F15-655-E Heliarc 161 - ESAB Welding & Cutting Products
Contents
1. Figure 1 Customer supplied single phase fused disconnect box and plug receptacle INPUT amp GROUND CONDUCTOR CU AWG Sizes per National Electric Code for 90 C rated copper conductors 30 C ambient Not more than three conductors in raceway or cable Local codes should be followed if they specify sizes other than those listed above Table 1 Recommended fuse size 13 INSTALLATION 2 2 Gas Inlet Hose rear panel Connect the gas hose to the bulk head fitting on rear of machine Connect the opposite end to the output fitting of the flowmeter regulator Set the flowmeter regulator to deliver between 15 to 25 cfh of Argon depending on application and surrounding conditions Primary Input Cable Gas Inlet Hose Connection Figure 2 Rear panel connections SECTION 2 INSTALLATION Welding Slope Down Current Time Over Temp Start Current Post Gas Flow Time Polarity Selector AC Switch Balance Control Power Process Mode Switch Selector Switch Positive Negative Output Output Receptacle Receptacle Gas Outlet to Torch Remote Control Socket 14 pin Figure 3 CONTROLS AND CONNECTIONS 14 SECTION 2 2 3 Positive Output Receptacle For2. ESAB A __ amp Heliarc 161 POWER SOURCE INSTRUCTION MANUAL P N 0558002625 208 and 230 V 1 Phase 50 60 Hz F15 655 E 12 2003 BE SURE THIS INFORMATION REACHES THE OPERATOR YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER These INSTRUCTIONS for experienced operators If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equip ment we urge you to read our booklet Precautions and Safe Practices for Arc Weld ing Cutting and Gouging Form 52 529 Do NOT permit untrained persons to install operate or maintain this equipment Do NOT attempt to install or operate this equip ment until you have read and fully understand these instructions If you do not fully understand these instructions contact your supplier for further information Be sure to read the Safety Precautions before installing or operating this equipment USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked periodically Mal functioning or poorly maintained equipment should not be used Parts that are broken missing worn distorted or contaminated should be replaced immediately Should such repair or replace ment become necessary the manufactu
3. IND 8712008550 AOEZ 8 LAS 7715008660 YSINNOSASNVUL LL 2427008550 V9L X Z HOLIMS LS 9712008550 IN MATA LNO 11 QALNOG 31033 ANGE 1712008980 202 55 31713 25 59 T Y 390143 0722008950 ZA SSANI Sana YI AW 24 SECTION 6 6 1 General Replacement Parts are illustrated on the following fig ures When ordering replacement parts order by part number and part name as illustrated on the figure Always provide the series or serial number of the unit on which the parts will be used The serial number is stamped on the unit nameplate 25 REPLACEMENT PARTS 6 2 Ordering Replacement parts may be ordered from your ESAB distributor or from ESAB Welding amp Cutting Products Attn Customer Service Dept PO Box 100545 Ebenezer Road Florence SC 29501 0545 Be sure to indicate any special shipping instruc tions when ordering replacement parts Refer to the Communications Guide on back cover of this manual for a list of customer service phone numbers SECTION 6 REPLACEMENT PARTS EN uo FR 9 A ql Y 4 lt LINA 4 a a Heliarc 161 AC DC SECTION 6 REPLACEMENT PARTS Heliarc 161 O ND gt 0558002625 0558002734 0558002735
4. Recommended Safe Practices for Air Carbon Arc Gouging and Cutting AWS C5 g Code For Safety in Welding and Cutting CSA Standard W117 2 SECTION 1 GENERAL Heliarc 161 Ac pc Square wave AC output gives superior welding with improved cleaning and lack of rectification m AC wave balance control allows adjustment from maximum cleaning to maximum penetration Built in Automatic Arc force fine tunes arc for YEAR stick welding from soft to a high penetration arc WARRANTY Two Stroke Four Stroke Non HF DC Starting or Two Stroke Four Stroke with HF starting Direct connections for Tig torch and electrode a holder for maximum convenience Adjustable postflow gas control protects weld area and extends tungsten life 12 ft 3 6 m gas hose Protected against overheating and overcurrent Small and portable inverter based 10 to 160A 8 TIG Welding Trigger Lock Adjustable downslope control ates Presettable start current 7 22 Low current draw Specifications Heliarc 161 AC DC Primary Input Voltage Phase 208 230Vac 1 ph 50 60 Hz Primary Input Current Rated Load 30 27 Amps EMS are een 83 POWER A ie 81 Welding Current Output DC AC AC Balance TIG Duty Cycle amp Rated Output 40 160 amps 16 4 v n STICK Duty Cycle 8 Rated Out
