Air Liquide A 225 AC/DC: ALW-M110500425 User manual

OWNER’S MANUAL
KEEP THIS MANUAL
The technical specifications and the wiring diagrams contained in this owner’s manual are valid only
for the model that has the part number indicated below.
A 225 AC/DC - A 250 AC/DC
A 225 AC/DC:ALW-M110500425
A 250 AC/DC:ALW-M110500426
Air Liquide Welding is a trademark of L’Air Liquide S.A. 08/01

TABLE OF CONTENTS
1 SAFETY PRECAUTIONS - READ BEFORE USING
1.1 INSTALLATION OF EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 PERSONAL PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.3 FIRE AND EXPLOSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4 METAL FUME HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.5 TRANSPORTING THE POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.6 MAGNETIC FIELDS CAN AFFECT PACEMAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.7 H.F. RADIATION CAN CAUSE INJURY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.8 ARC WELDING CAN CAUSE INTERFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.9 WELDING AND THE EFFECTS OF LOW FREQUENCY AND MAGNETIC FIELDS . . . . . . .5
1.10 PRINCIPAL SAFETY STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2 SPECIFICATIONS AND DESCRIPTION
2.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.3 COMES COMPLETE WITH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.4 DUTY CYCLE AND OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.5 VOLT-AMPERE CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3 OPERATION
3.1 FRONT PANEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4 INSTALLATION
4.1 CONNECTING THE EQUIPMENT TO THE MAIN SUPPLY . . . . . . . . . . . . . . . . . . . . . . . .11
4.2 SELECTING A LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.3 CONNECTION AND PREPARATION OF EQUIPMENT FOR STICK-ELECTRODE
WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.4 WELDING PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
4.5 INTERNAL CONNECTION FOR OPERATING 230, 460 OR 575 VOLTS . . . . . . . . . . . . . . .13
4.6 HOW TO INSTALL THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5 MAINTENANCE AND TROUBLESHOOTING
5.1 ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
6 A 225 AC/DC ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
7 A 250 AC/DC ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
8 A 225 AC/DC SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
9 A 250 AC/DC SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3
1. SAFETY PRECAUTIONS - READ BEFORE USING
WARNING
Read and understand this entire Owner’s Manual before installing, operating or servicing this equipment. While the informa-
tion contained in this Owner’s manual represents our best judgment, Air Liquide assumes no liability for its use.
Reproduction of this work, in whole or part, without written permission of the publisher is prohibited.
All rights reserved.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error
or omission in the Air Liquide A 225 AC/DC – A 250 AC/DC Owner’s Manual, whether such error results from negligence, acci-
dent or any other causes.
The use of welding equipment can cause
injury to the operator. The reading and understand-
ing of the safety standards mentioned below is com-
pulsory prior to connecting, preparing, using or
transporting welding equipment.
1.1 INSTALLATION OF EQUIPMENT
1. Installation and maintenance of equipment
must be performed in compliance with local
safety standards.
2. Frequently inspect the welder plug,
receptacle and wiring. If damaged, replace
immediately with approved electrical connec-
tions and adequately sized wiring.
3. Connect the welding ground as near as possi-
ble to the operating area.
4. Do not pass welding equipment cables through
or near lifting chains, crane cables or any elec-
trical lines.
5. If earth grounding of the workpiece is required,
ground it directly with a separate cable.
6. Do not touch the electrode if you are in contact
with the work, ground or another electrode from
a different welding machine.
7. Use only well-maintained equipment. Repair or
replace damaged parts immediately. Maintain
welding equipment according to owner’s manu-
al.
8. Never use welding equipment near water. Do
not spray water or other liquids on the welding
equipment.
9Avoid direct contact between wet garments and
metal parts that are electrically charged.
10. Always wear gloves and rubber-soled shoes
when working in wet areas or standing on
metal surfaces.
11. Always turn off welding equipment that is not
being used. Do not leave welding equipment
unattended.
Significant DC voltage exists after the removal
of input power to inverters. Always discharge
input capacitors before touching any parts.
Service work should be completed by quali-
fied personnel only.
1.2 PERSONAL PROTECTION
1. Welding operations produce radiation, noise,
heat and noxious fumes. Suitable safety pre-
cautions must be taken to minimize the risk.
2. Wear fire resistant work gloves, long
sleeve shirts, pants, safety shoes, cap and
welding helmet to protect the skin from radia-
tion and metal sparks.
3. Always wear ear protection.
4. Always wear eye protection with side shields.
5. Position a fire resistant screen around the
welding area to protect bystanders from radia-
tion, sparks and slag.

