SAF-FRO Filcord i250 Mig-Mag Welding User Manual
- June 3, 2024
- SAF-FRO
Table of Contents
Filcord i250 Mig-Mag Welding
FILCORD i250 & i300
IM3182 09/2022 REV02
OPERATOR’S MANUAL
Lincoln Electric Bester Sp. z o.o. ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland
ENGLISH
12/05
THANK YOU! For choosing the QUALITY of the Lincoln Electric products. Please
check packaging and equipment for damage. Claims for material damaged in
shipment must be notified
immediately to the dealer. For ease of use, please enter your product
identification data in the table below. Model Name, Code & Serial Number
can be found on the machine rating plate.
Model Name:
…………………………………………………………………………………………………………………………………………… Code & Serial number:
…………………………………………………………………… …………………………………………………………………… Date & Where Purchased:
…………………………………………………………………… ……………………………………………………………………
ENGLISH INDEX
Technical Specifications
……………………………………………………………………………………………………………………………………………1 ECO design
information……………………………………………………………………………………………………………………………………………3
Electromagnetic Compatibility (EMC)
…………………………………………………………………………………………………………………………5 Safety
…………………………………………………………………………………………………………………………………………………………………….6 Introduction
…………………………………………………………………………………………………………………………………………………………….. 8 Installation
and Operator Instructions …………………………………………………………………………………………………………………………8 WEEE
…………………………………………………………………………………………………………………………………………………………………..18 Spare
Parts……………………………………………………………………………………………………………………………………………………………18 REACh
…………………………………………………………………………………………………………………………………………………………………18 Authorized
Service Shops Location………………………………………………………………………………………………………………………….18
Electrical Schematic……………………………………………………………………………………………………………………………………………….18
Accessories …………………………………………………………………………………………………………………………………………………………..19
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Technical Specifications
NAME FILCORD i250 FILCORD i300
FILCORD i250 FILCORD i300
Input Voltage U1 400V ± 10%, 3-phase
INPUT EMC Class
A
INDEX W100000315 W100000316
Frequency 50/60Hz
FILCORD i250 FILCORD i300
FILCORD i250
FILCORD i300
FILCORD i250 FILCORD i300 FILCORD i250 FILCORD i300
Process
Input Power at Rated Cycle (40°C)
Input Amperes I1max
PF
GMAW/FCAW
12,8 kVA @ 35% Duty Cycle
18,2 A
0,61
SMAW
14 kVA @ 35% Duty Cycle
19,8 A
0,62
GMAW/FCAW 15 kVA @ 35% Duty Cycle
22,0 A
0,65
SMAW
14 kVA @ 35% Duty Cycle
19,8 A
0,62
RATED OUTPUT
Process
Open Circuit Voltage
Duty Cycle 40°C (based on a 10 min.
period)
Output Current
Output Voltage
35%
250A
26,5Vdc
GMAW
60%
230A
25,5Vdc
100%
175A
22,8Vdc
35%
250A
26,5Vdc
FCAW
72Vdc
60%
230A
25,5Vdc
100%
175A
22,8Vdc
35%
250A
30Vdc
SMAW
60%
190A
27,6Vdc
100%
150A
26Vdc
35%
300A
29Vdc
GMAW
60%
230A
25,5Vdc
100%
175A
22,8Vdc
35%
300A
29Vdc
FCAW
72Vdc
60%
230A
25,5Vdc
100%
175A
22,8Vdc
35%
250A
30Vdc
SMAW
60%
190A
27,6Vdc
100%
150A
26Vdc
WELDING CURRENT RANGE
GMAW
FCAW
SMAW
50A÷250A
50A÷250A
10A÷250A
50A÷300A
50A÷300A
10A÷250A
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse Type gR or Circuit Breaker Type D
Power Lead
16A, 400V AC
4 Conductor, 2,5mm2
16A, 400V AC
4 Conductor, 2,5mm2
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FILCORD i250 FILCORD i300
FILCORD i250 FILCORD i300
FILCORD i250 FILCORD i300
FILCORD i250 FILCORD i300
FILCORD i250 FILCORD i300
FILCORD i250 FILCORD i300
WELDING VOLTAGE REGULATION RANGE
GMAW
16,5 V ÷ 26,5 V
16,5 V ÷29 V
WIRE FEED SPEED RANGE / WIRE DIAMETER
WFS Range
Drive Rolls
FCAW 16,5 V ÷26,5 V 16,5 V ÷29 V
Drive roll diameter
1.5 ÷ 18m/min
4
Ø30
Solid Wires 0.6 ÷ 1.2 mm
Weight 50 kg 50 kg
Protection Rating IP23
Aluminum Wires
Cored Wires
1.0 ÷ 1.2 mm
0.8 ÷ 1.0 mm
DIMENSION Height
Width
Length
760 mm
395 mm
830 mm
OTHERS Maximum Gas Pressure
Operating Humidity (t=20°C)
0,5MPa (5 bar)
90 %
Operating Temperature from -10°C to +40°C
Storage Temperature from -25°C to 55°C
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ECO design information
The equipment has been designed in order to be compliant with the Directive
2009/125/EC and the Regulation 2019/1784/EU.
