Lincoln Electric IM709 User Manual

Demo Zone

™

OPERATOR’S MANUAL

IM709

December, 2000

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. DO

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

importantly, think before you act
and be careful.

For use with equipment having “K” Number:

K1854-1

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

• World's Leader in Welding and Cutting Products •

Copyright © 2001 Lincoln Global Inc.

RETURN TO MAIN INDEX

FOR ENGINE
powered equipment.

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

____________________________________________________

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

____________________________________________________

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from 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.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

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

___________________________________________________

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

i

SAFETY

i

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

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

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

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

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

2.d.1.

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

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

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

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

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

possible to the area being welded.

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

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

CALIFORNIA PROPOSITION 65 WARNINGS

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

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

The Above For Diesel Engines

The Above For Gasoline Engines

DEMO ZONE

ii

SAFETY

ii

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

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

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

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

Mar ‘95

FUMES AND GASES
can be dangerous.

5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon

vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors

to
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

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

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

DEMO ZONE

FOR ELECTRICALLY
powered equipment.

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

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

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

CYLINDER may explode
if damaged.

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

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

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

7.c. Cylinders should be located:

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

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

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

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

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

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

iii

SAFETY

iii

Mar ‘95

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

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

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

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

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even

though

they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the

Preparation

for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

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

6.f.

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

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

6.h. Also see item 1.c.

DEMO ZONE

iv

SAFETY

iv

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 suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

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

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

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

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

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

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

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

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

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

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

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

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

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

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du 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 émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, 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

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,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

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

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

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

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

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

Mar. ‘93

DEMO ZONE

Thank You

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

••• as much pride as we have in bringing this product to you!

Read this Operators Manual and any others included with this equipment completely before attempting to
use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety
instructions we have provided for your protection. The level of seriousness to be applied to each is explained
below:

WARNING

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

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

CAUTION

vv

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 refer to Individual machine Operator’s Manuals for Parts Order information.

vi

TABLE OF CONTENTS

Page

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

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

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

Input and Grounding Connections........................................................................................A-2

Input Power...................................................................................................................A-2

Grounding .....................................................................................................................A-2

Output Cables, Connections and Limitations .......................................................................A-2

Electrode and Work Cable Connections .......................................................................A-2

Installation of Field Installed Options....................................................................................A-3

Caster Wheels...............................................................................................................A-3

Installation of Equipment Required for Recommended Processes......................................A-3

General Installation Requirements.......................................................................................A-4

Location.........................................................................................................................A-4

Engine Exhaust.............................................................................................................A-4

Welding Smoke and Fume............................................................................................A-4

Stacking ........................................................................................................................A-4

Handling........................................................................................................................A-4

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

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

General Description..............................................................................................................B-1

Demo Zone ...................................................................................................................B-1

Recommended Processes and Equipment..........................................................................B-1

Recommended Processes............................................................................................B-1

Process Limitations.......................................................................................................B-1

Recommended Equipment / Interface..................................................................................B-2

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

Design Features...................................................................................................................B-2

Platform Commonalities................................................................................................B-2

Operational Controls and Features of the Demo Zone .................................................B-2

Circuit Breaker ..............................................................................................................B-2

Regulatory Requirements.....................................................................................................B-2

Operating Instructions ..........................................................................................................B-2

Additional Safety Precautions ..............................................................................................B-2

Welding and Cutting Area .............................................................................................B-2

Gas Cylinders................................................................................................................B-2

Power Sources..............................................................................................................B-2

Welder Operation .................................................................................................................B-3

Duty Cycle.....................................................................................................................B-3

Auxiliary Power Operation....................................................................................................B-3

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

Factory Installed Options / Accessories ................................................................C-1

Field Installed Options / Accessories.....................................................................C-1

Caster Wheels ................................................................................................C-1

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

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

Routine Maintenance.............................................................................................D-1

Periodic Maintenance............................................................................................D-1

Troubleshooting..............................................................................................Section E

Diagrams..........................................................................................................Section F

Wiring Diagram.......................................................................................................F-1

________________________________________________________________________

A-1

INSTALLATION

DEMO ZONE

A-1

TECHNICAL SPECIFICATIONS - Demo Zone (K-1854-1)

Voltage Specification Input Connection

Specification

230 VAC single phase, 40 amps Type 6-50P plug

ELECTRICAL INPUT REQUIREMENTS

RATED OUTPUT

HEIGHT WIDTH DEPTH WEIGHT

53.00 in. 66.00 in. 53.00 in. 1707 lbs. (w/o gas cylinders)
2467 lbs. (with gas cylinders)

1346.2 mm 1676.4 mm 1346.2 mm 774.3 kg. (w/o gas cylinders)

1119.0 kg. (with gas cylinders)

The Demo Zone is intended for display and demonstration use. It is intended for light duty operation.
The Demo Zone operator must observe the 40 amp input current limitation. Because of the input power
limitation, power sources (except Ranger 250) when used at maximum output must be operated at low
duty cycles. Refer to Welder Operation - Duty Cycle section of this manual.

