E300 3+2 Service Manual - Red-D
Contents
1. TE he ER rr 29 23 Ses 8 medias E Sum O pet 5 35 58 i LPS T EUM T BEE m n fu Sie Hi 7 t gt e i PE _ 3 i 22 E oe gt H tix 558 m i 1 je 12221 c EE rus H te 1 t Ai2. OPT PRIMARY KW OPERATION Welderentals An Airgas Company TABLE 2 RECOMMENDED COPPER CABLE SIZES AT 60 DUTY CYCLE Cable Sizes for Combined Length of Electrode Plus Work Cable Machine Size in Amps Up to 200 ft 200 to 250 ft CONTROL OF WELDING CURRENT There is one continuous current control which gives you complete adjustment of current from minimum to maximum For local control make sure the remote control switch is in the off position There is also the possibility of installing a remote control To control at a distance the remote control switch must be in the on position There is also an Arc Force control which produces an increase of amperage when the arc length is shortened such as in a tight groove or in pipe welding This control provides more arc force and eliminates the tendency of snuffing out the arc AUXILIARY POWER Your E300 3 2 is equipped with AC auxiliary power The AC unit provides a Duplex 120Volt receptacle and 2KW of maximum output The output circuit is protected with circuit breakers Power tools should always be grounded to the welded frame unless they are protected by an approved system of double insulation MAINTENANCE Have qualified personnel do the maintenance work Turn the engine off before working inside the machine In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the mai
3. 512 Female Euro connector 836 Overload Thermostat 100 degrees C 17 513 Plate 17 514 1 Grounding screw 17 515 WIRING DIAGRAMS RED D ARC Welderentals PRIMARY WIRING DIAGRAM 009 Idd AS aS 15 i er L kar un r k me meg 2 i vor j x 4839249 Li UIHBDISNYYL 11 gt lt tc lt x z RED D ARC WIRING DIAGRAM Welderentals An Airgas Company 22 430334 A009 80 Gave cds rum JULA A Igdf1 NE m Di ce i 451 4 Hii 130 kUn ICH 22 3746071689 auod 210 3223 Abs 0 03 2327 1 6 Jedd aao deses YuD4 4 chor RO dp wae cates MOL 04 3 48 4 iod oa Hen M JOLY 403 303 Dad iia 03293 N L E NO 430 aneng 553 09 c r dpt HIHYDJSNYYL pin ang 12 WIRING DIAGRAMS ke RED D ARC WIRING DIAGRAM Welderentals WITH OPTIONAL TIG PC BOARD EC dr ge 155 ae 5 S I E ES 7 TEE Elec trong panel 6591021 60 50 Ti l E Feat Mode select in fn
4. tanks drums or containers until the your head out of the fume Use enough ventilation and or proper steps have been taken to insure that such procedures will exhaust at the arc to keep fumes and gases away from the not cause flammable or toxic vapours from substances inside breathing zone When welding on galvanized lead or cadmium They can cause an explosion even though they have been plated steel and other metals which produce toxic fumes even cleaned For information purchase Recommended Safe greater care must be taken Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances SAFETY AWS F4 1 80 from the American Welding Society e Vent hollow castings or containers before heating cutting or welding They may explode f Also see items 6c and 9c 6 For Welding in General a Droplets of molten slag and metal are thrown or fall from the welding arc Protect yourself with oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses when in a welding area Use glasses with side shields when near slag chipping operations b Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when start i
5. A Base plate Fan Fan cover Capacitor 4uF Circuit breaker 10 A Plate Side Bracket Heatsink Lower Bracket SCR diode IR 171 RC40 Inside Bracket Zenamic Insulator Shunt Control panel frame assembly Relay Electronic panel GS9109b c CC CV Front plate Aluminum front name plate Circuit breaker 30 A Switch Potentiometer 10K Knob Lifting support bracket Stainless Steel Cover Voltage change cover Ground fault protector 25A Rubber protection cover On light Connection Plate Plate Inductor Rod Lifting Hook 1 1 1 13 1 1 1 1 1 1 1 1 2 3 1 1 1 1 1 2 1 2 4 1 6 2 6 3 1 1 1 1 1 1 1 4 2 2 1 1 1 1 1 1 3 1 1 8 1 10 QV RED D ARC Welderentals An Airgas Company ASSEMBLY MISC ASSEMBLY PARTS LIST CONTINUED SERIAL Zs 0880 AND ABOVE PART NAME amp DESCRIPTION NO REQ D PART NO CC CV Tig Stick mode select switch Optional lift arc 13 152 Electronic panel lift arc GS9414 Optional lift arc 17 629 Capacitor 40uF 450V 17 094 Tie rod 17 507 Nut 17 508 Circuit breaker support 16 305 Left heatsink 17 509 Right heatsink 17 510 Washer 14 270 Rubber protection cover 14 658 Plate 17 824 Output connector plate 17
6. E300 3 2 Electric Welder Service Manual RED D ARC Welderentals An Airgas Company Stick Mig Capability Welding Excellence Modular Construction Environment Protected 2 000 Watt AC Power for Tools SVM E300 3 2 SAFETY RED D ARC Welderentals An Airgas Company Arc Welding Safety Precautions PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH READ AND UNDERSTAND BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING MANUAL FOR THE WELDER AND OR OTHER EQUIPMENT TO BE USED AS WELL AS THE FOLLOWING GENERAL INFORMATION 1 HAVE ALL INSTALLATION OPERATION MAINTENANCE b Do not weld in locations near chlorinated hydrocarbon vapours AND REPAIR WORK performed only by qualified people coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapours to form 2 ELECTRIC SHOCK can kill phosgene a highly toxic gas and other irritating products Protect yourself from possible dangerous electrical shock a electrode and work or ground circuits are c Shielding gases used for arc welding can displace air and cause electrically hot when the welder is on Never permit injury or death Always use enough ventilation especially in contact between hot parts of the circuits and bare skin confined areas to insure breathing air is safe or wet clothing Wear dry hole free gloves to insulate hands d Read and understand the manufacturer s ins
