SA-250 PERKINS |
IM518-A |
October, 2000 |
Diesel Engine Driven DC Arc Welding Power Source
For use with machines having Code Number 10073 or 10073CV: 10074
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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. 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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
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OPERATOR’S MANUAL
Copyright © 2000 Lincoln Global Inc.
•World's Leader in Welding and Cutting Products •
•Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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SAFETY
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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
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
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.
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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes
outdoors.
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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.
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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.
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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.
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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.
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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.
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SAFETY |
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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.
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 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.
Mar ‘95
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SAFETY
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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.
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
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SAFETY
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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-inflamma- bles.
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
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Thank You
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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!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.
Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
TABLE OF CONTENTS
Page
GENERAL DESCRIPTION .................................................................................................. |
7 |
DESIGN SUMMARY............................................................................................................ |
7 |
OPTIONAL FEATURES....................................................................................................... |
8 |
SPECIFICATIONS ............................................................................................................... |
9 |
PRE-OPERATION INSTALLATION ................................................................................. |
10-11 |
Safety Precautions ....................................................................................................... |
10 |
Exhaust Spark Arrester ................................................................................................ |
10 |
Location/Ventilation ...................................................................................................... |
10 |
Machine Grounding ...................................................................................................... |
10 |
Lift Bail.......................................................................................................................... |
10 |
Trailers....................................................................................................................... |
10-11 |
Polarity Control and Cable Sizes.................................................................................. |
11 |
PRE-OPERATION SERVICE ............................................................................................. |
12 |
Oil ............................................................................................................................... |
12 |
Fuel............................................................................................................................... |
12 |
Cooling System ............................................................................................................ |
12 |
Battery Charging........................................................................................................... |
12 |
ENGINE OPERATION ........................................................................................................ |
13 |
Starting the Perkins D3.152 Engine ............................................................................. |
13 |
Stopping the Perkins D3.152 Engine............................................................................ |
13 |
WELDER OPERATION.................................................................................................... |
14-15 |
Duty Cycle .................................................................................................................... |
14 |
Control of Welding Current........................................................................................... |
14 |
Idler Operation.............................................................................................................. |
14 |
Auxiliary Power............................................................................................................. |
15 |
MAINTENANCE ............................................................................................................... |
15-17 |
General Instructions for Diesel Engine Welders........................................................... |
15 |
Cooling System ............................................................................................................ |
16 |
Bearings ....................................................................................................................... |
16 |
Commutator and Brushes............................................................................................. |
16 |
Idler Maintenance......................................................................................................... |
17 |
Nameplate .................................................................................................................... |
17 |
TROUBLESHOOTING ..................................................................................................... |
17-20 |
Welder Troubleshooting............................................................................................. |
17-19 |
Flashing the Fields ....................................................................................................... |
19 |
Electronic Idler Troubleshooting................................................................................... |
20 |
WIRING DIAGRAM - SA-250.............................................................................................. |
21 |
DIMENSION PRINT............................................................................................................ |
22 |
PARTS LISTS................................................................................. |
P237 Series, P78-D and P25-L |
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GENERAL DESCRIPTION |
Auxiliary Power |
The SA-250 is a heavy duty engine-driven DC arc welding power source capable of providing constant current output for stick welding or DC TIG welding. With the addition of the optional Wire Feed Module for K1283-4, the SA-250 will provide constant voltage output for running the LN-25, LN-23P or LN-7 wire feeders. The Wire Feed Module is factory-installed on the K1283-5 SA-250.
The SA-250 has a current range of 40-325 DC amps with a 60% duty cycle at 250 amps/40 volts. The units are also capable of providing 3 kVA of 115/230 volt, 60 Hertz AC auxiliary power.
3.0 kVA of nominal 115/230V, 60 Hz, AC1. (See Optional Features for Power Plug Kits).
(1)Output voltage is within ± 10% at all loads up to rated capacity.
Welder Enclosures
The complete welder is rubber mounted on a rugged steel base.
The output terminals are placed at the side of the machine so that they are protected by the door. The output terminals are labeled (+) and (-).
DESIGN SUMMARY
Control Panel
Both the engine and the welder controls are located on one recessed panel at the auxiliary power alternator end of the machine. The welder controls consist of a five step “Current Range Selector” switch and a “Fine Current Adjustment” rheostat. Each welder is equipped with a “Start” button and an “Idler Control” switch. The Perkins diesel uses a “Thermostart” button, and has a “Stop” control.
On this panel is also mounted an engine temperature gauge, a battery charging ammeter, an oil pressure gauge, and the three prong grounded type auxiliary power receptacle.
Copper Shunt Windings
For long life and dependable operation.
Remote Control
K924-1 (for K1283-4, -5) (Field Installed). Provides a receptacle switch and remote control box with 100 ft cord for fine current and OCV adjustment at the welding site.
Cranking System
A 12 volt electric starter is standard.
Air Cleaner
Heavy duty two stage dry type.
Muffler
A muffler to reduce engine noise is standard on the diesel engine units.
Engine Idler |
Engine Hour Meter |
The SA-250 is equipped with an electronic automatic engine idler. It automatically increases and decreases engine speed when starting and stopping welder or using auxiliary power. A built-in time delay permits changing electrodes before the engine slows to its low idle speed. The “Idler Control Switch” on the panel locks the idler in full speed position when desired.
A meter to record the hours of operation.
Diesel Engine Protection
The system shuts the engine down in the event of sudden low oil pressure or high coolant temperature.
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OPTIONAL FEATURES |
Power Plug Kit (K802C) |
Accessory Set (K703)
Includes electrode and work cables, headshield, work clamp, and electrode holder.
Ether Start Kit (K793-1) for Perkins Engine
When frequent starting is expected below 10°F (-12°C), remove the “thermostart” system and install the optional ether start kit to provide maximum cold weather starting assistance. Note: The required ether tank is not provided with the kit and must be purchased locally. Ether starting should only be used as required since indiscriminate application will contribute to shortened engine life. (Available for field installation
only).
•A power plug kit for the auxiliary power receptacles is available. (Provides a plug for each receptacle).
Trailer (K913)
Two-wheeled highway trailer with steel, torsion-bar axle, 54” (137cm) wheel track. Low sway, low center- of-gravity. Sturdy tread plate platform. Choice of 3 hitches. Add on fender & light package. For highway use, consult applicable local laws regarding possible additional requirements.
Order: K913-1 Base Trailer
K913-2 Ball Hitch
K913-3 Lunette Eye Hitch
K913-4 Clevis Pin Hitch
K913-5 Fender & Light Kit
Hi-Freq™ (K799)
Provides high frequency plus gas valve for DC TIG welding. (Request Publication E385).
Optional field installed water valve kit available. Order
K844.
Linc-Thaw™ (L2964-5) Control Unit
Includes meter and fuses to protect welder when thawing frozen water pipes.
WARNING
Pipe Thawing IS NOT a CSA approved procedure. If not done properly, it can result in fire, explosion, damage to wiring which may make it unsafe, damage to pipes, burning up the welder, or other hazards.
Do not use a welder to thaw pipe before reviewing Lincoln Bulletin E695.1 (dated October 1987 or later.)
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Mufflers
Mufflers are standard on the SA-250 Perkins.
Wire Feed Module (K623-1)
The Wire Feed Module is field-installed on the K1283-4, and factory-installed on the K1283-5 to provide CV (constant voltage) output for semiautomatic welding. Output rated at 250 Amps at 35 Volts with a 60% Duty Cycle and 310 Amps at 32 Volts with a 35% Duty Cycle.
DIMENSIONS
See dimension Print M8869-24 at the rear of this manual.
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