PHYSICAL DIMENSIONS

A-2

INSTALLATION

DEMO ZONE

A-2

SAFETY PRECAUTIONS

INPUT AND GROUNDING CONNECTIONS

INPUT POWER

The Demo Zone is designed to operate from 230 volt,
60 Hz single-phase input power with 40-amp capacity.
A 6-50R type receptacle must be provided by the
user. The receptacle must be installed by a qualified
person and must be in accordance with applicable
local and national electrical codes.

The lighting system requires 120 volt 60 Hz power.
Plug the line cord into a conventional 120 volt recepta­cle for lighting operation. The lighting system is for
display and convenience purposes.

The Input Plugs for the Demo Zone are connected at the
factory.

GROUNDING

When the Demo Zone is connected to a conventional
power distribution system, the frame of the Demo
Zone must be grounded. The input cable provided
with the Demo Zone contains a grounding conductor.
Additionally, another ground lead must be connected.
Connect the frame of the Demo Zone to a good elec­trical ground using the #1 AWG lead included with the
Demo Zone. The purpose of this additional ground is
to minimize disturbance of the high frequency unit and
to provide a path for stray welding currents.

Some applications may not use conventional input
power and instead utilize the generating capability of
the Ranger 250 for power. In this case, the ground
lead is required only if the high frequency unit of the
Square Wave TIG 175 is used.

OUTPUT CABLES AND
CONNECTIONS

ELECTRODE AND WORK CABLE CON­NECTIONS

The Demo Zone is supplied with the output cables
connected at the power sources for positive electrode
polarity. To change the polarity of a power source,
switch the cables at the output terminals of the power
source, or change the power source polarity switch as
applicable.

A bolted work lead runs from the work buss connec­tion of the Demo Zone to the work table. The work
table connection must be firm and secure.

ELECTRIC SHOCK can kill.

• Only qualified personnel should

perform this installation.

• Turn the input power OFF at the
circuit breaker or fuse box
before working on this
equipment.

• Do not touch electrically hot
parts.

• Always connect the Demo Zone to a power
supply grounded per the National Electrical
Code and any local codes.

• This demonstration rack is intended for

indoor use and display only.

• Shelter or protect from rain, moisture and
condensation.

• Do not operate electric equipment when
wet.

WARNING

CYLINDERS could explode
if damaged.

•Keep cylinders upright and
secured to a support.

• Keep cylinders away from areas
where they could be damaged.

• Never allow the electrodes or torches to touch
the cylinders.

• Keep cylinders away from live electrical circuits.

• Maximum inlet pressures must be observed.

CAUTION

------------------------------------------------------------------------

FALLING EQUIPMENT can cause
injury.

• Do not lift with gas cylinder in place.

• Do not trailer or transport over the
road

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust outside

------------------------------------------------------------------------

A-3

INSTALLATION

DEMO ZONE

A-3

INSTALLATION OF FIELD INSTALLED
OPTIONS

CASTER WHEELS (PART OF K1848-1)

Caster wheels, which are provided, can be installed
by lifting the Demo Zone approximately eight inches
above ground level. Use the mounting hardware sup­plied to fasten the caster wheel to the mounting plate.
Tighten all fasteners.

INSTALLATION OF EQUIPMENT
REQUIRED FOR RECOMMENDED
PROCESSES

1. As shipped from the factory, two diagonal braces
are bolted to either side of the Demo Zone. The
braces are approximately 62" in length.

•

Remove the brace on the tool box side of the Demo Zone

• Do not remove the brace located on the Ranger
250 side of the Demo Zone.

2. The Demo Zone is made for ease of set up. Drive
rolls are installed and liners are in the guns.

3. A Harris Kit, containing gas components, is includ­ed with the Demo Zone. Some details about the kit:

• The double flow meter-regulator is for the argon
gas cylinder. A "Y" fitting is also used on one of the
flow meter outlets. The argon is fed to the Spool
Gun, The Square Wave TIG 175 and the two-piece
TIG torch attached to the Ranger 250.

