Lincoln Electric POWERTEC 205C Series User manual

IM3021
09/2016
REV03
POWERTEC
205C, 255C & 305C
OPERATOR’S MANUAL
ENGLISH
Lincoln Electric Bester Sp. z o.o.
ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland
www.lincolnelectric.eu

English I English
Declaration of conformity
Lincoln Electric Bester Sp. z o.o.
Declares that the welding machine:
K14054-1 POWERTEC 205C 400V
K14054-2 POWERTEC 205C 230/400V
K14055-1 POWERTEC 255C 400V
K14055-2 POWERTEC 255C 230/400V
K14056-1 POWERTEC 305C 400V
K14056-2 POWERTEC 305C 230/400V
K14056-3 POWERTEC 305C 400V
K14056-4 POWERTEC 305C 230/400V
conforms to the following directives:
2014/35/EU , 2014/30/EU
and has been designed in compliance with the
following standards:
EN 60974-1:2012, EN 60974-5:2013,
EN 60974-10:2014
20.04.2016
Piotr Spytek
Operations Director
Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland
12/05

English II English
12/05
THANKS! For having chosen the QUALITY of the Lincoln Electric products.
Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified
immediately to the dealer.
For future reference record in the table below your equipment identification information. Model Name, Code & Serial
Number can be found on the machine rating plate.
Model Name:
………………………………………………………………………………………………………………………………………….
Code & Serial Number:
………………………………………………………………….. …………………………………………………………………..
Date & Where Purchased
…………………………………………………………………. …………………………………………………………………..
ENGLISH INDEX
Safety .............................................................................................................................................................................. 1
Introduction...................................................................................................................................................................... 2
Installation and Operator Instructions .............................................................................................................................. 3
Electromagnetic Compatibility (EMC) ............................................................................................................................ 12
Technical Specifications ................................................................................................................................................ 13
WEEE............................................................................................................................................................................ 15
Spare Parts.................................................................................................................................................................... 15
Electrical Schematic ...................................................................................................................................................... 15
Accessories ................................................................................................................................................................... 16

English 1 English
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.

English 2 English
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.
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.
Introduction
The welding machines of the POWERTEC C enable:
Welding GMAW (MIG/MAG)
Welding FCAW-GS / FCAW-SS
WARNING
In order to weld the cored wires which requiring negative
polarity, polarity change kit must be purchased by user
(see "Accessories" chapter).
The following equipment has been added to
POWERTEC 205C:
CD with Operator’s Manual
Work lead - 3m
Gas hose - 2m
Hose clamps – 2 units
The following equipment has been added to
POWERTEC 255C & 305C:
CD with Operator’s Manual
Work lead - 3m
Gas hose - 2m
Hose clamps – 2 units
Slow-blow fuse - 2A
Slow-blow fuse – 6,3A
Drive roll – V0.8/V1.0 (WARNING: for KNUMBER
K14056-3 and K14056-4 included 2 units of drive
rolls)
The following equipment was installed to the
POWERTEC 205C (see Figure 1.):
1. Gun holder
2. Galvanized chain – 0,7m
The following equipment was installed to the
POWERTEC 255C & 305C (see Figure 2.):
1. Gun holder
2. Galvanized chains – 2 units x 0,7m
3. Eye bolts – 2 units
12
Figure 1.
1
2
2
3
3
Figure 2.

English 3 English
For GMAW, FCAW-GS and FCAW-SS process, the
technical specification describes:
Type of welding wire
Wire diameter
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 15° 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.
Excessive extension of the duty cycle will cause the
thermal protection circuit to activate.
The machine is protected from overheating by a
temperature sensor.
Minutes or decrease
Duty Cycle
When the machine is overheated the Thermal Overload
Indicator light will turn "ON" on the front panel and the
output of the machine will turn "OFF". When the machine
has cooled to a safe temperature the Thermal Indicator
Overload light will go out and the machine may resume
normal operation. Note: For safety reasons the machine
will not come out of thermal shutdown if the trigger on
the welding gun has not been released.
Input Supply Connection
WARNING
Only a qualified electrician can connect the welding
machine to the supply network. Installation the outlet
plug to power lead and connecting the welding machine
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 grounding wires from the machine to the
input source.
For machines having the following KNUMBER:
K14054-1, K14055-1, K14056-1, K14056-3: the
allowable input voltage is 3x400V 50/60Hz.
K14054-2, K14055-2, K14056-2, K14056-4: the
allowable input voltages are 3x230V 50/60Hz and
3x400V 50/60Hz (400V: factory default).
For more information about input supply refer to the
technical specification section of this manual and to the
rating plate of the machine.
If it is necessary to change the input voltage:
The input cable must be disconnected from the
mains supply and the machine switched OFF.
Remove the left side panel.
Reconnect X11 and X12 according to the diagram
below:
Figure 3.
Replace the left side panel.

