Lincoln Electric SVM128-A User Manual
SVM128-A
March, 1999
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
CONT AINED THROUGHOUT .
And, most importantly, think
before you act and be careful.
SERVICE MANUAL
For use with machine code numbers 10073 or 10073CV.
SHIELD-ARC SA-250
Diesel Engine Driven DC Arc Welding Power Source
TM
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• 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
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American W elding Society, P .O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. AFree 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
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
____________________________________________________
____________________________________________________
____________________________________________________
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.
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FOR ENGINE
powered equipment.
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.
1.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.
SA-250
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.
Mar ‘95
ii ii
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
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
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.
vapors
to
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5.e. Also see item 1.b.
SA-250
Mar ‘95
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.
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Mar ‘95
SA-250
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales 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.
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 soud
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” CSAStandard
W 117.2-1974.
e pas, poser la pince à une endroit isolé de
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
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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
SA-250
v v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
RETURN TO MAIN INDEX
Page
Safety.................................................................................................................................................i-iv
Installation .............................................................................................................................Section A
Technical Specifications..............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation..............................................................................................................A-3
Pre-operation Engine Service.....................................................................................................A-4
Electrical Output Connections.....................................................................................................A-6
Operation...............................................................................................................................Section B
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-2
Recommended Applications........................................................................................................B-3
Operational Features and Controls .............................................................................................B-3
Design Features ..........................................................................................................................B-3
Welding Capability ......................................................................................................................B-4
Limitations .................................................................................................................................B-4
Controls and Settings..................................................................................................................B-5
Engine Operation........................................................................................................................B-8
Welding Operation ....................................................................................................................B-10
Auxiliary Power .........................................................................................................................B-12
Accessories ..........................................................................................................................Section C
Maintenance..........................................................................................................................Section D
Safety Precautions ......................................................................................................................D-2
Routine and Periodic Maintenance .............................................................................................D-2
Major Component Locations.....................................................................................................D-13
Theory of Operation .............................................................................................................Section E
Troubleshooting and Repair................................................................................................Section F
Electrical Diagrams..............................................................................................................Section G
Parts Manual ...............................................................................................................................P-237
SA-250
Section A-1 Section A-1
TABLE OF CONTENTS
- INSTALLATION SECTION -
Installation
Technical Specifications..............................................................................................................A-2
Safety Precautions......................................................................................................................A-3
Location and Ventilation..............................................................................................................A-3
Storing .................................................................................................................................A-3
Stacking................................................................................................................................A-4
Tilting .................................................................................................................................A-4
Lifting .................................................................................................................................A-4
High Altitude Operation.........................................................................................................A-4
Pre-operation Engine Service.....................................................................................................A-4
Oil ........................................................................................................................................A-4
Fuel .......................................................................................................................................A-4
Battery Connections .............................................................................................................A-4
Cooling System.....................................................................................................................A-5
Muffler .................................................................................................................................A-5
Exhaust Spark Arrester.........................................................................................................A-5
Trailer .................................................................................................................................A-5
Electrical Output Connections.....................................................................................................A-6
Welding Cable Connections.................................................................................................A-6
Cable Installation, Polarity Control, and Cable Sizes..............................................A-6
Machine Grounding ..............................................................................................................A-7
Auxiliary Power Receptacles, Plugs, and Hand-held Equipment .........................................A-7
Circuit Breakers....................................................................................................................A-7
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SA-250
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - SA-250
INPUT - DIESEL ENGINE
Manufacturer Description Speed Displacement Ignition Capacities
Perkins 3 cyl., 4 cycle 1725 RPM 152 cu. in. Electric Fuel: 15 gal.
D3.152 Water-cooled Full load (2500 cc) (57 liters)
diesel
38.2 HP @ 1800 RPM Oil: 7.2 qt.
1725 RPM High idle (6.9 liters)
1350 RPM Water/coolant: 10 qt.
Low idle (9.5 liters)
RATED OUTPUT - WELDER
Duty Cycle Amps Volts at Rated Amperes
100% Duty Cycle 200 DC Constant Current 40V
60% Duty Cycle 250 DC Constant Current 40V
35% Duty Cycle 325 DC Constant Current 33V
OUTPUT - WELDER AND GENERATOR
Welding Ranges Max. Open Circuit Voltage Auxiliary Power
40-325 Amps DC 98.5 3.0 kVA of 115/230 V, 60Hz Power
26 Amps @ 115 V
13 Amps @ 230 V
PHYSICAL DIMENSIONS
Height Width Depth Weight
43.1 in. 28 in. 67 in. 1650 lb.
1096 mm 711 mm 1702 mm 742.5 kg
1
Lincoln rating. Nema rating at 60% duty cycle is 250 amps @ 30 V.
2
15 amps can be drawn from either half of the receptacle. Total combined load of all receptacles cannot exceed 3.0 kVA.
(1)
(2)
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SA-250
A-3 A-3
INSTALLATION
Read this entire installation section before you
start installation.
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrodes with your
skin or wet clothing.
• Insulate yourself from the work
and ground.
• Always wear dry insulating
gloves.
ENGINE EXHAUST can kill.