• The other regulator is provided for the 75/25
argon/CO2 gas cylinder. Connect a "Y" fitting to this
regulator. The Power MIG and LN25 is fed from the
"Y" fitting. Use hoses with inert gas fittings. The
short hose is used with the LN7.

• The oxygen fitting (with 1/4 inch pipe thread) is for
use with the Pro-Cut gas hose. Use the short oxy­gen hose between the Pro-Cut and regulator.

4. Two plasma torches are provided with the Demo
Zone. Use the short length plasma torch with the
Demo Zone. The torch with the long length is not
recommended because the length is inconvenient
when used with the Demo Zone. Store the long
plasma torch. Use the long torch if the Pro Cut is
removed from the Demo Zone.

5. BEFORE the gas cylinders are installed, run the
gun for the Power MIG from the back of the rack
through the bench (under) and then up to the
Power MIG. This gun will run along the back of the
Square Wave TIG 175 and then to a gun holder. It
should be long enough to reach the worktable and
this helps keep the cables from getting tangled.

6. BEFORE the gas cylinders are installed, measure
the cable length needed for the spool gun (it is rout­ed the same way as the Power MIG gun) and coil
the rest, wire tie it and store it underneath the
bench between the Ranger and Power MIG.

7. BEFORE the gas cylinders are installed, connect
the battery in the Ranger 250.

8. Gas cylinder covers will improve the appearance of
your unit. When used, put the covers on before
installing the cylinder.

9. Place the cylinders in the Demo Zone. The cylin­ders can be installed by using the rear or side
openings, or a combination of both.

When using the rear frame opening, move the upper
and lower support bars out of way. Install the cylin­ders and replace the support bars to the closed
position.

When using side frame opening, lift brace and swing
out of the way. Install the cylinders and swing brace
back into position, push brace down through locking
tube to secure.

Place the air cylinder directly in back of the Pro Cut.
Place the argon cylinder next to the air cylinder.

10. Install the optional casters. This is easily done

after placing cylinders in Demo Zone, as the
height of the Demo Zone is higher with the wheels
installed.

11. Set up the two TIG torches provided. The TIG

torch that comes with the SW175 is used on both
AC and DC. A recommendation is to use a point at
one end of the tungsten and a ball at the other
end.

12. The welding table must exposed before demon-

strating. Pull the table to the open position when in
use. The table can be pushed back in, out of the
way, when the table is not in use. Since the table
has a bolted work lead permanently attached, no
work clamp is necessary for welding or cutting
operations.

HANDLING

A pallet jack or forklift truck can be used to move the
Demo Zone and to install the caster kit. The place­ment of the pallet jack or forks must balance the
Demo Zone load to prevent tipping.

FALLING EQUIPMENT can cause
injury.

• Do not lift the Demo Zone by over­head crane.

• Do not lift the Demo Zone with gas
cylinder in place.

• Lift from front of Demo Zone only.
Do not lift from left, right or rear
sides.

The Demo Zone is too heavy for one person to
move by hand on an inclined surface. Avoid situa­tions that may injure yourself or others.

A-4

INSTALLATION

DEMO ZONE

A-4

GENERAL INSTALLATION REQUIREMENTS

LOCATION

Locate the Demo Zone on a flat surface. The Demo
Zone is intended for indoor use only. The Demo Zone
must be sheltered from rain and water.

ENGINE EXHAUST

Provide an exhaust capability for the Ranger 250
machine. Flexible metal exhaust hose, available
from automobile parts stores, should be used to
exhaust gasses to the outdoors. The exhaust pipe
on the Ranger 250 is 1.5" diameter nominal. Use a
clamp at the muffler to ensure a good seal.

The exhaust pipe and flexible metal exhaust hose
is hot! Do not touch when hot. Keep flammable
material away from the exhaust hose. Place a "Hot

- Do not touch" sign near the hose to warn of the
hazard.

Ensure that there is sufficient fresh air and venti­lation available during operation of the Ranger

250.

WELDING SMOKE AND FUME

Provide an exhaust for welding smoke and fume.

STACKING

The Demo Zone is not designed for stacking.

CAUTION

WARNING

B-1

OPERATION

B-1

GENERAL DESCRIPTION

DEMO ZONE

The Demo Zone is a compact system to display and
demonstrate welding and cutting equipment.