6. Compressed gas cylinders
are potentially dangerous. Consult the supplier
for correct handling procedures. Always protect
compressed gas cylinders from the sun’s rays,
flames and sudden temperature changes.
1.3 FIRE AND EXPLOSION PREVENTION
Hot slag and sparks can
cause fire. The risk of fire and explosion can
be minimized by removing all flammable mate-
rial from the welding area.
1. Always perform welding operation with caution.
Containers and tubes that have been emptied
and thoroughly cleaned still represent a poten-
tial hazard.
2. Never perform welding operations or cut a
closed container or pipe.
3. Never perform welding operations on open con-
tainers or pipes that may have been contami-
nated with substances that could explode or
react when exposed to heat or humidity.
4. As a preventative measure, keep fire extin-
guishers near the welding operation.
1.4 METAL FUME HAZARDS
Welding fumes and gases may be
hazardous if inhaled.
1. Install a ventilation system in the welding area.
2. Use a forced air system when welding lead,
beryllium, cadmium, zinc, zinc-coated or paint-
ed material. Always wear a protective mask.
3. If the ventilation system is inadequate, use an
air respirator.
4. Beware of gas leaks. Shielding gases such as
argon are heavier than air and when used in
small spaces, will replace the air.
5. In the event that a welding operation occurs in
a confined place, the operator should be
accompanied by another person.
6. Always keep gas cylinders in a well-ventilated
area. Close the main gas valve when cylinder
is not in use.
7. Do not perform welding operations near chlori-
nated hydrocarbon vapors produced by
degreasing or painting. The heat generated by
arc rays can react to form phosgene, a highly
toxic gas.
8. Irritation of the eyes, nose and throat are symp-
toms of inadequate ventilation. Take immediate
steps to improve ventilation. Do not continue
welding if symptoms persist.
1.5 TRANSPORTINGTHE POWER SOURCE
1. The welding machine may be carried by the
handle.
2. Always disconnect the power source and
accessories from the main supply before lifting
or handling the welding equipment.
3. Do not drag, pull or lift welding equipment by
the weld cables.
1.6 MAGNETIC FIELDS CAN AFFECT
PACEMAKERS
1. Keep pacemaker wearers away from
welding operations.
2. Pacemaker wearers should consult with a
physician prior to being exposed to any welding
or cutting operation.
4