Efficiency and idle power consumption:
Index
W100000315 W100000316
Name
FILCORD i250 FILCORD i300
Efficiency when max power consumption / Idle power consumption
86% / 23W 86% / 23W
Equivalent model
No equivalent model No equivalent model
Idle state occurs under the condition specified in below table
IDLE STATE Condition MIG mode TIG mode STICK mode After 30 minutes of non- working Fan off
Presence X
X
The value of efficiency and consumption in idle state have been measured by
method and conditions defined in the product standard EN 60974-1:20XX.
Manufacturer’s name, product name, code number, product number, serial number
and date of production can be read from rating plate.
1
XXXXXXX
XXXXXXXXXX
3
Code: XXXXX XXXXXX-X
S/N: P1YYMMXXXXX
2
4
5
P1 YY MM
XXXXX
5A 5B 5C
5D
Where: 1-Manufacturer name and address 2-Product name 3-Code number 4-Product number 5-Serial number 5A- country of production 5B- year of production 5C- month of production 5D- progressive number different for each machine
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Typical gas usage for MIG/MAG equipment:
Material type
Wire diameter
[mm]
DC electrode positive
Current [A]
Voltage [V]
Carbon, low alloy steel
0,9 ÷ 1,1
95 ÷ 200 18 ÷ 22
Aluminium
0,8 ÷ 1,6 90 ÷ 240 18 ÷ 26
Austenic stainless steel
0,8 ÷ 1,6
85 ÷ 300 21 ÷ 28
Copper alloy 0,9 ÷ 1,6 175 ÷ 385 23 ÷ 26
Magnesium
1,6 ÷ 2,4
70 ÷ 335 16 ÷ 26
Wire Feeding [m/min] 3,5 6,5 5,5 9,5
3 – 7 6 – 11 4 – 15
Shielding Gas
Gas flow [l/min]
Ar 75%, CO2 25%
Argon Ar 98%, O2 2% / He 90%, Ar 7,5% CO2 2,5%
Argon Argon
12 14 ÷ 19 14 ÷ 16 12 ÷ 16 24 ÷ 28
TIG Process:
In TIG welding process, gas usage depends on cross-sectional area of the
nozzle. For commonly used torches:
Helium: 14-24 l/min Argon: 7-16 l/min
Notice: Excessive flow rates causes turbulence in the gas stream which may
aspirate atmospheric contamination into the welding pool.
Notice: A cross wind or draft moving can disrupt the shielding gas coverage,
in the interest of saving of protective gas use screen to block air flow.
End of life
At end of life of product, it has to be disposal for recycling in accordance with Directive 2012/19/EU (WEEE), information about the dismantling of product and Critical Raw Material (CRM) present in the product, can be found at https://www.lincolnelectric.com/en-gb/support/Pages/operator-manuals-eu.aspx
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Electromagnetic Compatibility (EMC)
11/04
This machine has been designed in accordance with all relevant directives and
standards. However, it may still generate electromagnetic disturbances that
can affect other systems like telecommunications (telephone, radio, and
television) or other safety systems. These disturbances can cause safety
problems in the affected systems. Read and understand this section to
eliminate or reduce the amount of electromagnetic disturbance generated by
this machine.
This machine has been designed to operate in an industrial area. To operate in
a domestic area it is necessary to observe particular precautions to eliminate
possible electromagnetic disturbances. The operator must install and operate
this equipment as described in this manual. If any electromagnetic
disturbances are detected the operator must put in place corrective actions to
eliminate these disturbances, if necessary with assistance from Lincoln
Electric.
WARNING Provided that the public low voltage system impedance at the point of
common coupling is lower than: 58 m for the FILCORD i250 59,9 m for the
FILCORD i300
This equipment is compliant with IEC 61000-3-11 and IEC 61000-3-12 and can be
connected to public low voltage systems. It is the responsibility of the
installer or user of the equipment to ensure, by consultation with the
distribution network operator if necessary, that the system impedance complies
with the impedance restrictions.
Before installing the machine, the operator must check the work area for any
devices that may malfunction because of electromagnetic disturbances. Consider
the following. Input and output cables, control cables, and telephone cables
that are in or adjacent to the work area and the machine. Radio and/or
television transmitters and receivers. Computers or computer controlled
equipment. Safety and control equipment for industrial processes. Equipment
for calibration and measurement. Personal medical devices like pacemakers and
hearing aids. Check the electromagnetic immunity for equipment operating in or
near the work area. The operator must be sure that all
equipment in the area is compatible. This may require additional protection
measures. The dimensions of the work area to consider will depend on the
construction of the area and other activities that are taking
place.