The Demo Zone contains:

- Square Wave TIG 175 Power Source

- Power MIG 255 Power Source

- Ranger 250 Power Source

- V350 Pro Power Source

- Pro Cut 55 Plasma Cutter

- LN-25 Wire Feeder

- LN-7GMA Wire Feeder

- Holder for 4 gas cylinders

- Welding table

- Power distribution system with circuit breaker protec­tion

- Welding cables and torches

- Tool box for storage of tools, welding accessories
and welding plates

- Illuminated lower area by neon and florescent lamps

- Prominent promotional sign

- Caster wheels allow easy movement.

All equipment on the Demo Zone is connected and
ready to weld. The Demo Zone obtains its power from
a 230V 40A receptacle.

RECOMMENDED PROCESSES AND
EQUIPMENT

RECOMMENDED PROCESSES

The Demo Zone is capable of demonstrating MIG,
TIG, SMAW, CAC and plasma cutting.

PROCESS LIMITATIONS

– determined by individual equipment

DEMO ZONE

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.

•

Read and follow “Electric Shock Warnings”
in the Safety section if welding must be
performed under electrically hazardous
conditions such as welding in wet areas or
on or in the workpiece.

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 containers that
have held combustibles.

ARC RAYS
can burn.

• Wear eye, ear and body
protection.

SAFETY PRECAUTIONS

Read and understand this entire section before oper­ating the machine.

Observe additional Safety Guidelines detailed in
the beginning of this manual.

WARNING

B-2

OPERATION

B-2

RECOMMENDED EQUIPMENT /
INTERFACE

EQUIPMENT LIMITATIONS

The Demo Zone is intended for indoor display and
demonstration use. The Demo Zone is intended for
light duty operation. Because of the input power limita­tion, power sources (except Ranger 250) may only be
used at maximum output with low duty cycles. (Refer
to Welder Operation-Duty Cycle section of this manu­al).

The Demo zone is not intended for road transportation
or to be hauled on a trailer.

The Demo zone must not be lifted with gas cylinders
in place.

DESIGN FEATURES

PLATFORM COMMONALTIES

The Demo Zone utilizes standard power source and
wire feeder configurations. Output cables and torches
are modified in length for use with the Demo Zone.

OPERATIONAL CONTROLS AND
FEATURES OF THE DEMO ZONE

Refer to the individual Operator’s Manuals for equip­ment included in the Demo Zone.

CIRCUIT BREAKER

The 230V input power to the Demo Zone is controlled
by a 40-amp circuit breaker located on the rear of the
Demo Zone.

REGULATORY REQUIREMENTS

The power source and wire feed equipment included
with the Demo Zone are individually listed or certified
to CSA or UL agencies.

OPERATING INSTRUCTIONS

Read and understand the Operator’s Manuals for
all of the equipment contained in the Demo Zone.
The operating instructions for each equipment
type are not repeated here in the Demo Zone man­ual.

Plug the Demo Zone into a 230 volt 40 amp recepta­cle. Locate the circuit breaker at the rear of the Demo
Zone and switch it on. Plug the lighting system into a
120 volt receptacle. Switch the power for individual
machines on as required for demonstration purposes.

ADDITIONAL SAFETY PRECAUTIONS

WELDING AND CUTTING AREA

Welding and Cutting must take place only on the
welding table provided with the Demo Zone. Do not
weld or cut on objects away from the Demo Zone
welding table. Do not weld on the frame of the Demo
Zone.

Direct sparks away from welding machines, especially
the fuel fill area of the Ranger 250.

POWER SOURCES

The Demo Zone is a flexible system capable of
demonstrating many varied processes. The set-up of
equipment may require polarity changes, torch
changes or electrode changes. Turn-off the welding
power source or plasma cutter when changing or con­necting output cables torches or electrodes.

DEMO ZONE

WARNING

CYLINDERS could explode
if damaged.

•Keep cylinders upright and secured to
a support.

• Keep cylinders away from areas where they could
be damaged.

• Never allow the electrodes or torches to touch the
cylinders.

• Keep cylinders away from live electrical circuits.

• Maximum inlet pressures must be observed.

• Do not lift Demo Zone with gas cylinders in place.

• Do not strike an arc on any gas cylinders. Never

allow the electrode, electrode holder or any other
electrically "hot" parts to touch a cylinder.

• Gas cylinders must be securely fastened to the

Demo Zone frame. Chains are supplied and are
attached to the frame.

• When caster wheels are installed, block the

Demo Zone from movement when removing or
installing gas clinders.