• Use in open, well ventilated
areas or vent exhaust to the outside.
LOCATION AND VENTILA TION
Always operate the SA-250 with the doors closed.
Leaving the doors open changes the designed air flow
and may cause overheating. Always operate the
welder with the case roof on and all machine components completely assembled.
Whenever you use the SA-250, be sure that clean
cooling air can flow through the machine’s diesel
engine and the generator. Avoid dusty, dirty areas.
Also, keep the machine away from heat sources. Do
not place the back end of the generator anywhere near
hot engine exhaust from another machine. And of
course, make sure that engine exhaust is ventilated to
an open, outside area.
The SA-250 may be used outdoors. Do not set the
machine in water. Such practices pose safety hazards
and cause improper operation and corrosion of parts.
STORING
1. Store the machine in a cool, dry place when it is not
in use. Protect it from dust and dirt. Keep it where
it can’t be accidentally damaged from construction
activities, moving vehicles, and other hazards.
2. Drain the engine oil and refill with fresh 10W30 oil.
Run the engine for about five minutes to circulate oil
to all the parts. See the
this manual for details on changing oil.
Maintenance
section of
• Do not stack anything on or near
the engine.
MOVING PARTS can injure.
• Do not operate this equipment
with any of its doors open or
guards off.
• Stop the engine before servicing
it.
• Keep away from moving parts.
See additional safety information at the front of this
manual.
Only qualified personnel should install, use, or service this equipment.
3. Remove the battery, recharge it, and adjust the
electrolyte level. Store the battery in a dry, dark
place. See the
tion about charging the battery.
4. See your engine operation manual for further information on fuel and engine preservation.
Maintenance
section for informa-
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SA-250
A-4 A-4
INSTALLATION
STACKING
SA-250 machines CANNOT be stacked.
TILTING
Place the machine on a secure, level surface whenever you use it or store it. Any surfaces you place it on
other than the ground must be firm, non-skid, and
structurally sound.
The diesel engine is designed to run in a level position
for best performance. If you do operate it at a slight
angle, be sure to check the oil regularly and keep the
oil level at the FULL mark as it would be in its normal
level condition. Also, fuel capacity will be a little less at
an angle.
LIFTING
The SA-250 weighs 1650 lb./743 kg. A lift bail is
provided for lifting with a hoist.
WARNING
FALLING EQUIPMENT can
cause injury.
WARNING
Keep hands away from the engine muffler or HOT
engine parts.
• Stop the engine when fueling.
• Do not smoke when fueling.
• Remove the fuel cap slowly to release pressure.
• Do not overfill the fuel tank.
• Wipe up spilled fuel and allow the fumes to clear
before starting the engine.
• Keep sparks and flame away from the fuel tank.
OIL
The SA-250 is shipped with the engine filled
with SAE 10W-30 oil. This should be fine
for most ambient operating temperature
conditions. See the engine operation manual for specific recommendations. CHECK THE OIL LEVEL
BEFORE YOU START THE ENGINE. This is an
added precaution. When full, the oil level should be up
to but not over the FULL mark on the dipstick. If it is
not full, add enough oil to fill it to the full mark. DO NOT
overfill.
For more oil fill and service information, see the
Maintenance
section of this manual.
Do not lift this machine using lift bail if
it is equipped with a heavy accessory
such as a trailer.
Lift only with equipment of adequate lifting capacity . Be
sure machine is stable when lifting.
HIGH ALTITUDE OPERATION
It may be necessary to derate welder output at higher
altitudes. Some engine adjustment may be required.
Contact a Perkins Service Representative.
PRE-OPERATION ENGINE SERVICE
Read and understand the information about the diesel
engine in the
this manual before you operate the SA-250.
Operation
and
Maintenance
sections of
FUEL
Fill the fuel tank with clean, diesel fuel only.
The SA-250 has a 15 gallon (57 liter) fuel
tank with a top fill and fuel gauge mounted
on the control panel. See the
Maintenance
about fuel.
sections of this manual for more details
Operation
and
BATTERY CONNECTIONS
–+
operate the machine, make sure the
IGNITION switch is in the OFF position and attach the
disconnected cable securely to the battery terminal. If
the battery is discharged and won't start the engine,
see the battery charging instructions in the
Maintenance
The SA-250 is shipped with the negative
battery cable disconnected. Before you
section.
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SA-250
A-5 A-5
INSTALLATION
COOLING SYSTEM
The cooling system has been filled at the factory with a
50-50 mixture of ethylene glycol antifreeze and water.
Check the radiator level and add a 50-50 solution as
needed. (See your engine manual or antifreeze container for alternate antifreeze recommendations.)
MUFFLER
This welder is supplied with an adjustable rain cap for
the muffler. Install the rain cap using the clamp provided with the outlet facing away from the direction in
which this unit will be transported. This will minimize
the amount of water and debris that could enter the
muffler during transportation.
EXHAUST SPARK ARRESTER
Some federal, state or local laws may require that
diesel engines be equipped with exhaust spark
arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
The standard mufflers included with these welders do
not qualify as a spark arrester. When required by local
regulations, suitable spark arresters must be installed
and properly maintained.