5. WORK PIECE OPERATION NOTE THE FOOT CONTROLLED MUST BE REMOVED FOR STICK OPERATION SECTION 3 2 Always commence with a last minute check for safety and protection 3 Check the tungsten electrode tip is correctly ground especially for DC applications see Figure 4 To ob tain a stable arc the electrode should be ground as shown Use less sharp point for AC applications 4 Adjust the tungsten electrode so that it extends be tween 5 32 1 4 beyond the end of the ceramic Cup A WARNING Always disconnect the unit from the main supply when changing tungsten electrodes or while convert ing between TIG and MMA applications 4 Switch on at the electricity supply Set the power on off switch to ON A EMI MMA mode is selected open circuit voltage is present at the output terminals as soon as the power switch is set to on 5 Ensure gas flow is correctly set usually 6 9 l min 12 18 cu ft hr 6 Position the tungsten 3 5mm 1 8 3 16 above the work warn bystanders to shield their eyes and lower your weld hood 7 If HF start mode has been selected depress the torch foot switch The HF output will automatically strike the arc without the need to touch the electrode to the work 8 If non HF mode has been selected press the torch foot switch and lightly touch the tungsten tip to the work and lift it off again to initiate the arc 9 Inthe 4 stroke mode the torch switch can be r
6. welding applications connect to the work using a suitable work return lead and clamp For MMA stick welding this is usually the connection point for the elec trode holder electrode positive 2 4 Negative Output Receptacle For TIG welding this is the power connection point for the TIG torch For MMA stick welding this is usually the work connection Note The tig torch must ALWAYS be connected to the nega tive terminal 2 5 Gas Outlet to Torch Connect the TIG torch gas hose to this fitting 2 6 Remote Control Socket 14 pin For connection of a remote control device like the FC 5B foot control TC 2B torch control or TC 3A Torch switch By depressing the foot pedal or thumb switch the weld current will increase or decrease within the range preset on the power source current control potentiometer 2 7 Power Switch Setting the switch to ON energizes the internal circuitry The switch should be illuminated when set to the position WARNING Dangerous voltages may still be present inside the unit when the power switch is off Always discon nect the unit from the main electricity supply before accessing internal parts 2 8 Process Mode Selector Switch Four different TIG operating modes are provided as well as MMA welding mode The TIG modes are as follows A 2 Stroke with HF High Frequency The normal method for TIG welding using non contact arc striking Press the torch switch or foot
7. 0558002736 0558002737 0558002738 0558002739 0558002740 0558002741 0558002742 0558002743 0558002744 34574 0558002746 0558002747 0558002748 0558002749 58 58 136208 35N22 Heliarc 161 AC DC Lid with Handle Strap Not Shown Knob 25mm Knob 22mm Connector Dinse Fan Fan Grid Inverter Main PCB Control PCB Inverter AC Ass y Fan Module HF PCB HF Generator Main Power Cable w Plug 10Ft EMI Filter ON OFF Switch Solenoid Valve Assembly Torch Socket Bulkhead Adaptor for Gas Fittings Gas Fitting Gas Inlet Nipple 27 SECTION 6 REPLACEMENT PARTS 28 Notes 29 Notes 30 Revision History The Edition of this book updates the Specification List on page 8 and describes the function of the Remote Control Socket in more detail The Edition of this book updates the Controls and Connections labels on page 10 Revision C update details were not added to this listing when completed Revision D Replaced schematic with latest version and made various text changes throughout the manual Revision E Updated block diagram on 24 31 ESAB Welding amp Cutting Products Florence SC Welding Equipment COMMUNICATION GUIDE CUSTOMER SERVICES A CUSTOMER SERVICE QUESTIONS Telephone 800 362 7080 Fax 800 634 7548 Hours 8 00 AM to 7 00 PM EST Order Entry Product Availability Pricing Order Information Returns B ENGINEERING SERVICE Telephone
