing. All drive rolls are stamped with the Accessories section.)
wire sizes they will feed. If a wire size other
than that stamped on the roll is used, the 3. Be sure the nozzle insulator is fully
drive roll must be changed. screwed onto the gun tube and does not
block the gas holes in the diffuser.
For instructions on replacing or changing
drive roll, see “Wire Drive Roll�? in Operation 4. If using an optional adjustable slip on
section or instruction decal inside the SP- nozzle, slip the appropriate gas nozzle
255 door. 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.

IDEALARC SP-255
D-2 MAINTENANCE
5. Adjust the gas nozzle as appropriate for out straight on a flat surface. Remove the
the GMAW process to be used. liner nut from the Fast-Mate�? connector
Typically, the contact tip end should be end of the cable and pull the liner out of the
flush to .12" (3.2 mm) extended for the cable.
short-circuiting transfer process and .12"
(3.2 mm) recessed for spray transfer. 4. Insert a new untrimmed liner into the
connector end of the cable. Be sure the
liner busing is stencilled appropriately for
LINER REMOVAL AND the wire size being used.
REPLACEMENT
5. Fully seat the liner bushing into the con-
nector. finger tighten the liner nut onto
NOTE: Changing the liner for a different
the cable connector. The gas diffuser, at
wire size requires replacement of the gas
this time, should not be installed onto
diffuser per the table below to properly
the end of the gun tube.
secure the different liner.

6. With the gas diffuser still removed from
Fixed Adjustable
the gun tube, be sure the cable is
Nozzle Gas Nozzle Gas
Replacement Size Stencilled Diffuser Diffuser straight, and then trim the liner to the
Diameter of Liner Part on End of Part No. Part No.
length shown in Figure D.1. Remove any
Electrodes Used Number Liner Bushing (and Stencil) (and Stencil)
burrs from the end of the liner.
.025-.030" Steel M16087-2 .030" (0.8 mm) S19418-3 S19418-2
(0.6-0.8 mm)
7. Screw the diffuser onto the end of the
.035-.045" Steel M16087-1 .045" (1.2 mm) S19418-3 S19418-1
gun tube and securely tighten. Be sure
(0.9-1.2 mm)
the gas diffuser is correct for the liner
3/64" Aluminum M16107-1 (Plastic Liner) S19418-3 S19418-1
(1.2 mm) being used. (see table left and diffuser
stencil.)

8. Tighten the set screw in the side of the
LINER REMOVAL, INSTALLATION,
gas diffuser against the cable liner using
AND TRIMMING INSTRUCTIONS
a 5/64" (2.0 mm) Allen wrench.
FOR MAGNUM 250SP
CAUTION
NOTICE: The variation in cable lengths pre-
vents the interchangeability of liners This screw should only be gently
between guns. Once a liner has been cut tightened. Overtightening will split or
for a particular gun, it should not be collapse the liner and cause poor wire
installed in another gun unless it can meet feeding.
the liner cutoff length requirement. Liners
are shipped with the jacket of the liner
extended the proper
FIGURE D.1
amount.
Liner trim length for the 250SP gun
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

IDEALARC SP-255
D-3
MAINTENANCE
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. Counter-clockwise
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.

MAGNUM 250SP GUN PARTS AND
ACCESSORIES
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
t
(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
t

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
Innershield)

GUN TUBE ASSEMBLIES
Standard (60°) S18920 *
45° S19890 t

* Included with Idealarc SP-255.
Included with K673-1 3/64" (1.2 mm) Aluminum Feeding kit.
t
5356 alloy aluminum wire is recommended to alleviate potential soft wire feed-
ing problems with push-type wire feeding.
�? Requires S19418-1 Gas Diffuser Assembly.
IDEALARC SP-255
D-4 NOTES

IDEALARC SP-255
E-1
TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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.
__________________________________________________________________________

Step 2. PERFORM EXTERNAL RECOM-
This Troubleshooting Guide is provided to
MENDED TESTS.
help you locate and correct possible
machine maladjustments. Simply follow the The second column labeled “POSSIBLE
three-step procedure listed below. AREAS OF MISADJUSTMENT(S)�? lists the
obvious external possibilities that may con-
tribute to the machine symptom. Perform
Step 1. LOCATE PROBLEM (SYMPTOM).
these tests/checks in the order listed. In
Look under the column labeled “PROBLEM
general, these tests can be conducted with-
(SYMPTOMS)�?. This column describes pos-
out removing the case wrap-around cover.
sible symptoms that the machine may
exhibit. Find the listing that best describes
Step 3. CONSULT LOCAL AUTHORIZED
the symptom that your machine is exhibit-
FIELD SERVICE FACILITY.
ing.
If you have exhausted all of the recom-
mended tests in Step 2, consult your local
Authorized Field Service facility.