TRAILER
If you use a non-Lincoln trailer, you must assume
responsibility that the method of attachment and usage
does not result in a safety hazard nor damage the
welding equipment. Some of the factors to be considered are as follows:
1. Design capacity of the trailer vs. the weight of the
Lincoln equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
3. Proper placement of the equipment on the trailer to
ensure stability side to side and front to back. This
includes when being moved and when standing by
itself for operation or service.
4. Typical conditions of use, such as travel speed,
roughness of the surfaces where the trailer will be
used, environmental conditions, likely maintenance.
5. Conformance with federal, state, and local laws.
Consult applicable federal, state, and local laws
about specific requirements for use on public highways.
Use of an incorrect arrester may lead to engine damage or performance loss. Contact the engine manufacturer for specific recommendations.
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CAUTION
SA-250
A-6 A-6
INSTALLATION
ELECTRICAL OUTPUT
CONNECTIONS
See Figure A.1 for the location of the 115 and 230 volt
receptacles, weld output terminals, and ground stud.
WELDING CABLE CONNECTIONS
CABLE INSTALLATION AND CABLE SIZES
With the engine off, route the electrode and work
cables through the strain relief bracket on the base and
connect to the terminals located on the fuel tank mounting rail. (See size recommendations below.) For positive polarity , connect the electrode cable to the terminal
marked Positive (+). For Negative polarity , connect the
electrode cable to the Negative (-) terminal. These
connections should be checked periodically and tightened if necessary.
FIGURE A.1 - SA-250 OUTPUT CONNECTIONS
CAUTION
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
• Do not cross the welding cables at the output terminal
connection. Keep the cables isolated and separate
from one another.
When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
Lincoln Electric offers a welding accessory kit with the
properly specified welding cables. See the
Accessories
information.
section of this manual for more
3
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4
2
1
5
TABLE A.1 - RECOMMENDED COPPER WELDING CABLE SIZE AND LENGTH
TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES
Amps Duty Cycle Up to 200 ft. 200 to 250 ft.
250 60% 1 1/0
350 25% 2/0 3/0
SA-250
1. 230 VAC RECEPTACLE
2. 115 VAC RECEPTACLE
3. OUTPUT TERMINALS
4. GROUND STUD
5. CABLE STRAIN RELIEF
Cable sizes for combined length of
electrode plus work cable
A-7 A-7
INSTALLATION
MACHINE GROUNDING
According to the United States National Electrical
Code, the frame of this portable generator is not
required to be grounded and is permitted to serve as
the grounding means for cord connected equipment
plugged into its receptacles.
Some state, local or other codes or unusual operating
circumstances may require the machine frame to be
grounded. It is recommended that you determine the
extent to which such requirements may apply to your
particular situation and follow them explicitly. A
machine grounding stud marked with the symbol
is provided on the welding generator frame foot.
(If an older portable welder does not have a grounding
stud, connect the ground wire to an unpainted frame
screw. See Figure A.2.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment.
WARNING
For further protection against electric shock, any electrical equipment connected to the generator receptacles must use a three-blade, grounded type plug or an
Underwriter's Laboratories (UL) approved double insulation system with a two-blade plug. Lincoln offers an
accessory plug kit that has the right type of plugs. See
the
Accessories
If you need ground fault protection for hand-held equipment, refer to the
for the GFCI Receptacle kit.
section of this manual for details.
Accessories
section of this manual
CIRCUIT BREAKERS
SA-250 welders are equipped with circuit breakers on the 115 and the 230
volt receptacles for overload protection. Under high heat a breaker may
tend to trip at lower loads than it would normally.
Operation with high ambient temperatures may cause
the breakers to trip at lower than normal loads.
CAUTION
Never bypass the circuit breakers. Without overload
protection, the SA-250 could overheat and/or cause
damage to the equipment being used.
Do not ground the machine to a pipe that carries explosive or combustible material.
When the SA-250 is mounted on a truck or a trailer, the
machine generator ground stud MUST be securely
connected to the metal frame of the vehicle. See
Figure A.2. The ground stud is marked with the ground
symbol.
AUXILIARY POWER RECEPTACLES,
PLUGS, AND HAND-HELD EQUIPMENT
The AC auxiliary power, supplied as a standard, has a
rating of 3.0 kVA of 115/230V AC (60 hertz).
With the 3.0 kVA, 115/230V AC auxiliary power, one
115V duplex and one 230V duplex grounding type
receptacle are provided. The circuit is protected with
circuit breakers.
The rating of 3.0 kVA permits a maximum continuous
current of 13 amps to be drawn from the 230 volt
duplex receptacle. Or a total of 26 amps can be drawn
from the 115 volt duplex receptacle. The 115 volt
duplex receptacle has a configuration which permits 15
amps to be drawn from either half of the receptacle.
The total combined load of all receptacles is not to
exceed 3.0 kVA.
