Lincoln Electric IM512 User Manual

INVERTEC

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Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought­ful operation on your part.

NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.

importantly, think before you act
and be careful.

And, most

DO

®

RACKS

Covers Rack codes 10038 thru 10045

IM512

May,2000

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

____________________________________________________

____________________________________________________

1.d. Keep all equipment safety guards, coversand devices in posi-

tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

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

ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

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

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

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

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

Mar ‘95

i

SAFETY

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

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

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

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

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

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

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

ii

SAFETY

FOR ENGINE
powered equipment.

7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

7.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not
start engine until fumes have been
eliminated.

____________________________________________________

7.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.

____________________________________________________

ELECTRIC AND MAGNETIC
FIELDS
may be dangerous

8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

8d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

8.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

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

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

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

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

possible to the area being welded.

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

Mar. ‘93

7.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

7.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing on
the throttle control rods while the engine is running.

7.g. To p revent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

___________________________________________________

7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

iii

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

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

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue ou
les vétements mouillés. Porter des gants secs et sans trous
pour isoler les mains.

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

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

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

soudage et la machine à souder en bon et sûr état defonc­tionnement.

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

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.

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

courant pour soudage semi-automatique, ces precautions
pour le porte-é
soudage.

lectrode s’applicuent aussi au pistolet de

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un échauf­fement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

, voir

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.

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

a. Utiliser un bon masque avec un verre filtrant approprié ainsi

qu’un verre blanc afin de se protéger les yeux du rayon­nement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’ autre personnel travaillant à proximité au

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

4. Des gouttes de laitier en fusion sont é mises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branchéà une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher
à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûretéà leur place.

iv

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric.
We want you to take pride in operating this Lincoln

Thank You

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.

Code Number _____________________________________
Serial Number _____________________________________
Model Name _____________________________________
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.

v

TABLE OF CONTENTS

Page

Safety .....................................................................................................................i-iv

Installation..................................................................................................................1-5

Technical Specifications.........................................................................................1-2

Physical Dimensions

Safety Precautions.....................................................................................................3

Mechanical Installation ( K898 & K912 Series).......................................................3-4

Mounting Products Supported ...................................................................................4

Electrical Installation...............................................................................................4-5

Fusing.........................................................................................................................5

Products Supported....................................................................................................5

Limitations ..................................................................................................................5

Operation....................................................................................................................6-8

Safety Instructions .....................................................................................................6

General Description...................................................................................................7

Power Up Procedure ..............................................................................................7-8

Transporting or Hoisting Racks...................................................................................8

Operating Optional Accessories .................................................................................8

Accessories...................................................................................................................9

Parts Manual ..........................................................................................................11-17

Wiring Diagrams ....................................................................................................18-19

vi

INVERTEC RACKS

INSTALLATION

TECHNICAL SPECIFICATIONS - INVERTEC RACKS

K898 Series of Aluminum Four Pack Racks

Product Number

K898-1
K898-2
K898-3
K898-4

Product Number

K912-1
K912-2
K912-3
K912-4

Product Number

K905-1
K906-2
K907-3
K908-4

Description

w/disconnect w/115V

w/disconnect

w/115V

K912 Series of Steel Eight Pack Racks

Description

w/disconnect w/115V

w/disconnect

w/115V

Optional Accessories

Description

115V Power Pack

Caster Wheel Kit

Quick Connect Plug Kit

50 Ft. Primary Extension Cord

Code Number

10038
10039
10040
10041

Code Number

10042
10043
10044
10045

Part Number

L9165-1
L9165-2
L9165-3
L9165-4

Part Number

L9166-1
L9166-2
L9166-3
L9166-4

Code Number

NONE
NONE
NONE
NONE

Weight

128 lbs / 58 kg

99 lbs / 45 kg

119 lbs / 54 kg

90 lbs / 41 kg

Weight

414 lbs / 188 kg
383 lbs / 174 kg
405 lbs / 184 kg
374 lbs / 170 kg

Part Number

M17121
M17122
M17123
M17124

Weights listed above are with standard skids.

Product

K898 Series
K898 Series
K912 Series

All Heights listed include the lift bale.

Physical Dimensions

Type

with Skids

with Caster Wheels

Skids only

Dimensions H / W / D

66.0” / 27.5” / 32.5” (167.6cm / 69.9cm / 82.6cm)

68.5” / 27.5” / 26.0” (174.0cm / 69.9cm / 66.0cm)

66.0” / 50.0” / 26.0” (167.6cm / 127.0cm / 66.0cm)

INVERTEC RACKS

- 1 -

INSTALLATION

ALUMINUM K898-1 with Skids

66.0

61.0

4.0

ON

O

OFF

1

22.0

27.5

INVERTEC RACK

ON

OFF

O O

115V

2

26.0

ON

WARNING

10

ON

OFF

OFF

O

3

R

4

11.3

32.3

66.0

61.0

STEEL K912-1 with Skids

50.0

INVERTEC RACK

OFFONO OFFONO OFFONO OFFONO OFFONO OFFONO OFFONO OFFONO

2

1

3

22.0

10

115V

4

R

5

6

22.5

26.0

WARNING

7

8

MANUFACTURED FOR

LINCOLN ELECTRIC CO.

4.0

- 2 -

INVERTEC RACKS

INSTALLATION

Read entire installation section before starting
installation.

Step 3 Attach K898-3, -4 Slave Unit to K898-1, -2
Primary Unit

Safety Precautions

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should
perform this installation.

• Turn the input power OFF at the
disconnect switch or fuse box or by
unplugging power cable before
working on this equipment.

• Do not touch electrically hot
parts.

MECHANICAL INSTALLATION

K898 Series of Aluminum Racks (4)

Step 1 Unpack Carton

Remove four pack cartons. Unpack skids and set
aside. Remove hardware mounting rack to pallet.
Remove screws that fasten hood down. For racks
with main disconnect, the switch must be in the “OFF”
position before the hood can be removed. Remove
hood from rack and take out parts bag and check
against the list provided.

Attach slave unit to primary unit only after skids or
casters have been installed to both the primary and
slave units.

Remove hood from both racks. Remove 2.00” knock­outs on primary and slave units. Place both racks in
upright position, side-by-side with slave unit to the
right when viewed from the front. Align units so that
the 2.00” holes are concentric. Clamp racks together.
Drill six .313” diameter clearance holes for a 1/4 - 20
bolt using the slave unit as a guide. Remove clamp.
Join slave unit to primary unit using close nipple with
two steel lock washers and two neoprene lock wash­ers as shown below. Do not tighten. Assemble slave
unit to primary unit with two 1/4 - 20 x 2.00” bolts, 4
flat washers and a rod coupling in six places as shown
below. Tighten lock nuts on close nipple. Cap close
nipple on each end with plastic bushing.

Neoprene
Lock Washer

Steel

Plastic Bushing

Lock Washer

Step 2 Attach Skids

Skids can be installed by hoisting rack one foot above
ground level. If hoist is not available, place rack skids
on level surface near rack approximately 27” apart
from outside edges. Two-man lift the four pack off
pallet and place onto skids with rack front perpendicu­lar to skids as shown below. Align holes. Place flat
washer on 1/4 - 20 x 2.25” bolt. Insert bolt from the
top side. Place 1/4 - 20 lock nut on bolt from bottom
side. Fasten four bolts and nuts per skid, securely.
The rack is ready for mounting products supported.

Mounting
Holes
(8 Places)

Bolt

CLOSE NIPPLE
CONNECTION

Bolt

Connections

Rod Coupling

Washer

FRONT

INVERTEC RACKS

- 3 -