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
12/05THANK 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 notifiedimmediately to the dealer. For ease of use, please enter your product identification data in the table below. Model Name, Code & Serial Numbercan be found on the machine rating plate.Model Name:…………………………………………………………………………………………………………………………………………… Code & Serial number:…………………………………………………………………… …………………………………………………………………… Date & Where Purchased:…………………………………………………………………… ……………………………………………………………………
ENGLISH INDEXTechnical 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 ClassA
INDEX W100000315 W100000316Frequency 50/60Hz
FILCORD i250 FILCORD i300FILCORD i250FILCORD i300FILCORD 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 i300FILCORD i250 FILCORD i300FILCORD i250 FILCORD i300FILCORD i250 FILCORD i300FILCORD i250 FILCORD i300FILCORD 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 VDrive roll diameter
1.5 ÷ 18m/min
4
Ø30
Solid Wires 0.6 ÷ 1.2 mmWeight 50 kg 50 kgProtection 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:
IndexW100000315 W100000316
NameFILCORD i250 FILCORD i300
Efficiency when max power consumption / Idle power consumption86% / 23W 86% / 23W
Equivalent modelNo 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 XX
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
5P1 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 9,53 – 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/minNotice: 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)11/04This 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 i300This 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 allequipment 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 takingplace.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 takeadditional 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 possibleconnect 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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Safety11/04WARNINGThis 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 wirefeeder).
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 EnvironmentThis 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 withan incline greater than 10° from horizontal. Do not use this machine for pipe thawing. This machine must be located where there is freecirculation 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 OverheatingThe 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 ConnectionWARNING 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 ConnectionsRefer 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 57 8
1
3
2
4
Figure 11. 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 26. 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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User Interface15 16 17 18
11Figure 39. 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.
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30
19
29
28
20
27
21
22
26 25 24 23Figure 413. 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
1.2The 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 OnOff
Strike
Weld
Off WeldOff
Weld
Burnback
Idle
time
4T Mode
Trigger Pulled 1 Arc Established Trigger Released 1 Trigger Pulled 2 Trigger Released 2
Idle OnOff
Strike
Weld
Burnback time
Idle
Weld
Off WeldOffFigure 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 0.25secondsRun-in WFS Adjust range: from 20 to 100percent 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 ProcessFILCORD 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 beused. Consult the electrode data for this information. Depending on the polarity of using electrode, connectthe 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 andsafety at welding, welding can be begun.User can set functions: The welding current Arc dynamics ARC FORCEWelding GMAW, FCAW ProcessFILCORD 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 / FCAWprocess to Euro Socket [1]. Depending on the using wire, connect the work leadto 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-GSprocesses), that the gas shield has been connected. Turn the machine on. Push the Cold Inch Switch [12] to feed the wire throughthe 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 synergicmodeIn synergic mode, the welding load voltage is not set by user. The correct welding load voltage will set by the machine’s software.
Table 3Wire 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 WireDepending 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 thespool 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. 300mmWARNING 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 SleeveTo 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.313233Figure 631. 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 torqueTurning 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 ForceThe 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 TorchTurn the welding machine off. Depending on welding process, connect the proper gunto 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 RollsWARNING 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 usedwire.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 ConnectionA 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 & LiftingWARNING Falling equipment can cause injury and damage to unit.
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Figure 8During transportation and lifting with a crane, adhere to the following rules: Power source does not include the eye bolt which canbe used to transport or lifting the machine. To lift use of suitable lifting equipment capacity. To lifting and transport use a travers and minimum twobelts. Lift only power source without gas cylinder, cooler andwire feeder, or/and any other accessories.
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MaintenanceWARNING 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 thework 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 lowpressure) 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 PolicyThe 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
07/06Do 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 Parts12/05Part 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 forany code number not listed. Use the illustration of assembly page and the table below to determine where the part is located for your particular codemachine. Use only the parts marked “X” in the column under the heading number called for in the assembly page (# indicate achange 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.REACh11/19Communication 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 Location09/16The 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-1019-125-1/08RKP69025-0608 KP69025-0809 KP69025-0810 KP69025-1012 KP69025-1216KP69025-0608A KP69025-0809A KP69025-1012A KP69025-0810A KP69025-1216AKP69025-0608R KP69025-0809R KP69025-1012R KP69025-0810R KP69025-1216RW10429-24-3M 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 200mmRoll 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 1.2/1.6Roll 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 1.2/1.6Roll 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 1.2/1.6MIG/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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