Lincoln Electric IM857 User Manual

Operator’s Manual

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Code: (ex: 10859)

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IM857-A | Issue D ate Dec- 13

© Lincoln Global, Inc. All Rights Reserved.

Register your machine:

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Authorized Service and Distributor Locator:

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THANK YOU FOR
SELECTING A QUALITY
LINCOLN ELEC TRIC PRODUCT.

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.

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.

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.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to
stay a reasonable distance away
from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning
label that appears on all containers
of welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to keep
the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your

face.

If you de velop unusual symptoms, see your supervisor. Perhaps the
welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate
(See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

ALSO, WEAR SAFETY GLASSES IN WORK
AREA AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly
cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly
toxic fumes or gases.

ADDITIONAL PRECAUTIONARY MEASURES

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

DIESEL ENGINES

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

GASOLINE ENGINES

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

SAFETY

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.

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 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.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.

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.

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.

3

SAFETY

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

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.

between the

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.

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 within applicable OSHA PEL and
ACGIH TLV limits 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. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.

5.c. 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.

3.j. Also see It ems 6.c. and 8.

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

injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.

5.e. 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.f. Also see item 1.b.

4

cause

SAFETY

WELDING AND CUTTING
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.

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.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

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

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety
Interactive Web Guide
for mobile devices

5

MINIFLEX®PORTABLE WELDING FUME EXTRACTOR

SAFETY

As a rule of thumb, for many mild steel electrode, if the air is visibly
clear and you are comfortable, then the ventilation is generally
adequate for your work. The most accurate way to determine if the
worker exposure does not exceed the applicable exposure limit for
compounds in the fumes and gases is to have an industrial hygienist
take and analyze a sample of the air you are breathing. This is
particularly important if you are welding with stainless, hardfacing or
Special Ventilation products. All Lincoln MSDS have a maximum fume
guideline number. If exposure to total fume is kept below that
number, exposure to all fume from the electrode (not coatings or
plating on the work) will be below the TLV.

There are steps that you can take to identify hazardous substances in
your welding environment. Read the product label and material safety
data sheet for the electrode posted in the work place or in the
electrode or flux container to see what fumes can be reasonably
expected from use of the product and to determine if special
ventilation is needed. Secondly, know what the base metal is and
determine if there is any paint, plating, or coating that could expose
you to toxic fumes and/or gases. Remove it from the metal being
welded, if possible. If you start to feel uncomfortable, dizzy or
nauseous, there is a possibility that you are being overexposed to
fumes and gases, or suffering from oxygen deficiency. Stop welding
and get some fresh air immediately. Notify your supervisor and co­workers so the situation can be corrected and other workers can
avoid the hazard. Be sure you are following these safe practices, the
consumable labeling and MSDS to improve the ventilation in your
area. Do not continue welding until the situation has been corrected.

NOTE: The MSDS for all Lincoln consumables is available on Lincoln’s web-

site: www.lincolnelectric.com

Before we turn to the methods available to control welding fume
exposure, you should understand a few basic terms:

Natural Ventilation is the movement of air through the

workplace caused by natural forces. Outside, this is usually the
wind. Inside, this may be the flow of air through open windows
and doors.

Mechanical Ventilation is the movement of air through the

workplace caused by an electrical device such as a portable fan
or permanently mounted fan in the ceiling or wall.

Source Extraction (Local Exhaust) is a mechanical device used

to capture welding fume at or near the arc and filter conta­minants out of the air.

The ventilation or exhaust needed for your application depends upon
many factors such as:

• Workspace volume

• Workspace configuration

• Number of welders

• Welding process and current

• Consumables used (mild steel, hardfacing, stainless, etc.)

• Allowable levels (TLV, PEL, etc.)

• Material welded (including paint or plating)

• Natural airflow

Your work area has adequate ventilation when there is enough
ventilation and/or exhaust to control worker exposure to hazardous
materials in the welding fumes and gases so the applicable limits for
those materials is not exceeded. See chart of TLV and PEL for Typical
Electrode Ingredients, the OSHA PEL (Permissible Exposure Limit), and
the recommended guideline, the ACGIH TLV (Threshold Limit Value),
for many compounds found in welding fume.

Ventilation

There are many methods which can be selected by the user to
provide adequate ventilation for the specific application. The following
section provides general information which may be helpful in
evaluating what type of ventilation equipment may be suitable for
your application. When ventilation equipment is installed, you should
confirm worker exposure is controlled within applicable OSHA PEL
and/or ACGIH TLV. According to OSHA regulations, when welding and
cutting (mild steels), natural ventilation is usually considered sufficient
to meet requirements, provided that:

1. The room or welding area contains at least 10,000 cubic feet
(about 22' x 22' x 22') for each welder.

2. The ceiling height is not less than 16 feet.

3. Cross ventilation is not blocked by partitions, equipment, or
other structural barriers.

4. Welding is not done in a confined space.

Spaces that do not meet these requirements should be equipped with
mechanical ventilating equipment that exhausts at least 2000 CFM of
air for each welder, except where local exhaust hoods or booths, or
air-line respirators are used.

Important Safety Note:

When welding with electrodes which require special
ventilation such as stainless or hardfacing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings which
produce hazardous fumes, keep exposure as low as
possible and below exposure limit values (PEL and TLV)
for materials in the fume using local exhaust or
mechanical ventilation. In con ned spaces or in some
circumstances, for example outdoors, a respirator may
be required if exposure cannot be controlled to the PEL
or TLV. (See MSDS and chart of TLV and PEL for Typical
Electrode Ingredients.) Additional precautions are also
required when welding on galvanized steel.