8. Position the electrode close to the point where weld ing is to start without touching the work 3 Cover your eyes by lowering your welding hood or handshield warn bystanders to protect their eyes 4 Scratch the electrode on the work surface near the start point as though striking a match The arc should strike 5 When the arc as stabilized feed the electrode into the hot pool of molten metal keeping the electrode at approximately 65 80 to the workpiece If the electrode freezes ie sticks to the workpiece gently twist the electrode and pull it free If this is not possible release the electrode from the holder switch off the supply and cut the electrode free Freezing will occur if heavy contact is made with the workpiece at too low a current setting 6 Once the arc is successfully struck and stable ad just the arc length to about the size of the electrode diameter 7 Weld bead size is dependent on the oscillation tech nique of th electrode Typically a small whipping or circular motion works best This combination of backward and downwards move ment requires skill which will be acquired after a few prac tice welds Switch off the main supply when welding is completed or while changing electrodes 20 OPERATION SECTION 4 4 0 MAINTENANCE amp FAULT FINDING Maintenance With the exception of the 2 rear panel cooling fans the Heliarc 161 contains no moving parts The HF generator is
9. fundido En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas 4 Chispas y part culas de metal caliente puede alojarse en las mangas enrolladas de la camisa el ruedo del pantal n o los bolsillos Mangas y cuellos deber n mantenerse abotonados bolsillos al frente de la camisa deber n ser cerrados o eliminados 5 Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no flamable como divisi n 6 Usecareta protectora adem s de sus gafas de seguridad cuando est removiendo escoria o puliendo La escoria puede estar caliente y desprenderse con velocidad Personas cercanas deber n usar gafas de seguridad y careta protectora FUEGO Y EXPLOSIONES El calor de las flamas y el arco pueden ocacionar fuegos Escoria caliente las chispas pueden causar fuegos y explosiones Por lo tanto 1 Remueva todo material combustible lejos del area de trabajo o cubra los materiales con una cobija a prueba de fuego Materiales combustibles incluyen madera ropa l quidos y gases flamables solventes pinturas papel etc 2 Chispas y part culas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios Aseg rese de que toda grieta y agujero est cubierto para proteger lugares adyacentes contra fuegos 3 No corte suelde o haga cualquier otro trabajo relacionado hasta que la
10. gapless requiring no adjustment The internals of the unit should be periodically cleaned using clean dry com press air at low pressure This should be done every 12 months or more frequently if the unit is used in particu larly dirty or dusty environments While the unit is open check that internal wiring and all connectors are in good condition 21 MAINTENANCE It is recommended that external connections and cables primary gas amp welding should be regularly inspected for signs of deterioration or damage Check that the front panel twist lock power connection plugs are properly locked in place push in and twist and show no evidence of overheating Inspect the primary lead and its main con nector ensure the earth ground conductor is properly connected Power the unit and confirm that both rear panel cooling fans are running SECTION 4 MAINTENANCE 22 SECTION 5 Fault Unit dead cooling fans not running no power ON light Tungsten is blued and weld sooty amp black HF sparks between tungsten and work but no arc transfer to workpiece Nothing happens when TIG torch switch is pressed No gas flows no HF or power at the tung sten Difficulty in initiating DC TIG arc Tungsten melts and transfers to weld pool Main fuse frequently blows If all else fails 23 TROUBLESHOOTING Remedy Check front panel power switch is on Check main supply Check main supply fuse Check argon shieldin
11. over temperature light will illuminate In this event leave the unit switched on with the fans running Reset is auto matic after the unit has cooled 16 INSTALLATION SECTION 3 3 0 OPERATION 3 1 Setting Up for TIG Welding 1 Connect the Heliarc TIG torch power lead to the negative output receptacle 2 Connect the Heliarc TIG torch gas hose to the front panel gas outlet 3 Connect a remote control trigger switch or foot con trol to the 14 way remote control socket 4 Connect the work cable to the positive output receptacle 5 Connect the gas inlet hose to the Argon regulator flowmeter turn on the cylinder valve and set the 6 Check the TIG torch is correctly assembled and the tungsten tip is properly prepared see later section Use 2 thoriated tungstens for DC TIG welding and 1 zirconiated for AC Recommended tungsten di ameters are as follows DC 2 thoriated 2 Ceriated or 1 5 Lanthanated 10 70A 1 6mm 1 16 50 160 2 4mm 3 32 1 zirconiated 2 Ceriated or Thoriated 1 5 Lanthanated 25 55A 1 6mm 1 16 3 Balance Setting 90 160A 2 4mm 3 32 10 Balance Setting Note When AC TIG welding turning the balance control clockwise to give greater cleaning increases the heat in the tungsten and hence reduces its maxi mum current capacity More melting or rounding or the tungsten will also be seen 3 2 TIG Welding 1 Set the front panel controls as req
