Lincoln Electric SA-250 User Manual
SA-250 PERKINS
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Diesel Engine Driven DC Arc Welding Power Source
For use with machines having Code Number 10073 or 10073CV: 10074
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful operation on your part.
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
importantly, think before you act
and be careful.
And, most
DO
IM518-A
October, 2000
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
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
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.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.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
SAFETY
ii
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.
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.
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.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
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
vapors
to
iii
SAFETY
iii
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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.
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 phosg
ment 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.
éne (gas forte-
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branchéà
une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûretéà leur
place.
Mar. ‘93
Thank You
vv
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 Immediatel
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:
y
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
– 6 –
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.
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.
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 (-).
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.
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.
Engine Idler
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.
Air Cleaner
Heavy duty two stage dry type.
Muffler
A muffler to reduce engine noise is standard on the
diesel engine units.
Engine Hour Meter
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.
– 7 –
OPTIONAL FEATURES
Accessory Set (K703)
Power Plug Kit (K802C)
• A power plug kit for the auxiliary power receptacles
is available. (Provides a plug for each receptacle).
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 pur-
chased locally. Ether starting should only be used as
required since indiscriminate application will contribute
to shortened engine life. (Available for field installation
only).
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
Trailer (K913)
Two-wheeled highway trailer with steel, torsion-bar
axle, 54” (137cm) wheel track. Low sway, low centerof-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
Wire Feed Module (K623-1)
The Wire Feed Module is field-installed on the K1283and 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.
4,
Includes meter and fuses to protect welder when
thawing frozen water pipes.
WARNING
Pipe Thawing IS
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.)
------------------------------------------------------------------------
Mufflers
Mufflers are standard on the SA-250 Perkins.
NOT a CSA approved procedure.
DIMENSIONS
See dimension Print M8869-24 at the rear of this manual.
– 8 –
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