CAUTION
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.
___________________________________________________________________

IDEALARC SP-255
E-2 TROUBLESHOOTING
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage Contact your LOCAL LINCOLN
is evident. AUTHORIZED FIELD SERVICE
FACILITY.

There is no wire feed or open 1. The gun trigger or cable may be
circuit voltage when the gun trigger faulty. check or replace gun
is pulled. The LCD display is “ON�? assembly..
indicating input power to the
SP-255.. 2. The thermal protection circuit
may be activated. Allow the
machine to cool and then reduce
the duty cycle and or wire feed
speed. If all recommended possible areas
of misadjustment have been
3. Make sure input voltage is checked and the problem persists,
correct and matches nameplate contact your local Lincoln
rating and reconnect panel Authorized Field Service Facility.
configuration.

Output voltage and wire feed is 1. Remove gun assembly from
present when gun trigger is not machine. If problem is solved
pulled (not activated). 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.

CAUTION
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.

IDEALARC SP-255
E-3
TROUBLESHOOTING
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Machine does not put out full 1. If “HIGH LINE�? or “LOW LINE�?
power. Welds are “cold�?. 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 If all recommended possible areas
assembly for loose or faulty con- of misadjustment have been
nections. checked and the problem persists,
contact your local Lincoln
Poor arc striking with electrode 1. Make sure settings for wire Authorized Field Service Facility.
sticking or blasting off. 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.

CAUTION
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.

IDEALARC SP-255
E-4 TROUBLESHOOTING
TROUBLESHOOTING GUIDE Observe Safety Guidelines
detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
The welding arc is unstable or 1. Check the work cable for loose
“hunting�?. or faulty connections.

2. Check the contact tip and
replace if worn or damaged. If all recommended possible areas
of misadjustment have been
3. Make sure the welding polarity is checked and the problem persists,
correct for the process being contact your local Lincoln
used. Authorized Field Service Facility.

4. Make sure the shielding gas is
correct for the process being
used.

5. The gun and cable assembly
may be faulty. Replace.

IDEALARC SP-255
E-5
TROUBLESHOOTING
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
FUNCTION PROBLEMS
The SP-255 stops feeding wire 1. Check for any restriction in the
while welding and the MOTOR wire feeding path.
OVERLOADED message appears
on the LCD display. 2. Make sure the correct size con-
tact tip, gun liner and drive rolls
are being used.

The voltage and/or wire feed speed 1. The thumbswitch circuit in the
are being changed even though the gun and cable assembly may be
gun thumbswitch or front panel faulty. Repair or replace. If all recommended possible areas
arrow keys are not activated. of misadjustment have been
checked and the problem persists,
The LCD display is not readable 1. There may have been an inter- contact your local Lincoln
even though the backlighting is nal system “fault�?. Turn input Authorized Field Service Facility.
functioning. 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.

Error messages or alarm continu- 1. There may be an error in the
ously beeps in bursts of three. system or the keypad entry. See
Explanation of Prompting and
Error Messages in the Operation
section.

IDEALARC SP-255
E-6 TROUBLESHOOTING
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
FEEDING PROBLEMS
1. The gun cable may be kinked or
Rough wire feeding or wire will not
twisted.
feed but drive rolls are turning.
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.
If all recommended possible areas
5. The electrode may be rusty or
of misadjustment have been
dirty.
checked and the problem persists,
6. Check for damaged or incorrect
contact your local Lincoln
contact tip.
Authorized Field Service Facility.
1. If the drive rolls are turning
There is no wire feed but arc
check the drive roll tension.
voltage is present.
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.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
GAS FLOW PROBLEMS
1. The Process gas type may be
Gas does not flow when gun trigger
set to NONE for Innershield.
is pulled.
Press Process key and enter
correct process including gas.
2. Make sure gas supply is con- If all recommended possible areas
nected properly and turned “on�?. of misadjustment have been
3. If the gas solenoid does actuate checked and the problem persists,
when the gun trigger is pulled contact your local Lincoln
there may be a restriction in the Authorized Field Service Facility.
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.

CAUTION
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.

IDEALARC SP-255
F-1
WIRING DIAGRAMS
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.

IDEALARC SP-255
F-2 WIRING DIAGRAMS
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.

IDEALARC SP-255
F-3
DIMENSION PRINT
SP-255 DIMENSION PRINT �? M16352 (1-31-92B)

Inches (Millimeters)

IDEALARC SP-255
NOTES
NOTES
NOTES
NOTES
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With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
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q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.

WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.

French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.

German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q Isole-se da peça e terra.

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.
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or

WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.

Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
q Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
q Débranchez le courant avant l’entre- q N’opérez pas avec les panneaux
q Gardez la tête à l’écart des fumées.
tien. ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira-
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.

German
q Strom vor Wartungsarbeiten q Anlage nie ohne Schutzgehäuse
q Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
nen; Maschine anhalten!) Betrieb setzen!
q Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!

Portuguese
q Não opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENÇÃO
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratória.
q Não toque as partes elétricas nuas. ou guardas removidas.

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.
LIMITED WARRANTY
STATEMENT OF LIMITED WARRANTY CONDITIONS OF WARRANTY
The Lincoln Electric Company (Lincoln) warrants to the TO OBTAIN WARRANTY COVERAGE:
end user (purchaser) of all new welding and cutting equip-
The purchaser must contact Lincoln or Lincoln’s Authorized
ment, electrode and flux (collectively called the “Goods�?)
Service Facility about any defect claimed under Lincoln’s
that it will be free of defects in workmanship and material.
warranty.
This warranty is void if Lincoln or its Authorized Service
Facility finds that the equipment has been subjected to Determination of warranty on welding and cutting equip-
improper installation, improper care or abnormal opera-
ment will be made by Lincoln or Lincoln’s Authorized
tions.
Service Facility.
WARRANTY PERIOD (1) (2) (3)
Lincoln will assume both the parts and labor expense of WARRANTY REPAIR:
correcting defects during the full warranty period. All war-
If Lincoln or Lincoln’s Authorized Service Facility confirms
ranty periods date from the date of purchase to the original
the existence of a defect covered by this warranty, the
end user and are as follows:
defect will be corrected by repair or replacement at
7 Years Lincoln’s option.
�? Main power rectifiers on all non-inverter low frequency
(50 and 60 Hz) type welders.
At Lincoln’s request, the purchaser must return, to Lincoln
3 Years or its Authorized Service Facility, any “Goods�? claimed
�? All Lincoln welding machines, wirefeeders and plasma defective under Lincoln’s warranty.
cutting machines unless listed below.
FREIGHT COSTS:
2 Years
The purchaser is responsible for shipment to and from the
�? Power Arc 5000
Ranger 10, Ranger 10-LX Lincoln Authorized Service Facility.
Weldanpower 125, Weldanpower 150
WARRANTY LIMITATIONS
1 Year
�? AC-100 Lincoln will not accept responsibility or liability for repairs
Invertec V100-S, Invertec V130-S, Invertec V200-T made outside of a Lincoln Authorized Service Facility.
Power Arc 4000
Pro-Cut 20
Lincoln’s liability under this warranty shall not exceed the
cost of correcting the defect of the Lincoln product.
�? All water coolers (internal or external models)

�? All stick electrode, welding wire and flux. Lincoln will not be liable for incidental or consequential
damages (such as loss of business, etc.) caused by the
�? Arc welding and cutting robots and robotic controllers
defect or the time involved to correct the defect.
�? All Environmental Systems equipment, including portable
units, central units, gun and cable assemblies and acces- This written warranty is the only express warranty provided
sories. (Does not include consumable items listed under
by Lincoln with respect to its products. Warranties implied
30 day warranty.)
by law such as the warranty of merchantability are limited
�? All welding and cutting accessories including gun and to the duration of this limited warranty for the equipment
cable assemblies, TIG and plasma torches, spool guns, involved.
wire feed modules, undercarriages, field installed options
that are sold separately, unattached options, welding
This warranty gives the purchaser specific legal rights. The
supplies, standard accessory sets, replacement parts,
purchaser may also have other rights which vary from state
and Magnum products. (Does not include expendable
parts listed under 30 day warranty) to state.
30 Days
Equipment manufactured for the Lincoln Electric Company is subject to
(1)
�? All consumable items that may be used with the environ-
mental systems described above. This includes hoses, the warranty period of the original manufacturer.
filters, belts and hose adapters.
All engines and engine accessories are warranted by the engine or
(2)

engine accessory manufacturer and are not covered by this warranty.
�? Expendable Parts - Lincoln is not responsible for the
replacement of any expendable part that is required due
SAE400 WELD N�? AIR compressor is warranted by the compressor man-
(3)
to normal wear.
ufacturer and not covered by this warranty.

Dec, �?97
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
�? Sales and Service through Subsidiaries and Distributors Worldwide �?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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