5
1.7 H.F. RADIATION CAN CAUSE INJURY
1. High frequency (HF) emissions can
interfere with radio navigation, safety devices,
computers and communication equipment.
2. Installation of welding equipment should be
performed by a qualified electrician.
3. The operator is responsible for having a quali-
fied electrician correct any interference problem
resulting from the welding equipment installa-
tion.
4. If notified by the FCC about interference, stop
using the welding equipment immediately.
5. Have the welding equipment installation
checked and maintained on a regular basis.
6. Keep high-frequency source doors and panels
tightly shut. Keep spark gaps at the correct set-
ting and use grounding to minimize the possi-
bility of interference.
1.8 ARC WELDING CAN CAUSE
INTERFERENCE
1. Electromagnetic energy can interfere
with sensitive electronic equipment such as
computers and computer-driven equipment like
robots.
2. Be sure that all equipment in the welding area
is electro-magnetically compatible.
3. To reduce possible interference, keep weld
cables as short as possible, close together and
down low.
4. Locate welding operations at least 100 meters
(350 feet) away from any sensitive electronic
equipment.
5. Be sure welding equipment is installed and
grounded according to this manual.
6. If interference still occurs, the operator must
take extra measures such as moving the weld-
ing machine, using shielded cables, using line
filters, or shielding the work area.
1.9 WELDING ANDTHE EFFECTS OF LOW
FREQUENCY AND MAGNETIC FIELDS
As welding current flows through welding cables, it
can cause electromagnetic fields.To reduce mag-
netic fields, use the following procedures:
1Keep cables close together by twisting or taping
them.
2. Arrange cables to one side and away from the
operator.
3. Do not coil or drape coils around operators
body.
4. Keep welding power source and cables as far
away from the operator as practically possible.
5. Connect work clamp to workpiece as close to
the weld as possible.
1.10 PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard
Z49.1 from the American Welding Society, 550
N.W. Lejeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR
1910, from the Superintendent of Documents,
U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation
for Welding and Cutting of Containers That Have
Held Hazardous Substances, American Welding
Society Standard AWS F4.1, from the American
Welding Society, 550 N.W.Lejeune Rd., Miami, FL
33126.
National Electrical Code, NFPA Standard 70, from
the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders,
CGA Pamphlet P-1, from the Compressed Gas
Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA
Standard W117.2, from the Canadian Standards
Association, Standard Sales, 178 Rexdale
Boulevard, Rexdale, Ontario M9W 1R3.
Safe Practices For Occupation And Educational
Eye And Face Protection, ANSI Standards Z87.1
from the American National Standards Institute,
1430 Broadway, NewYork, NY 10018.
Cutting And Welding Processes, NFPA Standards
51B, from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.

6
EQUIPMENT INSTALLATION AND MAINTENANCE MUST BE PERFORMED IN
COMPLIANCE WITH LOCAL SAFETY STANDARDS.
• INSTALLATION AND MAINTENANCE OPERATIONS MUST BE PERFORMED BY QUALIFIED PERSONS
ONLY.
• BEFORE INSTALLING the power source, check that the power socket satisfies ampere and voltage
requirements (see data table plate). ENSURE that the socket is protected by appropriate fuses and auto-
matic switches.
• CONNECT an approved standard plug corresponding to the system socket to the power supply cable.
Electric shock could be fatal
1. Never touch exposed electrical
parts.
2. Switch off and disconnect the
power source before installing
or opening.
3. Installation may be performed
by qualified persons only.
4. Installation procedure must
comply with national electricity
standards and all other relevant
regulations.
Fumes and gases may repre-
sent a safety hazard.
Fumes and gases generated
during welding may be danger-
ous if inhaled over a long period
of time.
1. Keep clear of fumes.
2. Ventilate welding area or wear
a breathing mask.
3. Install a natural or forced air
ventilation system in the work
area.
Use a protective mask with suit-
able glass filter (at least NR10)
to safeguard eyes.
1. Wear appropriate eye, ear and
body protection equipment.
2. Protect face, ears and neck
during welding operations.
Advise other persons in the
vicinity to look away and stand
clear of arc rays and hot metal.
The positioning of welding
equipment on inflammable sur-
faces could lead to fire outbreak
or explosion.
1. Never position equipment on
combustible or inflammable
surfaces.
2. Do not install equipment in the
vicinity of inflammable liquids.
A falling power source or other
equipment may cause serious
injury to persons or damage to
objects.
1. Always make use of the handle
to lift power source (applies to
portable models).
2. Use eye bolts and adequate lift-
ing equipment to raise the
power source.
WELDING MAY CAUSE FIRES OR
EXPLOSIONS. Never weld near
inflammable materials.
1. Beware of weld flame. Always
keep a fire extinguisher close at
hand.
2. Never place welding equipment
on inflammable surfaces.
3. Do not weld in closed containers.
4. Let welding equipment and
material cool before handling
them.
Moving parts may cause injury.
1. Keep clear of hazardous areas,
such as moving rollers.
2. Keep all doors, panels and
covers closed and in place.
Hot areas may cause injury.
Let the power source or other
parts cool before performing
any maintenance or servicing.
Welding wire may cause injury.
Do not point the torch toward
any part of the body, other per-
sons or any type of metal when
unwinding welding wire.