6

MINIFLEX®PORTABLE WELDING FUME EXTRACTOR

SAFETY

BIBLIOGRAPHY AND SUGGESTED READING

ANSI, Standard Z49.1, Safety in Welding, Cutting and Allied
Processes. Z49.1 is now available for download at no charge at

ANSI Z87.1, Practice for Occupational and Educational Eye and Face
Protection, American National Standards Institute, 11 West 42nd
Street, New York, NY 10036.

Arc Welding and Your Health: A Handbook of Health Information for
Welding. Published by The American Industrial Hygiene Association,
2700 Prosperity Avenue, Suite 250, Fairfax, VA 22031-4319.

NFPA Standard 51B, Cutting and Welding Processes, National Fire
Protection Association, 1 Batterymarch Park, P.O. Box 9146, Quincy,
MA 02269-9959.

OSHA General Industry Standard 29 CFR 1910 Subpart Q. OSHA
Hazard Communication Standard 29 CFR 1910.1200. Available from
the Occupational Safety and Health Administration at
http://www.osha.org or contact your local OSHA office.

The following publications are published by The American Welding
Society, P.O. Box 351040, Miami, Florida 33135. AWS publications
may be purchased from the American Welding society at
http://www.aws.org or by contacting the AWS at 800-443-9353.

LISTED BELOW ARE SOME TYPICAL INGREDIENTS IN WELDING ELECTRODES AND

THEIR TLV (ACGIH) GUIDELINES AND PEL (OSHA) EXPOSURE LIMITS

INGREDIENTS CAS No. TLV mg/m3PEL mg/m

Aluminum and/or aluminum alloys (as AI)***** 7429-90-5 1.0 15

Aluminum oxide and/or Bauxite***** 1344-28-1 1. 0 5**

Barium compounds (as Ba)***** 513-77-9 0.5 0.5

Chromium and chromium alloys or compounds (as Cr)***** 7440-47-3 0.5(b) 0.5(b)

Hexavalent Chromium (Cr VI) 18540-29-9 0.05(b) .005(b)

Copper Fume 7440-50-8 0.2 0.1

Cobalt Compounds 7440-48-4 0.02 0.1

Fluorides (as F) 7789-75-5 2.5 2.5

Iron 7439-89-6 10* 10*
Limestone and/or calcium carbonate 1317-65-3 10* 15

Lithium compounds (as Li) 554-13-2 15 10*

Magnesite 1309-48-4 10 15

Magnesium and/or magnesium alloys and compounds (as Mg) 7439-95-4 10* 10*

Manganese and/or manganese alloys and compounds (as Mn)***** 7439-96-5 0.02 5.0(c)

Mineral silicates 1332-58-7 5** 5**

Molybdenum alloys (as Mo) 7439-98-7 10 10

Nickel***** 7440-02-0 0.1 1

Silicates and other binders 1344-09-8 10* 10*
Silicon and/or silicon alloys and compounds (as Si) 7440-21-3 10* 10*

Strontium compounds (as Sr) 1633-05-2 10* 10*

Zirconium alloys and compounds (as Zr) 12004-83-0 5 5

http://www.lincolnelectric.com/community/safety/ or at the AWS
website http://www.aws.org.

AWS F1.1, Method for Sampling Airborne Particulates Generated by
Welding and Allied Processes.

AWS F1.2, Laboratory Method for Measuring Fume Generation Rates
and Total Fume Emission of Welding and Allied Processes.

AWS F1.3, Evaluating Contaminants in the Welding Environment: A
Strategic Sampling Guide.

AWS F1.5, Methods for Sampling and Analyzing Gases from Welding
and Allied Processes.

AWS F3.2, Ventilation Guide for Welding Fume Control

AWS F4.1, Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held
Hazardous Substances.

AWS SHF, Safety and Health Facts Sheets. Available free of charge
from the AWS website at http://www.aws.org.

3

Supplemental Information:

(*) Not listed. Nuisance value maximum is 10 milligrams per cubic

meter. PEL value for iron oxide is 10 milligrams per cubic meter.
TLV value for iron oxide is 5 milligrams per cubic meter.

(**) As respirable dust.

(*****) Subject to the reporting requirements of Sections 311, 312,

and 313 of the Emergency Planning and Community Right­to-Know Act of 1986 and of 40CFR 370 and 372.

(b) The PEL for chromium (VI) is .005 milligrams per cubic meter as

an 8 hour time weighted average. The TLV for water-soluble
chromium (VI) is 0.05 milligrams per cubic meter. The TLV for
insoluble chromium (VI) is 0.01 milligrams per cubic meter.

(c) Values are for manganese fume. STEL (Short Term Exposure

Limit) is 3.0 milligrams per cubic meter. OSHA PEL is a ceiling
value.

(****) The TLV for soluble barium compounds is 0.5 mg/m

TLV and PEL values are as of October 2013. Always check Safety
Data Sheet (SDS) with product or on the Lincoln Electric website at
http://www.lincolnelectric.com

7

3

.

MINIFLEX®PORTABLE WELDING FUME EXTRACTOR

Installation

General Description...................................................................................................9

Technical Specifications............................................................................................9

Installation ...............................................................................................................10

Operation

Safety Precautions ..................................................................................................11

Recommended Uses...............................................................................................11

Operating Instructions .............................................................................................11

Maintenance .................................................................................................................13

Troubleshooting Guide ...............................................................................................15

Accessories..................................................................................................................16

TABLE OF CONTENTS

Page

Wiring Diagram ............................................................................................................17

Parts ........................................................................................................................P-517