Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...
Page 6 - Thank You; CAUTION; Please Examine Carton and Equipment For Damage Immediately
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and...
Page 7 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS
vi APR96 IDEALARC SP-255 MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ................................................................................
Page 8 - vii
vii IDEALARC SP-255 MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Maintenance ....................................................................................................Section D Safety Precautions ...............................................................................................
Page 9 - INSTALLATION; TECHNICAL SPECIFICATIONS – IDEALARC
A-1 INSTALLATION AUG 95 IDEALARC SP-255 75C Copper Wire 75C Copper Wire in Conduit in Conduit Input Fuse or Input Ampere AWG (IEC) AWG (IEC) Voltage/ Breaker Size Rating on Sizes Sizes Frequency (Super Lag) Nameplate For lengths For lengths Ground Wire up to 100 ft. exceeding 100 ft. 208 60 53 8 (10...
Page 10 - SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.
A-2 INSTALLATION IDEALARC SP-255 OCT94 Read entire Installation section before startinginstallation. SAFETY PRECAUTIONS UNCRATING THE SP-255 Remove the staples from the bottom edge of the car-ton and lift off. Cut the tape securing the two rearwheels to the wooden shipping pallet. Using a 1/2 inch(o...
Page 11 - OUTPUT POLARITY CONNECTION
The 230/460/575 volt 60 Hz model is not equippedwith a plug, input cable or receptacle. 4. Using the following instructions have a qualified electrician connect the receptacle or cable to theinput power lines and the system ground per theU.S. National Electrical Code and any applicablelocal codes. S...
Page 12 - SHIELDING GAS
A-4 INSTALLATION IDEALARC SP-255 OCT94 However, the thumbswitch functions available onthe Magnum 250SP gun will only be operable fromthe front panel keypad. The gun trigger switch mustbe capable of switching 5 milliamps at 15 voltsDC– resistive. The gun trigger switch connected to the gun trig-ger c...
Page 13 - OPERATION
IDEALARC SP-255 B-1 OPERATION Read entire Operation section beforeoperating the SP-255. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground. • Always wear dry insulating gloves. FUMES AND GASES can bedangerous. ...
Page 14 - PRODUCT DESCRIPTION; POWER SWITCH
IDEALARC SP-255 B-2 OPERATION PRODUCT DESCRIPTION The SP-255 is a complete semiautomatic constantvoltage DC arc welding machine built to meet NEMAspecifications. It combines a constant voltage powersource and a constant speed wire feeder with a micro-computer-based controller. This forms an intellig...
Page 15 - START MODE SELECTIONS
B-3 OPERATION JAN96 IDEALARC SP-255 are held closed. The left pair will automatically contin-ue to increment or decrement the selection above it ata slow, steady rate as long as the key is pressed. Thecenter and right pairs will continue to increment anddecrement the selections above them at a slow ...
Page 16 - PROCEDURE KEYS; Figure 4 Figure 5
B-4 OPERATION IDEALARC SP-255 Center arrow keys—set Wire Diameter Right arrow keys—set Welding Gas The following 16 processes are programmed into theSP-255: PROCEDURE KEYS AUTO KEY Pressing the Auto Key once places the SP-255 intothe automatic mode of operation. Auto mode providesautomatic setup of ...
Page 17 - MEMORY KEYS
B-5 OPERATION IDEALARC SP-255 Repressing the Auto Key sets the recommended pro-cedure for the metal thickness displayed. MANUAL KEY Permits individual setting of wire feed speed and arcvoltage for manual procedure setup. The manualscreen displays wire feed speed, arc voltage, and ac u r s o r t h a ...
Page 18 - TIMER KEYS
B-6 OPERATION IDEALARC SP-255 OCT94 The six arrow keys perform no function during a recall. NOTE: The presently displayed setup is lost because it is replaced by the setup recalled from memory. Ifyou wish to save the present setup, save it to anunused memory first (see Save key), and then recallthe ...
Page 19 - GUN SWITCH KEYS; always
B-7 OPERATION IDEALARC SP-255 STITCH KEY Turns on the Stitch weld timers and displays selec-tions of the stitch ON and OFF times. Pressing theStitch key a second time returns the screen to theprevious display without turning off the stitch timers.Any time the Stitch weld timers are on and the displa...
Page 21 - -STEP TRIGGER INTERLOCK KEYS
B-9 OPERATION IDEALARC SP-255 the one that did not match (see Memory Number KeySection). 4-STEP TRIGGER INTERLOCK KEYS Pressing and Controls whether 4-step trigger interlock is activatedor deactivated. (See “Using 4-Step Trigger InterlockFunction” section.) NOTE: 4-Step Trigger is automatically deac...
Page 22 - GUN SWITCHES; Gun Trigger Switch; WIRE DRIVE ROLL; WIRE REEL LOADING; c o u n t e r c l o c k w i s e
B-10 OPERATION IDEALARC SP-255 GUN SWITCHES Gun Trigger Switch — Turns on arc voltage, wire feeder, and gas solenoid (except with Innershield)when closed. Also causes the screen to display theAuto or Manual screens (depending on which mode itis in), when the trigger is pulled. Turns off arc voltage,...