12. allows a standard one piece HW 17 to a 50m Twist Lock Order ing Information TC 3A Remote Torch Switch 30 ft cable with 14 pin plug 35783 Heliarc 161 acioc Power Source ele on off contactor control Note Does not provide current Heliarc 161 packages listed below include power source HW 17V TC 2B Torch Control 25 ft cable with 14 pin plug 33839 spare parts kit work cable TC 3A Torch Control Reg Flowmeter gas Attach to torch handle Provides remote current and contactor hose 15 ft Work Cable amp 1 Electrodes ach to torch handle control Heliarc 161 AC DC w HW 17V TL 12 1 2 0558002775 Heliarc 161 AC DC w HW 17V TL 12 1 2 ft amp Electrode Holder FC 5B 0558002776 Heliarc 161 AC DC w HW 17V TL 25 ft 0558002777 Heliarc 161 AC DC w 17 TL 25 RT Sales Literature order numbers amp Electrode Holder FC 5B 0558002778 Heladas aa ee naar ARC 23101 11 SECTION 1 1 0 INTRODUCTION The Heliarc 161 is an inverter based AC DC power source with squarewave output suitable for both TIG GTAW and STICK SMAW welding The unit operates from 230Vac single phase input power see specification and supplies up to 160A welding output at 35 duty cycle Front panel controls enable the operator to set output mode start current welding current current slope down time and gas post flo
13. control to start the arc Release the torch switch to ini tiate the down slope and stop welding 4 Stroke with HF For long duration welds the torch switch can be electronically latched Press to initiate the TIG arc the arc will strike and then remain at the start current level while the switch continues to be held Releasing the switch al lows the current to slope up to the main current setting Repressing the switch initiates the weld stop pro 15 INSTALLATION cedure If the switch is repressed and then im mediately released the arc will go off immedi ately Alternatively repressing and holding the switch permits the current to slope down to its final level where it will remain until the switch is finally released 2 Stroke Touch Start Non HF When HF may cause problems in surrounding sensitive equip ment see HF Emission Prevention touch start TIG striking can be used Press the switch and touch the tungsten momentarily to the work to initiate the arc Release the switch to slope down and stop welding D 4 Stroke Touch Start Non HF See above but using scratch start TIG striking method as described in c above When is selected open circuit voltage is immediately available at the output terminals and the HF and gas control circuitry are disabled 2 9 Polarity Selector Switch Selects either AC or DC petarity welding methods 2 10 AC Balance Control For AC TIG amp MMA welding
14. soudures ou des coupes ou lorsque vous en observez AVERTISSEZ les personnes se trouvant a proximite de a ce quelles ne regardent pas et a ce qu elles ne s exposent pas a son rayonnement ni a celui du metal incandescent Portez des gants ignifuges a crispins une tunique paisse a manches longues des pantalons sans rebord des chaussures a embout d acier et un casque de soudage ou une calotte de protection afin d eviter d exposer la peau au rayonnement de l arc lectrique ou du metal incandescent Il est galement souhaitable d utiliser un tablier ininflammable de fa on se prot ger des tincelles et du rayonnement thermique c Les tincelles ou les projections de m tal incandescent risquent de se loger dans des manches retrouss es des bords relev s de pantalons ou dans des poches Aussi convient il de garder boutonn s le col et les manches et de porter des v tements sans poches l avant Prot gez des tincelles et du rayonnement de l arc lectrique les autres personnes travaillant proximit l aide d un cran ininflammable ad quat Ne jamais omettre de porter des lunettes de s curit lorsque vous vous trouvez dans un secteur o l on effectue des op rations de soudage ou de coupage Parc Utilisez des lunettes de s curit crans ou verres lat raux pour piquer ou me ler le laitier Les piquetures incandescentes de laitier peuvent tre proje