FIGURE A.2 - GROUND STUD LOCATION
1
1. GROUND STUD
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SA-250
A-8 A-8
NOTES
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SA-250
Section B-1 Section B-1
TABLE OF CONTENTS
- OPERATION SECTION -
Operation...............................................................................................................................Section B
Safety Instructions.......................................................................................................................B-2
General Description ....................................................................................................................B-2
Recommended Applications........................................................................................................B-3
Welder .................................................................................................................................B-3
Generator..............................................................................................................................B-3
Operational Features and Controls .............................................................................................B-3
Design Features ..........................................................................................................................B-3
Welding Capability ......................................................................................................................B-4
Limitations .................................................................................................................................B-4
Controls and Settings..................................................................................................................B-5
Welder/Generator Controls...................................................................................................B-5
Control of Welding Current...................................................................................................B-6
Diesel Engine Controls:........................................................................................................B-7
Engine Operation........................................................................................................................B-8
Before Starting the Engine ...................................................................................................B-8
Starting the Engine...............................................................................................................B-8
Stopping the Engine.............................................................................................................B-9
Cold Weather Starting..........................................................................................................B-9
Break-in Period.....................................................................................................................B-9
Welding Operation ....................................................................................................................B-10
SA-250 DC Constant Current Stick or TIG Welding ...........................................................B-10
SA-250 DC Wire Feed Welding (Constant Voltage)...........................................................B-11
Auxiliary Power .........................................................................................................................B-12
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SA-250
B-2 B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section before operating your SA-250.
SAFETY INSTRUCTIONS
WARNING
Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet clothing.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
WARNING
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust to the outside.
• Do not stack anything on or near the
engine.
MOVING PARTS can injure.
• Do not operate this equipment with any
of its doors open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
Only qualified personnel should install, use, or service this equipment.
GENERAL DESCRIPTION
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.
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, the
SA-250 will provide constant voltage output for running
the LN-7 or LN-25 wire feeders.
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.
This unit uses the Perkins D3.152 three-cylinder,
industrial water-cooled diesel engine.
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SA-250
B-3 B-3
OPERATION
RECOMMENDED APPLICATIONS
WELDER
The SA-250 provides excellent constant current DC
welding output for stick (SMAW) welding and for DC
TIG welding. It also offers constant voltage output for
DC semiautomatic wire feed welding. For more details
on using the machine as a welder, see
Operation
in the
Operation
section of this manual.
Welding
GENERATOR
The SA-250 is also capable of providing 3.0 kVA of
115/230 volts of 60 Hertz AC auxiliary power.
OPERATIONAL FEA TURES AND
CONTROLS
The SA-250 was designed for simplicity. Therefore, it
has very few operating controls. Two switches are
used for welding operations:
• A five-position CURRENT RANGE SELECTOR
switch selects current output ranges for constant current stick or TIG applications and constant voltage
wire feed applications (with optional Wire Feed
Module - see the
• A FINE CURRENT ADJUSTMENT switch for fine
adjustment of current from minimum to maximum
within each range
Controls for the diesel engine control include a twoposition IGNITION ON/OFF toggle switch, a START
pushbutton, and a two-position IDLER switch that
selects engine speed for welding or auxiliary power
applications. See
section of this manual for details about starting, running, stopping, and breaking in the diesel engine.
Accessories
Engine Operation
section)
in the
Operation
DESIGN FEATURES
• Constant current DC Stick welding (SMAW) process
capability with output range from 40 - 325 DC amps.
• Constant current DC TIG Welding with output across
the entire range of settings.
• Work and Electrode welding cable mounting terminals.
• Separate ground stud for safe connection of case to
earth ground.
• Duplex, 230 volt auxiliary power receptacle.
• Duplex, 115 volt auxiliary power receptacles.
• Integrated generator output overload protection
through four 15 amp circuit breakers.
• Electric starting.
• Battery Charging Ammeter.
• Engine Oil Pressure Gauge.
• Engine Hour Meter for determining periodic maintenance.
• Top-of-the-line 38.2 HP Perkins diesel engine.
• Top-mounted 15 gallon (57.0 litter) fuel tank with
convenient top fill.
• Automatic engine shutdown protection for low oil
pressure.
• Automatic engine idler goes to low idle approximately 15 seconds after welding for greater fuel economy;
includes high idle switch.
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SA-250
B-4 B-4
OPERATION
WELDING CAPABILITY
The SA-250 is rated 250 amps, 40 volts constant current DC at 60% duty cycle based on a ten minute time
period. Longer duty cycles at lower output currents are
possible.
The current is continuously variable from 40 to 325
amps DC.
LIMITATIONS
• The SA-250 is not recommended for any processes
besides those that are normally performed using DC
stick welding (SMAW) and DC TIG welding. Specific
limitations on using the SA-250 for these processes
are described in the
this manual. Constant voltage welding is available
with the optional Wire Feed Module.
Welding Operation
section of
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SA-250
B-5 B-5
OPERATION
CONTROLS AND SETTINGS
The welder/generator controls are located on the
Output Control Panel of the machine case front. Diesel
engine idler control and start/stop controls are also on
FIGURE B.1 – OUTPUT CONTROLS
1
6
5
the case front. Welding output terminals and ground
stud are located on the machine left side, under the
door. See Figure B.1, B.2 and B.3 and the explanations that follow.
2
3
4
7
WELDER/GENERATOR CONTROLS
See Figure B.1 for the location of the following features:
1. CURRENT RANGE SELECTOR: Selects ranges
of continuous current output for constant current
stick or TIG applications and constant voltage wire
feed applications (with optional Wire Feed Module).