WARNING

B-3

OPERATION

B-3

WELDER OPERATION

DUTY CYCLE

Full output and duty cycle may not be obtained from
all power sources. The output and duty cycle may be
limited by the 40 amp input power limitation of the
Demo Zone. The duty cycle of the power source must
be adjusted to be within the capability of the 40 amp
input supply.

Duty cycle is based upon a ten minute period. A 10%
duty cycle represents 1 minute of welding and 9 min­utes of idling in a ten minute period.

Some examples of allowable duty cycles of the Demo
Zone are given. If the duty cycle or input currents
exceed the capability of the 40 amp circuit breaker,
the breaker will trip off. For lower output currents, the
duty cycle is extended from what is listed.

V350-PRO

200A at 28v 100% duty cycle 41A input
275A at 31V 10% duty cycle 62A input

Power MIG 255 (machine limited)

200A at 28v 60% duty cycle 37A input
250A at 30v 40% duty cycle 46A input

Pro Cut 55

55A 15% duty cycle 55A input

Square Wave TIG 175

150A 10% duty cycle 65A input

AUXILIARY POWER OPERATION

Duty cycle and maximum current may be less than
rated value if the power sources are powered from the
Ranger 250.
(Refer to Ranger 250 Operator’s Manual).

DEMO ZONE

C-1

ACCESSORIES

C-1

FACTORY INSTALLED OPTIONS /
ACCESSORIES

- none

FIELD INSTALLED OPTIONS /
ACCESSORIES

CASTER WHEELS

Caster wheels, which are provided, are a field
installed option for the Demo Zone. The 5-inch diame­ter caster wheels offer high mobility for in-shop use.

DEMO ZONE

D-1

MAINTENANCE

D-1

ROUTINE MAINTENANCE

Refer to individual Operator’s Manuals for routine
maintenance requirements.

Perform the following daily routine:

• Check that no combustible materials are in the weld­ing or cutting area or around the machine.

• Remove any debris, dust, dirt, or materials that could
block the air flow to the machines for cooling.

PERIODIC MAINTENANCE

Refer to individual Operator’s Manuals for periodic
maintenance requirements.

Perform the following periodically:

• Inspect the welding cables, torches and electrode
holders for any slits or punctures in the cable jacket,
or any condition that would affect the proper opera­tion.

• Inspect gas hoses and regulators.

• Inspect gas cylinder chains and fasteners.

• The weld table is insulated from the Demo Zone
frame. Inspect the weld table mechanism to ensure
that the insulation system is intact.

DEMO ZONE

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the
disconnect switchs or fuse boxes
before working on all equipment.

• Do not touch electrically hot parts.

• Have qualified personnel do all maintenance
and troubleshooting work.

• Turn engine or welders off before working
inside the machines or servicing the engine.

• Observe all safety precautions in the individual
machine Operator’s Manuals as well as this man­ual.

WARNING

SAFETY PRECAUTIONS

E-1

TROUBLESHOOTING

E-1

DEMO ZONE

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator. For your safety and to avoid Electrical Shock, please observe all safety
notes and precautions detailed throughout this and individual machine Operator’s Manuals.
Consult individual machine Operator’s Manuals for detailed troubleshooting of specific
machines.

__________________________________________________________________________

WARNING

F-1

DIAGRAMS

F-1

DEMO ZONE

15uF

15uF

250 V

TO WELDING

TABLE

250 V

10-2000

M19808

4700 OHM

5 W

LOWER

COPPER BAR

UPPER

COPPER BAR

WORK CIRCUIT

TO POWER SOURCE

WORK TERMINAL

4700 OHM

5 W

TO POWER S O URC E

WORK TERMINAL

50 AMP

RECEPTACLE

50 AMP

RECEPT ACLE

N.A.

DEMO ZONE WIRING DIAGRAM

40A

40A

230V INPUT C IRCUIT

N.A. BOX BONDED TO GROUND

NOTES:

TO GROUND PER

MATERIAL: WIRE 8 AWG TYPE OR THHN OR THWN OR GAS AND OIL RESISTANT 600 V (UL)

G
B

W

B = BLACK

G = GREEN

W = WHITE

LEAD COLOR CODE:

NATIONAL ELECTRIC CODE

230 VOLT INPUT

50 AMP

RECEPTACLE

50 AMP

RECEPTACLE

NOTES

DEMO ZONE

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

●

Não opere com as tampas removidas.

●

Desligue a corrente antes de fazer
serviço.

●

Não toque as partes elétricas nuas.

● Do not operate with panel open or

guards off.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

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