Consider the following guidelines to reduce electromagnetic emissions from the
machine. Connect the machine to the input supply according to this manual. If
disturbances occur if may be necessary to take
additional precautions such as filtering the input supply. The output cables
should be as short as possible and positioned together as close as possible to
each other. If possible
connect the work piece to ground in order to reduce the electromagnetic
emissions. The operator must check that connecting the work piece to ground
does not cause problems or unsafe operating conditions for personnel and
equipment. Shielding of cables in the work area can reduce electromagnetic
emissions. This may be necessary for special applications.
WARNING EMC classification of this product is class A in accordance with
electromagnetic compatibility standard EN 60974-10 which means that the
product is designed to be used in an industrial environment only.
WARNING The Class A equipment is not intended for use in residential locations
where the electrical power is provided by the public low-voltage supply
system. There may be potential difficulties in ensuring electromagnetic
compatibility in those locations, due to conducted as well as radiated
disturbances.
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Safety
11/04
WARNING
This equipment must be used by qualified personnel. Be sure that all
installation, operation, maintenance and repair procedures are performed only
by qualified person. Read and understand this manual before operating this
equipment. Failure to follow the instructions in this manual could cause
serious personal injury, loss of life, or damage to this equipment. Read and
understand the following explanations of the warning symbols. Lincoln Electric
is not responsible for damages caused by improper installation, improper care
or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid
serious personal injury, loss of life, or damage to this equipment. Protect
yourself and others from possible serious injury or death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before
operating this equipment. Arc welding can be hazardous. Failure to follow the
instructions in this manual could cause serious personal injury, loss of life,
or damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not
touch the electrode, work clamp, or connected work pieces when this equipment
is on. Insulate yourself from the electrode, work clamp and connected work
pieces.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect
switch at the fuse box before working on this equipment. Ground this equipment
in accordance with local electrical regulations.
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and
work clamp cables. If any insulation damage exists replace the cable
immediately. Do not place the electrode holder directly on the welding table
or any other surface in contact with the work clamp to avoid the risk of
accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing
through any conductor creates electric and magnetic fields (EMF). EMF fields
may interfere with some pacemakers and welders having a pacemaker shall
consult their physician before operating this equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.
ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC
Directive and EN 12198 Standard, the equipment is a category 2. It makes
mandatory the adoption of Personal Protective Equipment (PPE) having filter
with a protection degree up to a maximum of 15, as required by EN169 Standard.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases
hazardous to health. Avoid breathing these fumes and gases. To avoid these
dangers the operator must use enough ventilation or exhaust to keep fumes and
gases away from the breathing zone.
ARC RAYS CAN BURN: 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. Use suitable clothing made from durable flame-resistant material to
protect you skin and that of your helpers. Protect other nearby personnel with
suitable, non-flammable screening and warn them not to watch the arc nor
expose themselves to the arc.
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WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the
welding area and have a fire extinguisher readily available. Welding sparks
and hot materials from the welding process can easily go through small cracks
and openings to adjacent areas. Do not weld on any tanks, drums, containers,
or material until the proper steps have been taken to insure that no flammable
or toxic vapors will be present. Never operate this equipment when flammable
gases, vapors or liquid combustibles are present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot
surfaces and materials in work area can cause serious burns. Use gloves and
pliers when touching or moving materials in the work area.
CYLINDER MAY EXPLODE IF DAMAGED: 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. Always keep cylinders in an
upright position securely chained to a fixed support. Do not move or transport
gas cylinders with the protection cap removed. Do not allow the electrode,
electrode holder, work clamp or any other electrically live part to touch a
gas cylinder. Gas cylinders must be located away from areas where they may be
subjected to physical damage or the welding process including sparks and heat
sources. A GAS CYLINDER can be used with this machine. In this case, place the
gas cylinder on the back of the machine on the shelf intended for this and
secure it by attaching it to the machine with chains. The height of the
cylinder cannot exceed 1.65m.
MOVING PARTS ARE DANGEROUS: There are moving mechanical parts in this machine,
which can cause serious injury. Keep your hands, body and clothing away from
those parts during machine starting, operating and servicing.
SAFETY MARK: This equipment is suitable for supplying power for welding
operations carried out in an environment with increased hazard of electric
shock.
The manufacturer reserves the right to make changes and/or improvements in
design without upgrade at the same time the operator’s manual.
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Introduction
The welding machines FILCORD i250 and FILCORD i300 can be used for welding in below methods: GMAW FCAW SMAW
The complete package contains: Work lead with ground clamp 3m, Gas hose
2m, Drive roll V0.8/1.0 for solid wire (assembly in the wire
feeder).
Recommended equipment, which can be bought by user, was mentioned in the chapter “Accessories”.
Installation and Operator Instructions
Read this entire section before installation or operation of the machine.