See
Control of Welding Current
tion.
2. FINE CURRENT ADJUSTMENT: Allows fine
adjustment of current within the selected output
range. See
information.
3. 230 VOLT DUPLEX RECEPTACLE: Connection
point for supplying 230 volt power to operate one or
two electrical devices.
Control of Welding Current
for more informa-
for more
1. CURRENT RANGE SELECTOR
2. FINE CURRENT ADJUSTMENT
3. 230 VOLT DUPLEX RECEPTACLE
4. 115 VOLT DUPLEX RECEPTACLE
5. WELD OUTPUT TERMINAL (–)
6. WELD OUTPUT TEMRINAL (+)
7. GROUND STUD
4. 115 VOLT DUPLEX RECEPTACLE: Connection
point for supplying 115 volt power to operate one or
two electrical devices.
5. WELD OUTPUT TERMINAL (–) WITH FLANGE
NUT: Provides the connection point for either the
electrode holder or the work cable.
6. WELD OUTPUT TERMINAL (+) WITH FLANGE
NUT: Provides the connection point for either the
electrode holder or the work cable.
7. GROUND STUD: Provides a connection point for
connecting the machine case to earth ground for
the safest grounding procedure.
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SA-250
B-6 B-6
OPERATION
CONTROL OF WELDING CURRENT
CAUTION
• DO NOT turn the CURRENT RANGE SELECTOR
while welding because the current may arc between
the contacts and damage the switch.
• DO NOT attempt to set the CURRENT RANGE
SELECTOR between the five points designated on
the nameplate.
See Figure B.2. The CURRENT RANGE SELECTOR
provides five overlapping current ranges. The FINE
CURRENT ADJUSTMENT adjusts the current from
minimum to maximum within each range. Open circuit
voltage is also controlled by the FINE CURRENT
ADJUSTMENT, permitting control of the arc characteristics.
A high open circuit voltage setting provides the soft
"buttering" arc with best resistance to pop-outs preferred for most welding. To get this characteristic, set
the CURRENT RANGE SELECTOR to the lowest setting that still provides the current you need and set the
FINE CURRENT ADJUSTMENT near maximum. For
example: to obtain 175 amps and a soft arc, set the
CURRENT RANGE SELECTOR to the 190 -120 position and then adjust the FINE CURRENT ADJUSTMENT for 175 amps.
When a forceful "digging" arc is required, usually for
vertical and overhead welding, use a higher CURRENT
RANGE SELECTOR setting and lower open circuit
voltage. For example: to obtain 175 amps and a forceful arc, set the CURRENT RANGE SELECTOR to 240160 position and the FINE CURRENT ADJUSTMENT
setting to get 175 amps.
Some arc instability may be experienced with EXX10
electrodes when trying to operate with long arc techniques at settings at the lower end of the open circuit
voltage range.
CURRENT
RANGE
SELECTOR
FIGURE B.2 – CURRENT CONTROLS
240-160
220
MAX
IDLER
230 VOLT AC
190-120
CURRENT RANGE
SELECTION
130-80
IGNITION
90
MIN
ENGINE
PROTECTION
FINE CURRENT
ADJUSTMENT
115 VOLTAC
70
80
90
100
START
REMOTE
CONTROL
50
60
40
30
20
10
FINE
CURRENT
ADJUSTMENT
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SA-250
B-7 B-7
OPERATION
FIGURE B.3 – DIESEL ENGINE CONTROLS
190-120
8
240-160
220
MAX
7
IDLER
6
1. IDLER CONTROL TOGGLE
SWITCH
2. IGNITION TOGGLE SWITCH
3. RESET BUTTON
4. START PUSHBUTTONS
5. ENGINE HOUR METER
6. OIL PRESSURE GAUGE
7. AMMETER
8. WATER TEMPERATURE GAUGE
IGNITION
230 VOLT AC
132
DIESEL ENGINE CONTROLS
See Figure B.3 for the location of the following features:
1. IDLER CONTROL TOGGLE SWITCH: Adjusts the
running speed of the engine. The switch has two
positions, "HIGH" and "AUTO." In "HIGH," the
engine runs continuously at high idle. In "AUTO,"
the idler control works as follows:
Welding: The engine accelerates to high speed
when the electrode touches the work and strikes a
welding arc. The engine returns to low idle approximately 15 seconds after welding stops, as long as
no auxiliary power is being drawn.
Auxiliary Power: The engine accelerates to high
speed when power is drawn at the receptacles for
lights or tools. The engine returns to low idle
approximately 15 seconds after demand for
auxiliary power stops.
2. IGNITION CONTROL TOGGLE SWITCH: Has
two positions, ON and OFF. When the switch is in
the ON position, the diesel engine can be started
by pressing the START pushbutton. When the
switch is placed in the OFF position, the engine
stops.
3. RESET BUTTON: Resets engine protection circuit.
Press this button before starting the diesel engine.