A 250 AC/DC
7
2.2 SPECIFICATIONS
A 225 AC/DC
2.3 COMES COMPLETE WITH:
A 225 AC/DC
1. 2.4 m (8 ft) input power cord without plug
2. Handle and running gear
A 250 AC/DC
1. Handle and running gear
For options and accessories contact your dis-
tributor.
2.1 DESCRIPTION
The 225 AC/DC sets a new standard for econom-
ical AC/DC arc welding machines. This ruggedly-
built welder is a proven performer with serious
amperage to burn 2.5 mm (3/32 in) to 4.0 mm
(5/32 in) low-hydrogen and special-alloy electrodes.
A standard running gear improves mobility and
assists the operator in positioning the equipment
for those hard-to-reach areas.Standard dinse con-
nections increase the versatily of the equipment
and make welding cable replacement an easy
task.
The 230/460 volt, 1-phase input power gives oper-
ators the option of choosing the power connec-
tions that are right for them. Infinte current regula-
tion allows precise setting of amperage to achieve
the exact heat for your welding needs.
The 250 AC/DC sets a new standard for AC/DC
arc welding machines. This ruggedly-built welder
is a proven performer with serious amperage to
burn 2.5 mm (3/32 in) to 4.0 mm (5/32 in) low-hydro-
gen and special-alloy electrodes. A standard
running gear improves mobility and assists the
operator in positioning the equipment for those
hard-to-reach areas. Standard dinse connections
increase the versatily of the equipment and make
welding cable replacement an easy task.
The 230/460/575 volt, 1-phase input power gives
operators the option of choosing the power con-
nections that are right for them.Infinite current reg-
ulation allows precise setting of amperage to
achieve the exact heat for your welding needs.
2. SPECIFICATIONS AND DESCRIPTION

8
OUTPUT AMPERES
A 225 AC/DC
0
50
100
150
200
250
10 20 30 40 50 60 70 80 90 100
% DUTY CYCLE
AC
DC
OUTPUT AMPERES
A 250 AC/DC
0
50
100
150
200
250
300
10 20 30 40 50 60 70 80 90 100
% DUTY CYCLE
AC
DC
2.4 DUTY CYCLE AND OVERHEATING:
Duty cycle is the percentage of 10 minutes that the
unit can weld at its rated output without overheat-
ing. If the unit overheats, the weld output will stop.
To correct this situation, wait fifteen minutes for the
unit to cool. Reduce amperage or duty cycle
before starting to weld again.
OUTPUT AMPERES
OUTPUT AMPERES
A 225 AC/DC DUTY CYCLE
A 250 AC/DC DUTY CYCLE

2.5 VOLT-AMPERE CURVES
Volt-ampere curves show the maximum voltage and amperage output capabilities of the welding power source.
Curves of other settings fall under curves shown.
9
A225 AC/DC
0
10
20
30
40
50
60
70
80
90
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
Corrente (A)
Tensione (V)
MAX AC
MAX DC
MIN DC
MIN AC
Tensione (V)
A250 AC/DC
0
10
20
30
40
50
60
70
80
90
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
Corrente (A)
MAX AC
MAX DC
MIN AC
MIN DC
Amperage (A)
Amperage (A)
Voltage (V)Voltage (V)
A 225 AC/DC
A 250 AC/DC

10
3.1 FRONT PANEL CONTROLS
1. AMPERAGE ADJUSTMENT CONTROL
2. POWER-ON LIGHT
3. POWER SWITCH
4. AMPERAGE INDICATOR
5/6. AC WELD OUTPUT RECEPTACLE
7. POSITIVE WELD OUTPUT RECEPTACLE
8. NEGATIVE WELD OUTPUT RECEPTACLE
9. DATA PLATE
3. OPERATION
2314
6 9 7 85 6 9 7 85
2314