Location and Environment
This machine will operate in harsh environments. However, it is important that
simple preventative measures are followed to assure long life and reliable
operation. Do not place or operate this machine on a surface with
an incline greater than 10° from horizontal. Do not use this machine for pipe
thawing. This machine must be located where there is free
circulation of clean air without restrictions for air movement to and from the
air vents. Do not cover the machine with paper, cloth or rags when switched
on. Dirt and dust that can be drawn into the machine should be kept to a
minimum. This machine has a protection rating of IP23. Keep it dry when
possible and do not place it on wet ground or in puddles. Locate the machine
away from radio controlled machinery. Normal operation may adversely affect
the operation of nearby radio controlled machinery, which may result in injury
or equipment damage. Read the section on electromagnetic compatibility in this
manual. Do not operate in areas with an ambient temperature greater than 40°C.
Duty cycle and Overheating
The duty cycle of a welding machine is the percentage of time in a 10 minute
cycle at which the welder can operate the machine at rated welding current.
Example: 60% duty cycle
Welding for 6 minutes.
Break for 4 minutes.
Input Supply Connection
WARNING Only a qualified electrician can connect the welding machine to the
supply network. Installation had to be made in accordance with the appropriate
National Electrical Code and local regulations.
Check the input voltage, phase and frequency supplied to this machine before
turning it on. Verify the connection of ground wires from the machine to the
input source. The welding machine FILCORD i250, FILCORD i300, must be
connected to a correctly installed plug-in socket with an earth pin. Input
voltage is three-phase 400VAC, 50/60Hz. For more information about input
supply refer to the technical specification section of this manual and to the
rating plate of the machine.
Make sure that the amount of mains power available from the input supply is
adequate for normal operation of the machine. The necessary delayed fuse (or
circuit breaker with “D” characteristic) and cable sizes are indicated in the
technical specification section of this manual.
WARNING The welding machine can be supplied from a power generator of output
power at least 30% larger than input power of the welding machine.
WARNING When powering welder from a generator be sure to turn off welder
first, before generator is shut down, in order to prevent damage to welder!
Output Connections
Refer to points [1], [3] and [4] of the figures below.
Excessive extension of the duty cycle will cause the thermal protection circuit to activate.
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Minutes
or decrease Duty Cycle
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Controls and Operational Features
6 5
7 8
1
3
2
4
Figure 1
1. EURO Socket: For connecting a welding gun (for GMAW / FCAW processes).
2. Lead of Changing Polarity of EURO socket.
3. Positive Output Socket for the Welding Circuit: For connecting an
electrode holder with lead / work lead depending on the require configuration.
4. Negative Output Socket for the Welding Circuit: For connecting an
electrode holder with lead / work lead depending on the require configuration.
5. User Interface: See “User Interface” chapter.
Figure 2
6. Gas Connector: Connection for gas line.
7. Power Switch ON/OFF (I/O): Controls the input power to the machine. Be
sure the power source is connected to the mains supply before turning power on
(“I”).
8. Power Lead (3,4m): Connect the supply plug to the existing input cable
that is rated for the machine as indicated in this manual, and conforms to all
applicable standards. This connection shall be performed by a qualified person
only.
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9
10
12
User Interface
15 16 17 18
11
Figure 3
9. Spooled Wire (for GMAW / FCAW): Not supplied as standard.
10. Wire Spool Holder: Maximum 15kg spools. Maximum 300mm diameter spools.
Holder allows mounting plastic, steel and fiber spools onto 51 mm spindle.
Note: Plastic Brake Nut has a Left-hand thread.
11. Wire drive: 4-rolls wire drive.
12. Switch: Cold Inch / Gas Purge: This switch allows wire feeding (wire
test) and gas flow (gas test) without switching on the output voltage.
14
13
30
19
29
28
20
27
21
22
26 25 24 23
Figure 4
13. Thermal Overload Indicator: It indicates that the machine is overloaded
or that the cooling is not sufficient. Displays show: “ALA ot” = Alarm Over
Temperature message.
14. Input Power Indicator: This LED lights up when the welding machine is ON
and is ready to work.
15. Left Display: Shows wire feed speed or welding current. During welding
shows the actual welding current value.
16. Output Current LED Indicator: Informs that the Left Display shows the
output current in ampere.
17. Wire Feed Speed LED Indicator: Informs that the Left Display shows the
wire feed speed in m/min.
18. Right Display: Depending on the selected function and the welding program
shows the welding voltage in volts or value of Arc Force. During welding shows
the actual output welding voltage.
19. Inductance Control: Adjusts the hardness of the arc. A low value (1-4)
makes the arc harder (more spatter), while a high value (8-10) produces a
softer arc (less spatter). Adjustment range: 0 to +10.
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20. Wire Diameter or Manual Mode Selection Button: Sets the diameter of the welding wire for Synergic Mode or choose Manual Mode.