CURRENT RANGE
SELECTION
130-80
MIN
90
PROTECTION
ENGINE
FINE CURRENT
ADJUSTMENT
115 VOLT AC
70
80
90
100
START
REMOTE
CONTROL
50
60
40
30
20
10
5
4
4. START AND THERMOSTART PUSHBUTTONS:
Press the START button to start the diesel engine.
The IGNITION switch must be in the ON position.
The THERMOSTART button should be used for
starting when air temperature ranges between
10°F (-12°C) and freezing.
NOTE: If you press either ST ARTpushbutton when
the engine is running, you may damage the engine
flywheel gear or starter motor.
5. ENGINE HOUR METER: Records engine running
time. Use the meter to determine when to
perform required maintenance.
6. OIL PRESSURE GAUGE: Indicates engine oil
pressure. If no oil pressure shows on the gauge
within 30 seconds after startup, the engine should
be stopped by placing the IGNITION switch in the
OFF position.
7. AMMETER: Shows whether the charging circuit
is performing its job of charging the battery when
the engine is running. The meter will register
discharge during starting, but then the needle
should return to a position slightly toward positive
during running. The needle will hold position in the
center when the engine stops.
8. WATER TEMPERATURE GAUGE: Indicates tem-
perature of engine coolant.
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SA-250
B-8 B-8
OPERATION
ENGINE OPERATION
WARNING
DO NOT RUN THE ENGINE AT EXCESSIVE
SPEEDS. The maximum allowable high idle speed for
the SA-250 is 1800 RPM, no load. Do NOT increase
the idle speed on the engine. Severe personal injury
and damage to the machine can result if it is operated
at speeds above the maximum rated speed.
Read and understand all safety instructions included in
the Perkins engine instruction manual that is shipped
with your SA-250.
BEFORE STARTING THE ENGINE
Check and fill the engine oil level:
1. Be sure the machine is on a level
surface.
2. Remove the engine oil dipstick and wipe it with a
clean cloth. Reinsert the dipstick and check the
level on the dipstick. See
Maintenance section of this manual.
Figure D.1
in the
Check and fill the engine fuel tank:
WARNING
Do not add 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. Remove the fuel tank cap.
2. Fill the tank to allow approximately 1/4 inch (5 mm)
of tank space for fuel expansion. DO NOT FILL
THE TANK TO THE POINT OF OVERFLOW.
3. Replace the fuel tank cap and tighten securely.
NOTE: USE DIESEL FUEL ONLY. Purchase diesel
fuel in quantities that will be used within 30 days, to
assure freshness.
3. Add oil (if necessary) to bring the level up to the full
mark. Do not overfill.
4. Replace the dipstick.
STARTING THE ENGINE
NOTE: Remove all loads connected to the AC power
receptacles before starting the diesel engine.
1. Place the IDLER switch in the "HIGH" position and
the IGNITION switch in the ON position. Press the
RESET button, then press the START button.
NOTE: If the engine fails to start in 60 seconds, wait 30
seconds then repeat step 1.
2. When the engine starts running, observe the oil
pressure. If no pressure shows within 30 seconds,
stop the engine and consult the engine operating
manual.
3. Allow the engine to run at high idle for several minutes to warm the engine prior to welding.
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SA-250
B-9 B-9
OPERATION
STOPPING THE ENGINE
1. Remove all welding and generator power loads
and let the engine cool by running it for several
minutes at low idle.
2. Place the IGNITION switch in the OFF position.
When an engine is started for the first time, some of the
oil will be needed to fill the passages of the lubricating
system. Therefore, on initial starting, run the engine for
about five minutes and then stop the engine and
recheck the oil. If the level is down, fill to the full mark
again.
The engine controls were properly set at the factory
and should require no adjusting when received.
At the end of each day’s welding, drain accumulated
dirt and water from the sediment bowl under the fuel
tank and from the fuel filter per instructions in the
engine manufacturer’s operating manual. Refill the
fuel tank to minimize moisture condensation in the
tank. Also, running out of fuel tends to draw dirt into the
fuel system. Check the crankcase oil level.
In diesel engines, if the fuel supply is cut off or runs out
while the fuel pump is operating, air may be entrapped
in the fuel distribution system. See “How to Eliminate
Air From the Fuel System” in the
Maintenance
section.
COLD WEATHER STARTING
When temperatures are between 10oF (-12oC) and
freezing, use the standard Thermostart feature. Follow
the instructions on the nameplate and in the engine
manual shipped with the welder. With a fully charged
battery and the proper weight oil, the engine should
start satisfactorily even when the air temperature is
down to about 0oF (-18°C).
If the engine is frequently started below 10oF (-12°C),
you may want to remove the “Thermostart” and install
the optional ether starter kit. Installation and operating
instructions are included in the kit. Use ether starting
only when required because excessive use shortens
engine life.
It is important to follow the engine manufacturer’s recommendations for oil and fuel to obtain satisfactory
cold weather performance. Consult the engine manual and the
Maintenance
section of this manual.
BREAK-IN PERIOD
Any engine will use a small amount of oil during its
break-in period. For the diesel engine on the SA-250,
break-in is about 200 running hours.
Check the oil twice a day during break-in. Change the
oil and oil filter cartridge after the first 25 hours of operation. Also change the fuel filter cartridge. For more
details, see the
Maintenance
section of this manual.