English 4 English
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.
Output Connections
Refer to points [6], [7] and [8] in the Figure 4.
Controls and Operational Features
POWERTEC 205C POWERTEC
255C & 305C
1
5
34
6
7
8
1
2 5
3
4
6
7 8
2
Figure 4.
1. 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"). After input power is connected and the
power switch is turned on, the power switch will light
up to indicate the machine is ready to weld.
2. Thermal Overload Indicator: This lamp
will light up when the machine is
overheated and the output has been
turned off. This can occur if the ambient
temperature is above 40°C or the duty cycle of the
machine has been exceeded. Leave the machine on
to allow the internal components to cool, when the
lamp turns off normal operation is possible.
3. Welding Load Voltage Switch: Adjust the
welding load voltage. POWERTEC 205C
has 1 switch (10 steps). POWERTEC
255C and 305C have 2 switches (2 and 10 steps).
WARNING
Do not switch Welding Load Voltage [3] during welding.
4. WFS (Wire Feeding Speed) Control
Knob: It enables continuous control of
wire feeding speed in the range from 1 to
20 m/min.
5. Digital Display Panel: Available as an option(see
"Accessories" chapter).
6. EURO Socket: For connecting a welding gun (for
GMAW, FCAW-GS / FCAW-SS process).
7. Low Inductance Negative Output Socket:
For connecting a work lead.
8. High Inductance Negative Output
Socket: For connecting a work lead.
9
10
11
10
11
9
POWERTEC 205C POWERTEC
255C & 305C
Figure 5.
9. Gas Connector: Connection for gas line.
WARNING
The welding machine supports all suitable shielding
gases at a maximum pressure of 5,0 Bar.
10. Hole Plug: For CO2gas heater socket (see
"Accessories" chapter - K14009-1 CO2Heater
Connection Kit).
11. Power Lead (5m): 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 only by a qualified person.
12 14 15
16
17
19
20
22
21
K14054-1 POWERTEC 205C 400V
K14054-2 POWERTEC 205C 230/400V
23 24
Figure 6.

English 5 English
K14055-1 POWERTEC 255C 400V
K14055-2 POWERTEC 255C 230/400V
K14056-1 POWERTEC 305C 400V
K14056-2 POWERTEC 305C 230/400V
1514
19
20
22
21
12
16
18
23 24
Figure 7.
1514
19
20
22
21
13
16
18
K14056-3 POWERTEC 305C 400V
K14056-4 POWERTEC 305C 230/400V
23 24
Figure 8.
12. Wire Drive (for GMAW, FCAW-GS / FCAW-SS
process): 2-roll wire drive. Only For machines having
the following KNUMBER:
K14054-1 POWERTEC 205C 400V
K14054-2 POWERTEC 205C 230/400V
K14055-1 POWERTEC 255C 400V
K14055-2 POWERTEC 255C 230/400V
K14056-1 POWERTEC 305C 400V
K14056-2 POWERTEC 305C 230/400V
13. Wire Drive (for GMAW, FCAW-GS / FCAW-SS
process): 4-roll wire drive. Only For machines having
the following KNUMBER:
K14056-3 POWERTEC 305C 400V
K14056-4 POWERTEC 305C 230/400V
14. Welding Wire (for GMAW / FCAW-GS / FCAW-SS).
15. Spooled Wire (for GMAW / FCAW-GS / FCAW-SS):
The machine does not include a spooled wire.
16. Wire Spool Support: Maximum 15kg spools. Accepts
plastic, steel and fiber spools onto 51mm spindle.
Also accepts Readi-Reel®type spools onto included
spindle adapter.
WARNING
Be sure that the right side panel of machine is closed
during welding.
17. Holes for Polarity Changing Kit: see "Accessories"
chapter. Only For machines having the following
KNUMBER:
K14054-1 POWERTEC 205C 400V
K14054-2 POWERTEC 205C 230/400V
WARNING
Positive (+) polarity is set at the factory.
WARNING
Before welding check the polarity for using wires.
18. Cover of Changing Polarity: Covering holes for
Changing Polarity Kit, which can be purchased
separately (see "Accessories" chapter). Only For
machines having the following KNUMBER:
K14055-1 POWERTEC 255C 400V
K14055-2 POWERTEC 255C 230/400V
K14056-1 POWERTEC 305C 400V
K14056-2 POWERTEC 305C 230/400V
K14056-3 POWERTEC 305C 400V
K14056-4 POWERTEC 305C 230/400V
WARNING
Positive (+) polarity is set at the factory.
WARNING
Before welding check the polarity for using wires.
19. Cold Inch / Gas Purge Switch: This switch enables
wire feeding or gas flow without turning on output
voltage.
20. Gun Mode Switch: It enables selection of 2-step or 4-
step gun mode. The functionality of 2T/4T mode is
shown in the Figure 9.
21. Burnback Time Control Knob: Sets the time that the
weld output continues 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 start.
22. Spot Welding Time Control Knob: Adjusts the time
welding will continue even if the trigger is still pulled.
This option has no effect in 4-Step Trigger Mode.
Trigger pressed
Trigger released
A Welding current
B Burnback time
C WFS
G Gas
Fi
g
ure 9.