Process Symbol
Description
0.6 Available wire diameter depends on choosing gas shielding type,
0.8 type of wire and welding wire 0.9 material.
1.0
1.2
The machine works in Manual mode. Welding parameters (wire feed speed and
voltage) are selected by the user.
21. Wire Material Selection Button: sets the type of wire materials (for Synergic Mode only):
Process Symbol
Description
Fe Steel
Al Aluminum
SS Stainless steel
22. Burnback Time Selection Button for Synergic and Manual Mode, allow to choose and set burnback time:
Process Symbol
Description
Burnback Time – amount of time that the welding is continued after the wire
stops feeding. It prevents the wire from sticking in the puddle and prepares
the end of the wire for the next arc ignition.
Regulation range: from 0,02 to 0,25 seconds.
24. Run-In WFS Button: Allow to show and set the Run-in wire feed speed value (for Synergic and Manual Mode):
Process Symbol
Description
Run-in WFS sets the wire feed speed from the time the trigger is pulled
until an arc is established.
Adjust range: from 20 to 100 percent of the WFS value.
When Run-In value is more than max WFS, machine keep max WFS.
25. Gas Selection Button: Enables the selection of the type of shielding gas (for Synergic Mode only).
Process Symbol
Description
To choose gas shielding.
26. Selection Button to Display Workpoint as WFS or A: Allows to change the operating point display as wire feed speed (WFS) in [m/min] or as an output current value in [A]. Only available in synergic mode.
Process Symbol
Description
Workpoint values are displayed in m/min.
Workpoint values are displayed as an amperage [A].
23. Welding Wire Type Selection Button: Set welding wire type (for Synergic Mode only):
Process Symbol
Description
For Synergic Mode only Gas shield required
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27. Torch Trigger Mode Button (2-Step/4-Step): Change the function of the torch trigger.
Process Symbol
Description
2-Step trigger operation turns welding on and off as direct response to the trigger. Welding process starts when the torch trigger is press. 4-Step mode allows to continue welding, when the torch trigger is released. To stop welding, the torch trigger should be pressed again.4-step model facilitates to make long welds.
2T Mode
Trigger Pulled Arc Established Trigger Released
Idle On
Off
Strike
Weld
Off Weld
Off
Weld
Burnback
Idle
time
4T Mode
Trigger Pulled 1 Arc Established Trigger Released 1 Trigger Pulled 2 Trigger Released 2
Idle On
Off
Strike
Weld
Burnback time
Idle
Weld
Off Weld
Off
Figure 5
28. Welding Process Selection Button: Allow to choose the welding process:
Symbol
Description
GMAW/FACW welding mode.
SMAW welding mode.
29. The Center Control: Sets the value shown on the right display. Depending on welding processes or selected function can be set:
Process Symbol
Description
The welding voltage (also during welding).
Burnback Time Adjust range: from 0.02 to 0.25
seconds
Run-in WFS Adjust range: from 20 to 100
percent of the WFS value.
ARC FORCE, the output current is temporarily increased to clear short circuit
connections between the electrode and the workpiece. Lower values will provide
less short circuit current and a softer arc. Higher settings will provide a
higher short circuit current, a more forceful arc and possibly more spatter.
Adjust range: from 0 to 100.
30. Left Control: Sets the value shown on the left display. Depending on welding process can be set:
Process Mark
Description
Workpoint values are displayed in m/min.
Workpoint values are displayed as an amperage [A].
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Welding SMAW Process
FILCORD i250, FILCORD i300 does not include the electrode holder with lead
necessary for SMAW welding, but the one can be purchased separately.
Procedure of begin welding of SMAW process: First turn the machine off.
Determine the electrode polarity for the electrode to be
used. Consult the electrode data for this information. Depending on the
polarity of using electrode, connect
the work lead and the electrode holder with lead to output socket [3] or [4]
and lock them. See the Table 1.
Table 1.
Output socket
The electrode holder with lead to SMAW
[3]
DC (+)
POLARITY
Work lead
[4]
The electrode holder with lead to SMAW
[3]
DC (-)
Work lead
[4]
Connect the work lead to the welding piece with the work clamp.
Install the proper electrode in the electrode holder. Turn the welding machine
on. Set welding mode to SMAW. Set the welding parameters. The welding machine
is now ready to weld. By applying the principle of occupational health and
safety at welding, welding can be begun.
User can set functions: The welding current Arc dynamics ARC FORCE
Welding GMAW, FCAW Process
FILCORD i250, FILCORD i300 can be used to welding GMAW, FCAW-GS, FCAW-SS
process. NOTE: Welding FCAW-SS process is possible in Manual Mode only.
In FILCORD i250, FILCORD i300 can be set: Wire Feed Speed, WFS The welding
voltage Burnback Time Run-in WFS 2-Step/4-Step Polarization DC+/DC Inductance
Preparation the Machine for Welding GMAW and FCAW Process.