15. 843 664 4416 Fax 800 446 5693 Hours 7 30 AM to 5 00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting C TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Hours 8 00 AM to 5 00 PM EST Part Numbers Technical Applications Specifications Equipment Recommendations D LITERATURE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 Hours 7 30 AM to 4 00 PM EST E WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 5557 Hours 7 30 AM to 3 30 PM EST Repair Estimates Repair Status WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Hours 7 30 AM to 4 00 PM EST Training School Information and Registrations G WELDING PROCESS ASSISTANCE Telephone 800 ESAB 123 Hours 7 30 AM to 4 00 PM EST H TECHNICAL ASST CONSUMABLES Telephone 800 933 7070 Hours 7 30 AM to 5 00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Telephone 800 ESAB 123 Fax 843 664 4452 Hours 7 30 AM to 5 00 PM EST or visit us on the web at http www esabna com The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator Global Company Information Press Releases Customer Feedback amp Support ESAB Welding amp Cutting Products PO Box 100545 Florence SC 29501 0545 F15 655 E 12 2003
16. A 02269 ELECTRICAL SHOCK Contact with live electrical parts and ground can cause severe injury or death DO NOT use AC welding current in damp areas if move ment is confined or if there is danger of falling 1 Be sure the power source frame chassis is connected to the ground system of the input power 2 Connect the workpiece to a good electrical ground 3 Connect the work cable to the workpiece A poor or missing connection can expose you or others to a fatal shock 4 Use well maintained equipment Replace worn or dam aged cables 5 Keep everything dry including clothing work area cables torch electrode holder and power source 6 Make sure that all parts of your body are insulated from work and from ground 7 Do not stand directly on metal or the earth while working tight quarters or a damp area stand on dry boards or an insulating platform and wear rubber soled shoes 8 Puton dry hole free gloves before turning on the power 9 Turn off the power before removing your gloves 10 Refer to ANSI ASC Standard 249 1 listed on next page for specific grounding recommendations Do not mistake the work lead for a ground cable ELECTRIC AND MAGNETIC FIELDS May be dangerous Electric current flow ing through any conductor causes lo aN calized Electric and Magnetic Fields EMF Welding and cutting current cre Qe ates EMF around welding cables and welding machines Therefore 1 We
17. ary cabling and welding cables should be kept separate from other main wiring and control signal ling or communications eg telephone cables If in terference occurs then greater separation or re rout ing should be considered Welding cables should be kept as short as practically possible Interference may also be reduced by separating the welding equipment from the other equipment af fected A partition brick wall or particularly a metal screen will also reduce interference Proper equip ment grounding earthing or bonding must be imple mented and maintained E This equipment should be routinely maintained ac cording to the manufacturers instructions and using only approved spare parts F All access and service covers must be closed and properly fastened when the equipment is being used This equipment should not be modified in any way except for those changes and adjustments approved by the manufacturer SECTION 2 2 0 INSTALLATION amp CONTROLS See Fig 1 2 1 Main Input Cable rear panel Connect to a suitable 230V single phase electricity sup ply see specification The power source operating on 230V 1 phase input power is equipped with a 8 ft 3 conductor cable with plug An optional mating receptacle P N 674540 is available A switched outlet containing suitable fusing should be used refer to specification for fusing details If in doubt consult a qualified engineer electrician
