Lincoln Electric WELDANPOWER 230+, Operating Manual

Page 1: ...coln Electric welders are designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part Read and observe the general...

Page 2: ...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 e Also see Item...

Page 3: ...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...

Page 4: ...ing can interfere with a pacemakers function Generally the interference does not permanently damage the pacemaker Once the wearer leaves the arc welding environment or stops welding the pacemaker retu...

Page 5: ...lding or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surroundin...

Page 6: ...n High Idle Diecast Aluminium 3300 RPM Crankcase Low Idle 2200 RPM Engine Diesel DESIGN FEATURES AC DC Stick Welding Constant Current AC 30 230 Amps DC 30 210 Amps 100 Duty Cycle on All Settings Outpu...

Page 7: ...ust be field installed in the TIG Module when used with a Weldanpower 230 Additionally the K936 3 control cable is required if remote control is used If remote control is not used the K936 4 control c...

Page 8: ...Page 8 Weldanpower 230 IMA 572F...

Page 9: ...m batteries If acid contacts eyes or skin flush immediately with large quantities of clean drinking water In cases of acid contacting the eyes consult a doctor immediately After use wash out empty ele...

Page 10: ...periodically and tightened if necessary Loose connections will result in overheating of the output studs When welding at a considerable distance from the welder be sure you use ample size welding cabl...

Page 11: ...supplied without accessories Arc Start switches amptrols cables torches and mounting brackets must be purchased separately OPERATING INSTRUCTIONS Additional Safety Precautions Always operate the weld...

Page 12: ...n 20 seconds if the engine does not start Allow at least 1 minute between cranking periods to avoid damage to electrical components After running at high engine speed for 8 12 seconds the engine will...

Page 13: ...osal of residues are negligible under normal conditions of use On the contrary during grinding of electrode tips there is generation of radioactive dust with the risk of internal exposure It is theref...

Page 14: ...and power loads are permitted by following the Table below The permissible currents assume that the fine output control is set at 10 A lower setting of the fine output control will decrease the avail...

Page 15: ...h low pressure air periodically In particularly dirty locations this may be required once a week See page 18 for Ground Test Procedure Engine Adjustments Adjustments to the engine are to be made only...

Page 16: ...nclude the other company s name and part number and other relevant information 3 Parts should be ordered from Lincoln its offices or the nearest Authorised Field Service Shop The Lincoln Service Direc...

Page 17: ...ltage signal from the 1 Check for disconnected or idle when using auxiliary current sensor broken leads in idler sensing power circuit 2 Auxiliary power load less 2 Idler may not function with less th...

Page 18: ...of the mega tester to the front panel ground stud and the other lead to the electrode output stud Apply the test Min resistance 1M 11 Auxiliary circuit to welding circuit test Connect one lead of the...

Page 19: ...number is not listed Contact the Service Department for any code numbers not listed Only those suffixes which require distinction from the basic codes are shown PARTS LIST AP 229 C AP 229 D NO CODE NO...

Page 20: ...MA 572F AP 229C Operative 18 12 03 Supercedes 1 6 99 Shown Ref AG1368A A2 9 98M for Code 1530 When ordering parts quote Parts List No Part No Description Machine Code and Serial Numbers 16 17 1 2 3 4...

Page 21: ...Base Assembly L9027 1 x x 12 Upper Case Front Assy Ref AP229D 1 x Upper Case Front Assy Ref AP229D 1 x 13 Case Side Left G2542 1 x x 14 Selector Switch Assy M17013 1 x x 15 Fuel Trough M16533 1 x x 1...

Page 22: ...ly AP 229C2 Operative 18 12 03 Supercedes 1 6 99 1 2 3 4 5 6 7 7a 8 11 12 43 9 10 14 42 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Ref AG1368 3 for Code 1421 1436 Page 22 Weldanpower 230 IM...

Page 23: ...x x 24 Output Stud M13900 2 x x 25 Flange Nut Output Stud T3960 2 x x 26 Choke Coil Lamination Assy L9036 1 1 x x 27 Choke Cable AT2626 6 1 x x 28 Rectifier Assy L9050 1 1 x x 29 Knob T10491 1 1 x x...

Page 24: ...0 Petrol Front Panel Assembly AP 229D Operative 18 12 03 Supercedes 1 6 99 1 12 8 4 3 Shown Ref AL2514 3 A20 1 99M for Code 1530 and above Ref AL2514 1 A13 12 95 for Codes 1421 1436 Page 24 Weldanpowe...

Page 25: ...x x x 6 Engine toggle switch DPDT T10800 25 1 x x Engine toggle switch DPDT S13146 1 1 x 7 Idler toggle switch SPST T10800 20 1 x x x 8 Toggle Switch DPDT T10800 36 1 x Toggle Switch SPDT T13562 1 x...

Page 26: ...MA 572F WELDANPOWER 230 WIRING DIAGRAM PETROL ENGINE Ref AM3421 1 A31 1 96M for Codes 1436 1421 This diagram is indicative only Refer to diagram inside machine case or write to factory quoting macine...