Procedure of welding in GMAW or FCAW process: Determine the wire polarity for
the wire to be used.
Consult the wire data for this information. Connect output the gas-cooled gun
to GMAW / FCAW
process to Euro Socket [1]. Depending on the using wire, connect the work lead
to output socket [3] or [4]. See the Table 2.
Table 2
Output socket
Lead of Changing Polarity [2] [3]
DC (+)
POLARITY
Work lead
[4]
Lead of Changing Polarity [2] [3]
DC (-)
Work lead
[4]
Connect the work lead to the welding piece with the work clamp.
Install the proper wire. Install the proper drive roll. Make sure, if it is
needed (GMAW, FCAW-GS
processes), that the gas shield has been connected. Turn the machine on. Push
the Cold Inch Switch [12] to feed the wire through
the gun liner until the wire comes out of the threaded end. Install a proper
contact tip. Check gas flow with Gas Purge Switch [12] GMAW and FCAW
processes. Close the left side panel. Set welding mode to GMAW The welding
machine is now ready to weld. By applying the principle of occupational health
and safety at welding, welding can be begun.
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Welding GMAW Process in synergic
mode
In synergic mode, the welding load voltage is not set by user. The correct
welding load voltage will set by the machine’s software.
Table 3
Wire Diameter
Wire type
The optimum output welding voltage is automatically set by the machine when changing the wire feed speed m/min or the output current value in A, depending on the selected workpoint. Table 3 below show all available synergic welding programs.
Wire Material
Gas Type
0.6
Solid
Fe
CO2
0.8
Solid
Fe
CO2
0.9
Solid
Fe
CO2
1.0
Solid
Fe
CO2
1.2
Solid
Fe
CO2
0.6
Solid
Fe
MIX
0.8
Solid
Fe
MIX
0.9
Solid
Fe
MIX
1.0
Solid
Fe
MIX
1.2
Solid
Fe
MIX
0.8
Solid
Ss
MIX
0.9
Solid
Ss
MIX
1.0
Solid
Ss
MIX
1.2
Solid
Ss
MIX
0.8
Flux-Cored
Fe
CO2
0.9
Flux-Cored
Fe
CO2
1.0
Flux-Cored
Fe
CO2
1.2
Flux-Cored
Fe
CO2
0.8
Flux-Cored
Fe
MIX
0.9
Flux-Cored
Fe
MIX
1.0
Flux-Cored
Fe
MIX
1.2
Flux-Cored
Fe
MIX
1.0
Solid
Al
Ar
1.2
Solid
Al
Ar
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Loading the Electrode Wire
Depending on the type of wire spool it can be installed on the wire spool
support without adapter or installed with use applicable adapter that must be
purchased separately (see “Accessories” chapter).
WARNING Turn the input power OFF at the welding power source before
installation or changing a wire spool.
Turn the machine off. Open the side cover of the machine. Unscrew the locking
nut of the sleeve. Load the spool with the wire on the sleeve such that the
spool turns anticlockwise when the wire is fed into the wire feeder. Make sure
that the spool locating pin goes into the fitting hole on the spool. Screw in
the fastening cap of the sleeve. Put on the wire roll using the correct groove
corresponding to the wire diameter. Free the end of the wire and cut off the
bent end making sure it has no burr. The device is adapted to the spool max.
300mm
WARNING Sharp end of the wire can hurt.
Rotate the wire spool anticlockwise and thread the end of the wire into the
wire feeder as far as the Euro socket.
Adjust force of pressure roll of the wire feeder properly.
Adjustments of Brake Torque of Sleeve
To avoid spontaneous unrolling of the welding wire the sleeve is fitted with a
brake. Adjustment is carried by rotation of its Allen screw M8, which is
placed inside of the sleeve frame after unscrewing the fastening cap of the
sleeve.
31
32
33
Figure 6
31. Fastening cap. 32. Adjusting Allen screw M8. 33. Pressing spring.
Turning the Allen screw M8 anticlockwise increases the spring tension and you
can increase the brake torque
Turning the Allen screw M8 clockwise decreases the spring tension and you can
decrease the brake torque.
After finishing of adjustment, you should screw in the fastening cap again.
Adjusting of Force of Pressure Roll Force
The pressure arm controls the amount of force the drive rolls exert on the
wire. Pressure force is adjusted by turning the adjustment nut clockwise to
increase force, counterclockwise to decrease force. Proper adjustment of
pressure arm gives the best welding performance.
WARNING If the roll pressure is too low the roll will slide on the wire. If
the roll pressure is set too high the wire may be deformed, which will cause
feeding problems in the welding gun. The pressure force should be set
properly. Decrease the pressure force slowly until the wire just begins to
slide on the drive roll and then increase the force slightly by turning of the
adjustment nut by one turn.