18. ating this is an indication that ventilation is not adequate Stop work and take necessary steps to im prove ventilation in the work area Do not continue to operate if physical discomfort persists Refer to ANSI ASC Standard 249 1 see listing below for specific ventilation recommendations WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code 25249 5 et seq CYLINDER HANDLING Cylinders if mishandled can rupture and violently release gas Sudden rupture of cylin der valve or relief device can injure or kill Therefore Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder Do not use adaptors Maintain hoses and fittings in good condition Follow manufacturer s operating instructions for mounting regu lator to a compressed gas cylinder Always secure cylinders in an upright position by chain or strap to suitable hand trucks undercarriages benches walls post or racks Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit When notin use keep cylinder valves closed Have valve protection cap in place if regulator is not connected Secure and move cylinders by using suitable hand trucks Avoid rough handling
19. ctices for Arc Welding Cutting and Gouging Form 52 529 The following publications which are available from the American Welding Society 550 N W LeJuene Road Mi ami FL 33126 are recommended to you 1 2 3 A ANSI ASC 249 1 Safety in Welding and Cutting AWS C5 1 Recommended Practices for Plasma Arc Welding AWS C5 2 Recommended Practices for Plasma Arc Cutting AWS C5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting AWS 5 5 Recommended Practices for Gas Tungsten Arc Welding AWS 5 6 Recommended Practices for Gas Metal Arc Welding AWS SP Safe Practices Reprint Welding Handbook ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances MEANING OF SYMBOLS As used through out this manual Means Attention Be Alert Your safety is involved Means immediate hazards which if ANEJ not avoided will result in immediate serious personal injury or loss of life Means potential hazards which could WARNING result in personal injury or loss of life Means hazards which could result in A CAUTION minor personal injury PRECAUCION DE SEGURIDAD ADVERTENCIA Estas Precauciones de Seguridad son para su proteccion Ellas hacen resumen de informacion proveniente de las referencias listadas en la secci n Informaci n Adicional Sobre La Seguridad Antes de hacer cualquie
20. d other radiation and can injure skin and eyes Hot metal can cause burns Training in the proper use of the processes and equip ment is essential to prevent accidents Therefore 1 Always wear safety glasses with side shields in any work area even if welding helmets face shields and goggles are also required 2 Use a face shield fitted with the correct filter and cover plates to protect your eyes face neck and ears from sparks and rays of the arc when operating or observing operations Warn bystanders not to watch the arc and to expose themselves to the rays of the electric arc or hot metal Wear flameproof gauntlet type gloves heavy long sleeve shirt cuffless trousers high topped shoes and a weld ing helmet or cap for hair protection to protect against arc rays and hot sparks or hot metal A flameproof apron may also be desirable as protection against radiated heat and sparks 4 Hot sparks or metal can lodge in rolled up sleeves trouser cuffs or pockets Sleeves and collars should be kept buttoned and open pockets eliminated from the front of clothing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 6 Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hot and can fly far Bystanders should also wear goggles over safety glasses f FIRES AND EXPLOSIONS Heat from 2 flames and arcs can start fires Hot slag
21. dar las maquinas tanto 1 Soldadores u Operadores que use marca pasos para el corazon deberan consultar a su m dico antes de soldar Campo Electromagn tico EMF puede interferir con algunos marca pasos 2 Exponerse a campos electromagn ticos EMF puede causar otros efectos de salud a n desconocidos Los soldadores deber n usar los siguientes procedimientos para minimizar exponerse al EMF A Mantenga el electrodo y el cable a la pieza de trabajo juntos hasta llegar a la pieza que usted quiere soldar Aseg relos uno junto al otro con cinta adhesiva cuando sea posible B Nunca envuelva los cables de soldar alrededor de su cuerpo C Nunca ubique su cuerpo entre la antorcha y el cable a la pieza de trabajo Mantega los cables a un s lo lado de su cuerpo D Conecte el cable de trabajo a la pieza de trabajo lo m s cercano posible al rea de la soldadura E Mantenga la fuente de poder y los cables de soldar lo m s lejos posible de su cuerpo PRECAUCION DE SEGURIDAD HUMO Y GASES El humo y los gases pueden causar malestar da o particularmente espacios sin ventilaci n No inhale el humo o gases El gas de proteccion puede causar falta de oxigeno Por lo tanto Siempre provea ventilaci n adecuada en el area de trabajo por medio natural o mecanico No solde corte o ranure materiales con hierro galvanizado acero inoxidable cobre zinc plomo ber lio o cadmio a