Page 27: ...WELDANPOWER 230 WIRING DIAGRAM PETROL ENGINE This diagram is indicative only Refer to diagram inside machine case or write to factory quoting macine codes and serial numbers Ref AM3421 4 A12 8 98M for...

Page 28: ...WELDANPOWER 230 WIRING DIAGRAM PETROL ENGINE This diagram is indicative only Refer to diagram inside machine case or write to factory quoting macine codes and serial numbers Ref AM3421A4 A2 9 98M for...

Page 29: ...30 Page 29 WELDANPOWER 230 WIRING DIAGRAM PETROL ENGINE This diagram is indicative only Refer to diagram inside machine case or write to factory quoting macine codes and serial numbers Ref AM3421 7 A6...

Page 30: ...A 572F WELDANPOWER 230 WIRING DIAGRAM PETROL ENGINE This diagram is indicative only Refer to diagram inside machine case or write to factory quoting macine codes and serial numbers Ref AM3421B4 A08 10...

Page 31: ...t for machine if its code number is not listed Contact the Service Department for any code numbers not listed Only those suffixes which require distinction from the basic codes are shown PARTS LIST AP...

Page 32: ...anpower 230 IMA 572F Weldanpower 230 Diesel General Assembly AP 86C Operative 18 12 03 Supercedes 1 6 99 1 2 3 4 6 6 9 10 11 2 12 13 14 22 21 20 18 19 16 15 SEE DETAIL AP 86E Ref AG1368 6 A16 5 99M fo...

Page 33: ...ssembly AL2514 2 1 x x x 10 Case Side Left G2542 1 x x x 11 Selector Switch Assembly M17013 1 x x x 12 Fuel Trough M16533 1 x x x 13 Fuel Cap Diesel S19568 1 1 x x x 14 Roof G2534 1 x x x 15 Rubber Gr...

Page 34: ...y AP 86C2 Operative 18 12 03 Supercedes 1 6 99 SEE PRESSURE SWITCH DETAIL AP 86E 15 14 13 11 10 9 5 6 7 8 16 SEE REGULATOR PLUG DETAIL AP 86F 24 23 19 18 21 20 22 25 17 28 12 27 26 25 29 4 2 31 30 1 3...

Page 35: ...ssy AM3558 1 x 19 Rubber Mount Engine End AT4023 2 x x x Rebound Washer AT2943Z 2 x x x Steel Tube AT3831 2 x x x 3 8 UNC x 2 3 4 H T Hex Hd Screw NSS 2 x x x 3 8 UNC Nyloc Nut NSS 2 x x x 3 8 Lockwas...

Page 36: ...Page 36 Weldanpower 230 IMA 572F Ref AL2514 2 7 19 96G Weldanpower 230 Diesel Front Panel Assembly AP 86D Operative 18 12 03 Supercedes 14 2 97 12...

Page 37: ...1 1 x x 7 Toggle Switch SPST T10800 55 1 x x 8 Circuit Breaker 15 amp T12287 22 3 x x 9 Miniature Hourmeter S17475 3 1 x x 10 Plug Base 240V 15amp AT1875 5 3 x x 11 Outlet Rain Flap Strip AS4587 1 x...

Page 38: ...230 Diesel Miscellaneous Details AP 86E Operative 18 12 03 Supercedes 1 6 99 2 CONTROL PCB IDLER CONTROL 6 3 4 5 7 9 8 12 11 CONTROL BOX ASSEMBLY DETAIL ENGINE OIL PRESSURE SWITCH DETAIL ROTOR BLOWER...

Page 39: ...x x Expansion Nut S14020 3 4 x x x x 3 Oil Pressure Switch AS4677 1 1 x x x x 4 Oil Fitting Adaptor Nipple AS4584 1 x x x x 5 Sleeving oil Gauge Line 1 x x Cable Tie 3 x x Nylon Tubing Oil Gauge Line...

Page 40: ...MA 572F WELDANPOWER 230 WIRING DIAGRAM DIESEL ENGINE This diagram is indicative only Refer to diagram inside machine case or write to factory quoting macine codes and serial numbers Ref AM3421 2 A16 4...

Page 41: ...230 Page 41 WELDANPOWER 230 WIRING DIAGRAM DIESEL ENGINE This diagram is indicative only Refer to diagram inside machine case or write to factory quoting macine codes and serial numbers Ref AM3421 6 A...

Page 42: ...IMA 572F WELDANPOWER 230 WIRING DIAGRAM DIESEL ENGINE This diagram is indicative only Refer to diagram inside machine case or write to factory quoting macine codes and serial numbers Ref AM3421 9 A28...

Page 43: ...IMA572F Weldanpower 230 Page 43 NOTES...

Page 44: ...way liable for the operation non operation or malfunction of any such battery CONDITION OF WARRANTY TO OBTAIN WARRANTY COVERAGE The purchaser must contact Lincoln or Lincoln s Authorised Service Facil...