Inserting Electrode Wire into Welding Torch
Turn the welding machine off. Depending on welding process, connect the proper
gun
to the euro socket, the rated parameters of the gun and of the welding machine
should be matched. Remote the nozzle from the gun and contact tip or
protection cap and contact tip. Next, straighten the gun out flat. Turn the
welding machine on. Push the Cold Inch Switch [12] to feed the wire through
the gun liner until the wire comes out of the threaded end. When switch is
released spool of wire should not unwind. Adjust wire spool brake accordingly.
Turn the welding machine off. Install a proper contact tip. Depending on the
welding process and the type of the gun, install the nozzle (GMAW process) or
protection cap (FCAW- process).
WARNING Take precaution to keep eyes and hands away from the end of the gun
while the wire is being come out of the threated end.
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Changing Driving Rolls
WARNING Turn the input power off of the welding power source before
installation or changing drive rolls.
FILCORD i250, FILCORD i300 is equipped with drive roll V0.8/V1.0 for steel
wire. For others wire type or / and diameter, the proper drive rolls kit you
can find in Accessories chapter and follow instructions: Turn the input power
OFF. Unlock 2 rolls by turning 2 Quick-Change Carrier Gear
[38]. Release the pressure roll levers [39]. Change the drive rolls [37]
corresponding to the used
wire.
WARNING Be sure that the gun liner and contact tip are also sized to match the
selected wire size.
WARNING For wires with the diameter larger than 1.6mm, the following parts
have to be changed: The guide tube of the feeding console [35] and [36]. The
guide tube of the Euro Socket [34].
Lock 2 new rolls by turning 2 Quick-Change Carrier Gear [38].
Insert the wire through the guide tube, over the roller and through the guide
tube of Euro Socket into liner of gun. The wire can be pushed into the liner
manually for a few centimeters, and should feed easily and without any force.
Lock the pressure roll lever [39].
Gas Connection
A gas cylinder must be installed with a proper flow regulator. Once a gas
cylinder with a flow regulator has been securely installed, connect the gas
hose from the regulator to the machine gas inlet connector.
WARNING The welding machine supports all suitable shielding gases including
carbon dioxide, argon and helium at a maximum pressure of 5,0 bars.
Transport & Lifting
WARNING Falling equipment can cause injury and damage to unit.
39 34
38 35
36 37
Figure 7
English
Figure 8
During transportation and lifting with a crane, adhere to the following rules:
Power source does not include the eye bolt which can
be used to transport or lifting the machine. To lift use of suitable lifting
equipment capacity. To lifting and transport use a travers and minimum two
belts. Lift only power source without gas cylinder, cooler and
wire feeder, or/and any other accessories.
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Maintenance
WARNING For any repair operations, modifications or maintenances, it is
recommended to contact the nearest Technical Service Center or Lincoln
Electric. Repairs and modifications performed by unauthorized service or
personnel will cause, that the manufacturer’s warranty will become null and
void.
Any noticeable damage should be reported immediately and repaired.
Routine maintenance (everyday) Check condition of insulation and connections
of the
work leads and insulation of power lead. If any insulation damage exists
replace the lead immediately. Remove the spatters from the welding gun nozzle.
Spatters could interfere with the shielding gas flow to the arc. Check the
welding gun condition: replace it, if necessary. Check condition and operation
of the cooling fan. Keep clean its airflow slots.
Periodic maintenance (every 200 working hours but at list once every year)
Perform the routine maintenance and, in addition: Keep the machine clean.
Using a dry (and low
pressure) airflow, remove the dust from the external case and from the cabinet
inside. If it is required, clean and tighten all weld terminals.
The frequency of the maintenance operations may vary in accordance with the
working environment where the machine is placed.
WARNING Do not touch electrically live parts.
WARNING Before the case of welding machine will be removed, the welding
machine had to be turned off and the power lead had to be disconnected from
mains socket.
WARNING Mains supply network must be disconnected from the machine before each
maintenance and service. After each repair, perform proper tests to ensure
safety.
Customer Assistance Policy
The business of The Lincoln Electric Company is manufacturing and selling high
quality welding equipment, consumables, and cutting equipment. Our challenge
is to meet the needs of our customers and to exceed their expectations. On
occasion, purchasers may ask Lincoln Electric for advice or information about
their use of our products. We respond to our customers based on the best
information in our possession at that time. Lincoln Electric is not in a
position to warrant or guarantee such advice, and assumes no liability, with
respect to such information or advice. We expressly disclaim any warranty of
any kind, including any warranty of fitness for any customer’s particular
purpose, with respect to such information or advice. As a matter of practical
consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the
provision of information or advice create, expand or alter any warranty with
respect to the sale of our products Lincoln Electric is a responsive
manufacturer, but the selection and use of specific products sold by Lincoln
Electric is solely within the control of, and remains the sole responsibility
of the customer. Many variables beyond the control of Lincoln Electric affect
the results obtained in applying these types of fabrication methods and
service requirements. Subject to Change This information is accurate to the
best of our knowledge at the time of printing. Please refer to www.saf-fro.com
for any updated information.