22. de toute trace de substance susceptible de produire des vapeurs inflammables ou toxiques En vue d assurer la prevention des incendies il convient de disposer d un materiel d extinction pr t servir imm diatement tel qu un tuyau d arrosage un seau eau un seau de sable ou un extincteur portatif Une fois le travail termin inspectez le secteur de fa on a vous assurer qu aucune tincelle ou projec tion de m tal incandescent ne risque de provoquer ult rieurement un feu CHOC ELECTRIQUE Le gougeage l arc et l arc au plasma exige l emploi de tensions vide relativement importantes or celles ci risquent de causer des dommages corporels graves et m me mortels en cas d utilisation inad quate La gravit du choc lectrique re u d pend du chemin suivi par le courant travers le corps humain et de son intensit Ne laissez jamais de surfaces m talliques sous tension venir au contact direct de la peau ou de v tements humides Veillez porter des gants bien secs Si vous devez effectuer un travail sur une surface m tallique ou dans un secteur humide veillez assu rer votre isolation corporelle en portant des gants secs et des chaussures semelles de caoutchouc et en vous tenant sur une planche ou une plate forme s che Mettez toujours la terre le poste de soudage coupage en le reliant par un c ble une bonne prise de terre N utilisez jamais de c bles uses
23. eleased once the arc has struck 19 OPERATION Note In 4 stroke the arc will start at the start current setting until the switch is released 10 Release press amp release the torch switch to down slope the current and stop welding 11 Maintain the torch in position over the weldpool while the post gas purge is running 3 2 1 MMA Welding Set Up IMPORTANT If a Foot Control is connected to the unit it must be removed before attempting to use the unit for MMA welding Removing the Foot Control allows full cur rent control at the front panel 1 Connect the electrode holder lead to the Positive output connection 2 Connect work workbench to the Negative output connection NOTE Some electrodes are recommended for use DC Electrode Negative polarity If so reverse con nections made in 1 and 2 above 3 Set the polarity switch as required DC or AC 4 Setthe welding current control to the required weld ing current value 5 Set Start Current at 100 maximum arc will not transfer properly if this control is below 100 Set the process selector switch to MMA Fit the appropriate electrode in the holder SECTION 3 3 2 2 MMA Welding 1 Keeping the electrode holder away from the work or exposed metal surfaces connect the unit to the main supply and switch the power on off switch to ON TEE Open circuit voltage is now present at the electrode holder 2
24. g gas supply is on and flow is adequate Check work lead is properly connected to a clean location on the workpiece Check the torch switch is properly connected at the 14 pin socket Check the switch and switch wires Check a 2 thoriated ceriated or lanthanated tungsten is being used Check for a good work lead connection Test machine in touch start mode to confirm arc can be established Regrind tung sten tip Check TIG torch is connected to minus output socket If AC TIG welding reduce setting on bal ance control towards more negative polarity maximum penetration or use a larger tungsten Welding current level being used causes primary current to exceed fuse rating Use a larger fuse refer to specification section Contact your ESAB distributor or an authorized ESAB Service Center TROUBLESHOOTING SECTION 5 INdLNO rL2008550 TOIV4AHSS 712008940 ANIDVSS 1 zoz 2 0 END Y eNoz o a ZNO 9 ENDE 4 G INJ 1 008990 99d YALYAANI ANIOVSS vZ2Z008SS0 99d HJOLVIINID LOVIHSS 1712008650 10 1 DADVSS 0v2Z008SS0 49d HALHIANI 2A ZSSANI 8512008560 ZHO9 0S ADEZ 0ZZ OZLXOZL NWA 434 SNYNL SHOLONGNI NOWINOD 21 LT 672Z008SS0 Z1 11 HLIM NOLIFSNNOD HOMOL 10 1 00 1