English 6 English
WARNING
Spot Timer has no effect in 4-Step Trigger Mode.
23. Slow-Blow Fuse, F1: Shuts off the supply power
when the current exceeds 2A in primary cable. After
the fuse burns out, it must be replaced with a new
one. (See "Spare Parts" chapter).
POWERTEC
205C 255C 305C
Slow-blow
fuse , F1 2A 2A 2A
24. Slow-Blow Fuse, F2: Shuts off the supply power
when the current exceeds 6,3A in secondary cable.
After the fuse burns out, it must be replaced with a
new one. (See "Spare Parts" chapter).
POWERTEC
205C 255C 305C
Slow-blow
fuse , F2 6,3A 6,3A 6,3A
Welding Cables Connections
Insert the plug of the work lead into the socket [7] or [8].
The other end of this lead connects to the welding piece
with the work clamp.
Connect the necessary gun for GMAW, FCAW-GS or
FCAW-SS process to the Euro Socket [6]. Contact tip
and gun’s liner must be adjusted to the type and
diameter of using wire.
Wire Spool Loading
Wire spool type S300 and BS300 cab be installed on the
wire spool support [16] without adapter.
Wire spool type S200, B300 or Readi-Reel® can be
installed, but the applicable adapter must be purchased.
The applicable adapter can be purchased
separately(see "Accessories" chapter).
Wire Spool Type S300 & BS300 Loading
WARNING
Turn off the power source while mounting electrode wire.
2728 26
25
Figure 10.
Turn the machine off.
Open the right side panel.
Unscrew the Locking Nut [25] and remove it from the
Spindle [27].
Place the spool type S300 or BS300 [26] on the
Spindle [27] making certain the Spindle Brake Pin
[28] is put in the hole in back side of spool type S300
or SB300.
WARNING
Position the spool type S300 or SB300 so that it will
rotate in a direction when feeding so as to be de-reeled
from bottom of the spool.
Re-install the locking nut [25]. Make sure that the
locking nut is tightened.
Wire Spool Type S200 Loading
WARNING
Turn off the power source while mounting electrode wire.
25
31
292728
30
Figure 11.
Turn the machine off.
Open the right side panel.
Unscrew the Locking Nut [25] and remove it from the
Spindle [27].
Place the adapter of spool type S200 [29] on the
spindle [27] making certain the spindle brake pin [28]
is put in the hole in back side of the adapter [29]. The
adapter of spool type S200 can be purchased
separately (see "Accessories" chapter).
Place the spool type S200 [31] on the spindle [27]
making certain that the adapter brake pin [30] is put
in the hole in the back side of the spool.
WARNING
Position the spool type S200 so that it will rotate in a
direction when feeding so as to be de-reeled from
bottom of the spool.
Re-install the locking nut [25]. Make sure that the
locking nut is tightened.

English 7 English
Wire Spool Type B300 Loading
WARNING
Turn off the power source while mounting electrode wire.
27
25
32
28
33
Figure 12.
Turn the machine off.
Open the right side panel.
Unscrew the Locking Nut [25] and remove it from the
spindle [27].
Place the adapter of spool type B300 [32] on the
spindle [27].Make certain that the spindle brake pin
[28] is put in the hole in the back side of the adapter.
The adapter of spool type B300 can be purchased
separately (see "Accessories" chapter).
Re-install the locking nut [25]. Make sure that the
locking nut is tightened.
35
32
33
34
36
Figure 13.
Rotate the spindle and adapter so the retaining
spring [33] is at the 12 o'clock position.
Place the spool type B300 [35] on the adapter [32].
Set one of the B300 inside cage wires [36] on the
slot [34] in the retaining spring tab [33] and slide the
spool onto the adapter.
WARNING
Position the spool type B300 so that it will rotate in a
direction when feeding so as to be de-reeled from
bottom of the spool.
33
35
Figure 14.
Wire Spool Type Readi-Reel®Loading
WARNING
Turn off the power source while mounting electrode wire.
27
28 37
25
40
36
38
39
Figure 15.
Turn the machine off.
Open the right side panel.
Unscrew the locking nut [25] and remove it from the
spindle [27].
Place the adapter of spool type Readi-Reel®[37] on
the spindle [27].Make certain that the spindle brake
pin [28] is put in the hole in the back side of the
adapter. The adapter of spool type Readi-Reel®can
be purchased separately (see "Accessories"
chapter).
Re-install the locking nut [25]. Make sure that the
locking nut is tightened.
Rotate the spindle and adapter so the retaining
spring [38] is at the 12 o'clock position.
Place the spool type Readi-Reel®[40] on the adapter
[37]. Set one of the Readi-Reel®inside cage wires
[36] on the slot [39] in the retaining spring tab [38].
WARNING
Position the spool type Readi-Reel®so that it will rotate
in a direction when feeding so as to be de-reeled from
bottom of the spool.