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CAUTION
During break-in, subject the SA-250 to only moderate
loads. Avoid long periods running at idle. Before stopping the engine, remove all loads and allow the engine
to cool several minutes.
SA-250
B-10 B-10
OPERATION
WELDING OPERATION
TO USE THE SA-250 FOR DC CONSTANT
CURRENT STICK OR TIG WELDING:
1. Remove the flange nuts from the weld output terminals and place the work and electrode welding
cables over the terminals. See Figure B.4.
Replace and tighten the flange nuts securely. Be
sure the connections are tight.
2. Select the appropriate electrode.
3. Attach the work clamp securely to the work you are
welding.
4. Insert the electrode into the electrode holder.
5. Start the diesel engine. See
this section of the manual.
6. Set the Idler Switch to “AUTO.”
7. Set the CURRENT RANGE SELECTOR to a setting equal to or slightly higher than the desired
welding current.
8. Set the FINE CURRENT ADJUSTMENT to the setting that gives the best arc characteristics for the
range selected. See
in this section of the manual.
9. Strike an arc and begin welding.
Control of Welding Current
Engine Operation
After you finish welding:
1. Stop the engine. See
section of the manual.
2. Allow the electrode and work to cool completely.
3. Remove the work clamp from the work.
4. Remove any remaining piece of electrode from the
electrode holder.
in
Engine Operation
in this
FIGURE B.4 – WELDING CIRCUIT CONNECTIONS FOR STICK WELDING
1. FLANGE NUT
2. ELECTRODE CABLE
3. ELECTRODE HOLDER
4. ELECTRODE
5. WORK
6. WORK CLAMP
7. WORK CABLE
7
6
54
1
3
2
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SA-250
B-11 B-11
OPERATION
TO USE THE SA-250 FOR DC WIRE FEED
WELDING (CONSTANT VOLTAGE WITH
WIRE FEED MODULE):
1. Connect the LN-25 or LN-7 Wire Feeder. Follow
the installation instructions provided with the wire
feeder.
2. Set the machine for CV operation.
3. Start the diesel engine. See
this section of the manual.
4. Set the Idler Switch to "AUTO."
5. Set the CURRENT RANGE SELECTOR to a setting appropriate for your wire size and wire feed
speed. See Table B.1 for recommended settings.
6. Set the VOLTAGE ADJUSTMENT to the setting
that gives the best arc characteristics for the range
selected.
7. Pull the gun trigger and begin welding.
Diameter (inches) Wire Speed Range Appropriate Current Range
.035 80-110 75 to 120 Amps
.045 70-130 120 to 170 Amps
Engine Operation
RANGE SETTINGS FOR WIRE SIZE/SPEED
(inches/minute)
in
TABLE B.1
.068 40-90 125 to 210 Amps
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SA-250
B-12 B-12
OPERATION
AUXILIARY POWER
WARNING
Be sure that any electrical equipment plugged into the
generator AC power receptacles can withstand a ±10%
voltage and a ±3% frequency variation.
The AC auxiliary power, supplied as a standard, has a
rating of 3.0 kVA of 115/230V AC power (60 hertz).
One 1 15V duplex and one 230V duplex grounding type
receptacle are provided. The circuit is protected with
circuit breakers.
The rating of 3.0 kVA permits a maximum continuous
current of 13 amps to be drawn from the 230 volt
duplex receptacle. Or a total of 26 amps can be drawn
from the 115 volt duplex receptacle. The 115 volt
duplex receptacle permits 15 amps to be drawn from
either half. The total combined load of all receptacles
must not exceed 3.0 kVA.
An optional power plug kit is available. When this kit is
specified, the customer is supplied with a plug for each
receptacle. See the
ual.
Accessories
section of this man-
To use the generator as an auxiliary power supply:
1. Start the diesel engine. See
this section of the manual.
2. Set the IDLER switch to AUTO. Set the CURRENT
RANGE SELECTOR to “MAX.” See
3. Plug the load(s) into the appropriate 115 volt or 230
volt power receptacle.
Engine Operation
Figure B.1.
in
An optional GFCI 115 volt receptacle kit is also available. Note that the use of this GFCI kit reduces available current to a total of 20 Amps of available 115 volt
power. See the
Accessories
section of this manual.
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SA-250
Section C-1 Section C-1
TABLE OF CONTENTS
- ACCESSORIES -
Accessories...........................................................................................................................Section C
Options/Accessories ...................................................................................................................C-2
TIG Welding Accessories ............................................................................................................C-3
Semiautomatic FCAW and MIG Welding Accessories ...............................................................C-3
Connection of Lincoln Electric Wire Feeders..............................................................................C-4
Connection of the LN-7 using K867 Universal Adapter........................................................C-4
Connection of the LN-7 using K584 Input Cable Assembly .................................................C-5
Connection of the LN-25 using K867 Universal Adapter......................................................C-6
Connection of the LN-25 “Across the Arc”...........................................................................C-7
Connection of the K488 SG Control Module and K487 Magnum Spool Gun......................C-8
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SA-250
C-2 C-2
ACCESSORIES
OPTIONS/ACCESSORIES
The following options/accessories are available for
your SA-250 from your local Lincoln Distributor.