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WEEE
07/06
Do not dispose of electrical equipment together with normal waste! In
observance of European Directive 2012/19/EC on Waste Electrical and Electronic
Equipment (WEEE) and its implementation in accordance with national law,
electrical equipment that has reached the end of its life must be collected
separately and returned to an environmentally compatible recycling facility.
As the owner of the equipment, you should get information on approved
collection systems from our local representative. By applying this European
Directive you will protect the environment and human health!
Spare Parts
12/05
Part List reading instructions Do not use this part list for a machine if its
code number is not listed. Contact the Lincoln Electric Service Department for
any code number not listed. Use the illustration of assembly page and the
table below to determine where the part is located for your particular code
machine. Use only the parts marked “X” in the column under the heading number
called for in the assembly page (# indicate a
change in this printing).
First, read the Part List reading instructions above, then refer to the “Spare
Part” manual supplied with the machine that contains a picture-descriptive
part number cross-reference.
REACh
11/19
Communication in accordance with Article 33.1 of Regulation (EC) No 1907/2006
REACh. Some parts inside this product contain: Bisphenol A, BPAEC 201-245-8,
, CAS 80-05-7 Cadmium,EC 231-152-8, CAS 7440-43-9 Lead,EC 231-100-4, CAS
7439-92-1 Phenol, 4-nonyl-, branched,EC 284-325-5, CAS 84852-15-3 in more than
0,1% w/w in homogeneous material. These substances are included in the
“Candidate List of Substances of Very High Concern for Authorisation” of
REACh. Your particular product may contain one or more of the listed
substances. Instructions for safe use: use according to Manufacturer
instructions, wash hands after use; keep out of reach of children, do not put
in mouth, dispose in accordance with local regulations.
Authorized Service Shops Location
09/16
The purchaser must contact Lincoln Electric or Authorized Service Facility
about any defect claimed under warranty period.
Contact your local Sales Representative for assistance in locating the nearest
Authorized Service Facility.
Electrical Schematic
Refer to the “Spare Part” manual supplied with the machine.
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Accessories
E/H-300A-50-xM E/H-400A-70-xM K10158-1 K10158 R-1019-125-1/08R
KP69025-0608 KP69025-0809 KP69025-0810 KP69025-1012 KP69025-1216
KP69025-0608A KP69025-0809A KP69025-1012A KP69025-0810A KP69025-1216A
KP69025-0608R KP69025-0809R KP69025-1012R KP69025-0810R KP69025-1216R
W10429-24-3M W10429-24-4M W10429-24-5M W10429-25-3M W10429-25-4M W10429-25-5M
W10429-36-3M W10429-36-4M W10429-36-5M
OPTIONS & ACCESSORIES Electrode holder 300A/50mm², x=5 (5m) or x=10 (10m)
Electrode holder 400A/70mm², x=5 (5m) or x=10 (10m) Adapter for spool type
S300 Adapter for spool 300mm Adapter for spool 200mm
Roll Kit For Solid Wires SOLID DRIVE ROLL 0.6/0.8 SOLID DRIVE ROLL 0.8/0.9
SOLID DRIVE ROLL 0.8/1.0 SOLID DRIVE ROLL 1.0/1.2 SOLID DRIVE ROLL 1.2/1.6
Roll Kit For Aluminum Wires ALUMINUM DRIVE ROLL 0.6/0.8 ALUMINUM DRIVE ROLL
0.8/0.9 ALUMINUM DRIVE ROLL 1.0/1.2 ALUMINUM DRIVE ROLL 0.8/1.0 ALUMINUM DRIVE
ROLL 1.2/1.6
Roll Kit For Cored Wires FLUX CORED DRIVE ROLL 0.6/0.8 FLUX CORED DRIVE ROLL
0.8/0.9 FLUX CORED DRIVE ROLL 1.0/1.2 FLUX CORED DRIVE ROLL 0.8/1.0 FLUX CORED
DRIVE ROLL 1.2/1.6
MIG/MAG TORCHES LGS2 240 G-3.0M MIG GUN AIR COOLED LGS2 240 G-4.0M MIG GUN AIR
COOLED LGS2 240 G-5.0M MIG GUN AIR COOLED LGS2 250 G-3.0M MIG GUN AIR COOLED
LGS2 250 G-4.0M MIG GUN AIR COOLED LGS2 250 G-5.0M MIG GUN AIR COOLED LGS2 360
G-3.0M MIG GUN AIR COOLED LGS2 360 G-4.0M MIG GUN AIR COOLED LGS2 360 G-5.0M
MIG GUN AIR COOLED
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References
- Welders, Welding Wire, Welding Equipment, Accessories & Gear | Lincoln Electric
- Operator Manuals, Spares and Wiring Diagrams | Lincoln Electric
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