7. Tig applications CV for most semi automatic Mig applications 9 Arc force control To use arc force turn switch to ON position Arc force is used mostly when using 6010 7010 type electrodes especially for down hand By using more arc force it makes the arc more forceful and prevents sticking When a smoother arc is desired use less arc force 10 Arc force on off switch 11 Hot start on off switch When the switch is on a boost of current is applied for a very short time when the arc is struck This is used in applications when arc starting is difficult Do not use for Tig applications when soft start is desired 12 Positive electrode terminal 13 Negative MIG terminal has the least inductance and is recommended for MIG welding and arc air 14 Negative stick terminal has the most inductance and is recommended for Stick and DC Tig welding 15 15Amp circuit breaker 16 120 V single phase outlet 17 10Amp fuse for relay 120V 18 IOAmp fuse for fan motor 19 Terminal board for wire feeder connections 20 Serial number TROUBLESHOOTING WARNING d ron RED D AR Welderentals An Airgas Company e Have qualified personnel do the troubleshooting work Turn the engine off before working inside the machine In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their rem
8. associated equipment and CGA publication P 1 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis RED D AR Welderentals An Airgas Company e Highway Arlington VA 22202 8 For Electrically Powered Equipment a Turn off input power using the disconnect switch at the fuse box before working on the equipment Make the electrical installation in accordance with the National Electrical Code all local codes and the manufacturer s recommendations Properly ground the equipment in accordance with the National Electrical Code and the manufacturer s recommendations For Engine Powered Equipment Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running Operate the internal combustion engines in open well ventilated areas or vent the engine exhaust fumes outdoors Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and if possible allow it to cool when refuelling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when nec essary and replace them w
9. g Never simultaneously touch electrically hot parts of electrode 5 FIRE OR EXPLOSION can cause death or property damage holders connected to two welders because voltage between the a Remove fire hazards well away from the area If this 1s not pos two can be the total of the open circuit voltage of both welders sible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from h Ifusing the welder as a power source for mechanized welding welding can easily go through small cracks and openings to the above precautions also apply for the automatic electrode adjacent areas Have a fire extinguisher readily available electrode reel welding head nozzle or semiautomatic welding gun b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations i When working above floor level protect yourself from Refer to Safety in Welding and Cutting ANSI Standard 249 1 a fall should you get a shock and the operating information for the equipment being used j Also see Items and 8 c When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause 3 FUMES AND GASES can be dangerous to your health overheating and create a fire hazard a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep d Do not heat cut or weld
10. hen the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work dis connect the spark plug wires distributor cap or magneto wire as appropriate To avoid scalding do not remove the radiator pressure cap when the engine is hot For more detailed information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 abeo OPERATION RED D ARC Welderentals OPERATION RATED OUTPUT DC For best operating characteristics and longest unit life take care in selecting an installation site Avoid locations exposed to high humidity dust high ambient temperature or corrosive fumes Make sure that the ventilator openings are not obstructed Connect welding machine to input voltage Set INPUT CONTACTOR CONTROL ON OFF SWITCH to ON UP position For LOCAL control set the CURRENT CONTROL LOCAL REMOTE SWITCH to local OFF position Adjust the welding current by the CURRENT CONTROL potentiometer located on the front panel For REMOTE control set the above switch
11. ng operating or repairing equipment c Besure the work cable is connected to the work as close to the welding area as practical Work cables connected to the building framework or other locations some distance from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail For Gas Shielded Arc Welding Use only compressed gas cylinders containing the correct shield ing gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition 1 b Always keeps cylinders in an upright position securely chained to an undercarriage or fixed support c Cylinders should be located Away from areas where they may be struck or subjected to physical damage Asafe distance from arc welding or cutting operations and any other source of heat sparks or flame d Never allow the electrode electrode holder or any other electri cally hot parts to touch a cylinder e Keep your head and face away from the cylinder valve outlet when opening the cylinder valve f Valve protection caps should always be in place and handtight except when the cylinder is in use or connected for use g Read and follow the instructions on compressed gas cylinders
12. ntenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine or generator fan If a problem cannot be corrected by following the instructions take the machine to the nearest RED D ARC location GENERAL INSTRUCTIONS 1 Blow out the welder and controls with an air hose at least once every two months In particularly dirty locations this cleaning may be necessary once a week Use low pressure air to avoid driving dirt into the insulation WARNING Uncovered rotating equipment can be dangerous Use care so your hands hair clothing or tools do not catch in the rotating parts DYNER CONTROL PANEL RED D ARC Welderentals CONTROL PANEL FEATURES SSS JRR LL ESO 003 M RE Wi 0 1 i 1 WAG NW RR py SA We M EU Uy ii VE JG un 20 21 Voltage change cover 22 Supply cable input 23 Grounding screw 19 18 17 16 1 On Off Switch Breaker 30 2 Ground fault protector 3 On light 4 Stick Tig mode select switch optional 5 Remote current switch Switch must be off when using machine with no remote control ON when using with remote control 6 Welding current control Use to adjust amperage desired 7 Remote current control receptacle 8 CC CV mode select switch CC for all Stick and
13. oval is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan If a problem cannot be corrected by following the instructions take the machine to the nearest Red D Arc Location TROUBLE CAUSE WHAT TO DO 1 Welder does not start Note It is normal for the Fan not to run when machine is cold No input power Check power switch Check lines voltage Check power supply and connections Welder has not output Remote control switch is in ON position with no remote OCV OV Put remote switch in OFF position Welder has abnormal arc Defective SCR Check OCV If low check for defective SCRs Also check all connections Defective PC board Check OCV If low check for defective PC board Also check all connections gt m TT OPTIONALS MISCELLANEOUS ASSEMBLY SERIAL Zs 0880 AND ABOVE 5 lo SN ww EI T 9 s EO P M TM ay 41 RED D ARC Welderentals ASSEMBLY MISC ASSEMBLY PARTS LIST Veiderentals SERIAL Zs 0880 AND ABOVE Transformer assembly Over load Thermostat 132 degrees C Transformer Support Insulator Terminal Board Over load 63 degrees C Bracket Front panel Reactor Resistor 100 Ohm Rod Frame Assembly Base rails Louvers Circuit breaker 15
14. to remote ON position Adjust the welding current by the potentiometer located in the remote control For this mode of operation it will be necessary to use a Remote Control Pendant plugged into the REMOTE CONTROL RECEPTACLE THE ARC FORCE CONTROL potentiometer varies the dynamic slope of the volt amp curves It essentially charges the short circuit arc current and produces an increase of amperage when the arc is shortened Strong arc force is best suited for use with 6010 electrodes where there is a tendency for sticking especially for down hand welding MAINTENANCE Lubrication The fan motor is permanently lubricated and will never need oil or grease No other points require lubrication Cleaning For uninterrupted satisfactory service from this welding machine it is necessary to keep the machine clean dry and well ventilated At lease every two months or more often as necessary wipe and blow out all dirt from the machine s internal components with air pressure of not over 25psi Be sure to wipe the fan blades clean TECHNICAL DATA DIMENSIONS 680 x 405 x 530 mm LxWxH 26 8 x15 9 x20 9 in NET WEIGHT 117kg 258 Ibs DIMENSIONS 775 x 535 x 560 mm in frame 30 5 x 21 x 22 in NET WEIGHT 130kg 285 Ibs in frame CSA APPROVED Amperes Volts Duty cycle WELDING VOLTAGE AND CURRENT RANGE Minimum current at 20 Volt Maximum current at 34 Volt INPUT 3 PHASE 60Hz AT RATED LOAD 480V AMPS OPT 600V AMPS
15. tructions for this equipment and the consumables to be used including the materi b Always insulate yourself from the work and ground by using dry al safety data sheet MSDS and follow your employer s safety insulation When welding in damp locations on metal floors practices gratings or scaffolds and when in positions such as sitting or lying make certain the insulation is large enough to cover your e Also see item 9b full area of physical contact with work and ground 4 ARC RAYS can injure eyes and burn skin c Always be sure the work cable makes a good electrical connec a Use a shield with the proper filter and cover plates to protect tion with the metal being welded The connection should be as your eyes from sparks and the rays of the arc when welding or close as possible to the area being welded observing open arc welding Headshield and filter lens should conform to ANSI Z87 1 standards d Ground the work or metal to be welded to a good electrical ground b Use suitable clothing made from durable flame resistant materi al to protect your skin and that of your helpers from the arc rays e Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition c Protect other nearby personnel with suitable nonflammable screening and or warn them not to watch the arc nor expose f Never dip the electrode in water for cooling themselves to the arc rays or to hot spatter or metal
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