Trailer (K913) - Two-wheeled trailer for in-plant and
yard towing. Various hitches and accessories are
available. For highway use, consult applicable federal,
state, and local laws.
Power Plug Kit (K802-C) - Provides a plug for each
auxiliary receptacle.
Ether Start Kit (K793-1) - Automatic ether start kit provides cold weather starting assistance in temperatures
below 10oF (-12.2oC). Requires an ether tank that must
be purchased locally. “Thermostart” system must be
removed.
NOTE: Ether starting can contribute to shortened
engine life. Avoid unnecessary or indiscriminate use.
Linc Thaw™ Control Unit (L2964-5) - Includes meter
and fuses to protect the welder when thawing frozen
water pipes.
Wire Feed Module - (K623-1) - Provides constant
voltage output for semiautomatic welding. Includes
remote for CV mode and internal “Cold Tip Contactor.”
Accessory Kit (K703) - Includes the following:
• Electrode cable
• Work cable
• Headshield
• Work clamp
• Insulated electrode holder
Remote Control - (K924-1) - Includes a receptacle
switch and control box with 100 ft. (7.5 meters) of 4conductor cable. Allows fine current and OCV to be
controlled remotely.
GFCI Receptacle Kit (K896-2) - Includes a UL
approved 1 15 volt ground fault circuit interrupter receptacle (duplex type) with covers and installation instructions. Each half of the receptacle is rated 15 amps, but
the maximum total current from the GFCI duplex is limited to 20 amps. The GFCI receptacle replaces the
factory installed 115 volt duplex receptacle.
WARNING
PIPE THAWING can result in fire, explosion, damage
to pipes, wiring, and the welder as well as other unsafe
or hazardous conditions. Do not use a welder to thaw
pipes before reviewing Lincoln Bulletin E695.1 (dated
October 1987 or later).
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SA-250
C-3 C-3
ACCESSORIES
TIG WELDING ACCESSORIES
TIG Module (K930-1) - The TIG Module is an acces-
sory that provides high frequency and shielding gas
control for DC GTAW (TIG) welding applications.
The K930-1 TIG Module is supplied without accessories. Arc Start switches, Amptrols, cables, torches
and mounting brackets must be purchased separately.
Control Cable (K936-4) - Control cable for connecting
the K930-1 TIG Module to an SA-250.
Arc Start Switch (K814) - Remote start switch for TIG
module (K930-1).
NOTE: TIG welding requires a Magnum™ TIG Gun,
appropriate Magnum Parts Kit and argon gas.
SEMIAUTOMATIC WELDING ACCESSORIES
LN-25 Wire Feeder - This portable wire feeder is capa-
ble of CC/CV wire feed welding.
LN-7 Wire Feeder - Semiautomatic, constant speed
wire feeder. For CV operation only.
NOTE: Gas-shielded welding requires a Magnum Gun.
Gasless welding requires an Innershield Gun.
Magnum Spool Gun (K487-25) - A lightweight, semi-
automatic wire feeder for aluminum welding with argon
gas. Has built-in remote wire speed control in the handle. Requires the K488 SG Control Module with appropriate control cable. Includes 25 feet (7.6 meters) of
power cable.
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SA-250
CONNECTION OF THE LN-7 TO THE
SA-250 WITH K623-1 WIRE FEED MODULE USING
K867 UNIVERSAL ADAPTER (SEE FIGURE C.1.)
1. Shut the welder off.
2. Connect the electrode cable from the LN-7 to the
“+” terminal of the welder. Connect the work
cable to the “CV–” terminal of the welder.
NOTE: Welding cable must be sized for current and
duty cycle of application.
NOTE: Figure C.1 shows the electrode connected for
positive polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
SA-250 output terminals.
3. Connect the K867 Universal Adapter to the K291 or
K404 input cable and the 14 pin amphenol of the
SA-250 as indicated in Figure C.1. Make the proper connections for local or remote control according to Figure C.1.
4. Connect the K291 or K404 input cable to the LN-7.
5. Place the IDLER switch in the “HIGH” position.
Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control
circuits may be damaged. The engine governor setting is preset at the factory — do not adjust above
RPM specifications listed in this manual.
6. Adjust wire feed speed at the LN-7.
NOTE: For remote control, a K775 remote control is
required. See Figure C.1.
When the welder is in local control, the electrode is
always “HOT.”
ACCESSORIES
C-4 C-4
SA-250
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CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS
CAUTION
CAUTION
FIGURE C.1
SA-250/LN-7 WITH K867 ADAPTER CONNECTION DIAGRAM
Splice Leads
and Insulate
Insulate Each
Unused Lead
Individually
TO
WORK
14 PIN
AMPHENOL
LN-7
CONTROL
BOX
SPARE
82
81
42
41
31 31
32 32
22
44
21
75
76
77
75
76
77
21
GND GND
GREEN
K291 OR K404
INPUT CABLE
K775 OPTIONAL
REMOTE CONTROL
K867 UNIVERSAL
ADAPTER PLUG
ELECTRODE CABLE
TO LN-7
CV-
+
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