Page 23 - securely; MOUNTING OF 10 TO 44 LBS. SPOOLS; TO START THE WELDER; IDLE ROLL PRESSURE SETTING
B-11 OPERATION IDEALARC SP-255 Check to be sure the retaining spring has fullyreturned to the locking position and has securely locked the Readi-Reel cage in place. Retainingspring must rest on the cage not the welding elec-trode. To remove Readi-Reel from Adapter, depress retain-ing spring tab with...
Page 24 - MAKING AN AUTO MODE WELD
B-12 OPERATION IDEALARC SP-255 OCT94 3. If the only result was drive roll slippage, loosen the gun cable Fast-Mate™ connection nut from thefront of the SP-255 and pull the gun cable forwardabout 6” (152 mm). There should be a slight wavi-ness in the exposed wire. If there is no waviness,the pressure...
Page 25 - SPOT WELD MODE
B-13 OPERATION IDEALARC SP-255 12. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operategun trigger to release gas pressure, and turn offSP-255. SPOT WELD MODE Arc spot plug welds are used when continuous weldsare not needed or to hold thin sheet metal togeth...
Page 26 - EXPLANATION OF PROMPTING AND ERROR MESSAGES; On Screen Error Message; OVERCURRENT PROTECTION
EXPLANATION OF PROMPTING AND ERROR MESSAGES On Screen Error Message Message Explanation PROCESS MUSTMATCH WIRE & GAS ONLY SET UP FOR.035 STAINLESS ONLY ARGON USEDWITH ALUMINUM ONLY SET UP FOR.045 OUTERSHIELD NO GAS REQUIREDWITH INNERSHIELD MEMORY 1 NOWCONTAINS SETUP MEMORY 2IS EMPTY MEMORY 4 DOE...
Page 29 - MagnumTM; ACCESSORIES; SPOOL GUN DESCRIPTION
for use of the K487 Spool Gun (with remotes p e e d c o n t r o l ) , o r t h e K 4 6 9 S p o o l G u n(requires K518 Connection Adapter). It also provides single switch transfer ofTrigger and Wire Speed Controls betweenthe 250SP gun or the spool gun for samepolarity welding with different wire and ...
Page 31 - DISABLING SPOOL GUN
C-3 ACCESSORIES IDEALARC SP-255 memory 4 is recalled and appears on thedisplay. This whole cycle is repeatable aslong as the unit remains in Toggle mode. DISABLING SPOOL GUN When the Spool Gun Adapter box transferswitch is set to FEEDER Gun position, thedisplay will flash between these two mes-sages...
Page 32 - NOTES
Page 33 - MAINTENANCE; GUN TUBES AND NOZZLES; • Have qualified person-; ROUTINE MAINTENANCE; GENERAL MAINTENANCE
D-1 MAINTENANCE IDEALARC SP-255 GUN TUBES AND NOZZLES 1. Replace worn contact tips as required. 2. Remove spatter from inside of gas noz- zle and from tip after each 10 minutes ofarc time or as required. CABLE CLEANING Clean cable liner after using approximately300 pounds (136 kg) of electrode. Remo...
Page 34 - not; Liner trim length for the 250SP gun
D-2 MAINTENANCE IDEALARC SP-255 out straight on a flat surface. Remove theliner nut from the Fast-Mate™ connectorend of the cable and pull the liner out of thecable. 4. Insert a new untrimmed liner into the connector end of the cable. Be sure theliner busing is stencilled appropriately forthe wire s...
Page 37 - TROUBLESHOOTING; Step 3. CONSULT LOCAL AUTHORIZED; HOW TO USE TROUBLESHOOTING GUIDE; LOCAL AUTHORIZED LINCOLN ELECTRIC
E-1 TROUBLESHOOTING IDEALARC SP-255 Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM(SYMPTOMS)”. This column describes pos-sible symptoms that the machine mayexhibit. Find the listing that best describesthe symptom that your machine is exhibit-ing. Step 2. PERFORM EXTERNAL RE...
Page 38 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS
IDEALARC SP-255 E-2 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) Major physical or electrical damageis evident. There is no wire feed or opencircuit voltage when the gun triggeris pulled. The LCD display is “ON”indicatin...
Page 41 - FUNCTION PROBLEMS
E-5 TROUBLESHOOTING IDEALARC SP-255 Observe Safety Guidelinesdetailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) The SP-255 stops feeding wirewhile welding and the MOTOROVERLOADED message appearson the LCD display. The voltage and/or wire feed speedare being changed ev...
Page 42 - FEEDING PROBLEMS
IDEALARC SP-255 E-6 TROUBLESHOOTING Observe Safety Guidelinesdetailed in the beginning of this manual. TROUBLESHOOTING GUIDE If for any reason you do not understand the test procedures or are unable to Perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FAC...
Page 43 - WIRING DIAGRAMS
F-1 WIRING DIAGRAMS IDEALARC SP-255 SP-255 WIRING DIAGRAM: L9688 (DUAL VOLTAGE) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
Page 45 - DIMENSION PRINT
F-3 DIMENSION PRINT IDEALARC SP-255 SP-255 DIMENSION PRINT – M16352 (1-31-92B) Inches (Millimeters)
Page 50 - Lincoln Welding School; BASIC COURSE
Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P l ...
Page 53 - CONDITIONS OF WARRANTY; WARRANTY LIMITATIONS; LIMITED WARRANTY
• 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 STATEMENT OF LIMITED WARRANTY The Lin...