25. icidad primario Conecte la pieza de trabajo a un buen sistema de tierra f sica Conecte el cable de retorno a la pieza de trabajo Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque el ctrico fatal 4 Use el equipo solamente si est en buenas condiciones Reemplaze cables rotos da ados o con conductores expuestos 5 Mantenga todo seco incluyendo su ropa el rea de trabajo los cables antorchas pinza del electrodo y la fuente de poder 6 Aseg rese que todas las partes de su cuerpo est n insuladas de ambos la pieza de trabajo y tierra 7 Nose pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o reas h medas trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma 8 Use guantes secos y sin agujeros antes de energizar el equipo 9 Apage el equipo antes de quitarse sus guantes 10 Use como referencia la publicaci n ANSI ASC Standard Z49 1 listado en la pr xima p gina para recomendaciones espec ficas de como conectar el equipo a tierra No confunda el cable de soldar a la pieza de trabajo con el cable a tierra oy CAMPOS ELECTRICOS Y MAGNETICOS Son peligrosos La corriente el ctrica fluye atrav s de cualquier conductor causando a nivel lo cal Campos El ctricos y Magn ticos EMF Las corrientes en el rea de corte _9 R y soldadura crean EMF alrrededor de los cables de sol
26. ion de soudage ou de coupage peuvent s av rer toxiques Aussi est il n cessaire de disposer en permanence d un dispositif ad quat de ventilation de type aspirant afin d elimi ner du voisinage de l op rateur tout d gagement de fum e visible f Consultez les recommandations particuli res en mati re de ventilation indiqu es l alin a 6 de la norme 249 1 de ENTRETIEN DE L QUIPEMENT Un quipement entretenu de fa on d fectueuse ou inad quate risque non seulement de r aliser un travail de mauvaise qualit mais chose plus grave encore d entra ner des dommages corporels graves voire mortels en d clenchant des incendies ou des chocs lectriques Observez par cons quent les pr cautions suivantes 10 a Efforcez vous de toujours confier un personnel qua l installation le d pannage et l entretien du poste de soudage et de coupage N effectuez aucune r paration lectrique sur l quipement moins d tre qua lifi cet effet Ne proc dez jamais une t che d entretien quelconque l int rieur du poste de soudage coupage avant d avoir d branch l alimentation lectrique Maintenez en bon tat de fonctionnement les c bles le c ble de masse les branchements le cordon d alimentation et le poste de soudage coupage N utilisez jamais le poste ou l quipement s il pr sente une d fectuosit quelconque Prenez soin du poste de soudage et de coupage et des
27. lders having pacemakers should consult their physi cian before welding EMF may interfere with some pace makers Exposure to EMF may have other health effects which are unknown Welders should use the following procedures to minimize exposure to EMF A Route the electrode and work cables together Secure them with tape when possible B Never coil the torch or work cable around your body C Do not place your body between the torch and work cables Route cables on the same side of your body D Connect the work cable to the workpiece as close as possible to the area being welded E Keep welding power source and cables as far away from your body as possible SAFETY PRECAUTIONS _ FUMES AND GASES Fumes and gases can cause discomfort or harm _ particularly in confined spaces Do not breathe fumes and gases Shield ing gases can cause asphyxiation Therefore Always provide adequate ventilation in the work area by natural or mechanical means Do not weld cut or gouge on materials such as galvanized steel stainless steel copper zinc lead beryllium or cadmium unless positive mechanical ventilation is provided Do not breathe fumes from these materials Do not operate near degreasing and spraying opera tions The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene a highly toxic gas and other irritant gases If you develop momentary eye nose or throat irritation while oper
28. menos que provea ventilaci n mec nica positiva No respire los gases producidos por estos materiales No opere cerca de lugares donde se aplique substancias qu micas en aerosol El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosf geno o gas t xico y otros irritant es Si moment neamente desarrolla inrritaci n de ojos nariz ogarganta mientras est operando es indicaci n de que la ventilaci n no es apropiada Pare de trabajar y tome las medidas necesarias para mejorar la ventilaci n en el rea de trabajo No contin e operando si el malestar f sico persiste Haga referencia a la publicaci n ANSI ASC Standard 249 1 Vea la lista a continuaci n para recomendaciones espec ficas en la ventilaci n ADVERTENCIA Este producto cuando se utiliza para soldaduras o cortes produce humos o gases los cuales contienen qu micos conocidos por el Estado de California de causar defectos en el nacimiento o en algunos casos Cancer California Health amp Safety Code 25249 5 et seq MANEJO DE CILINDROS Los cilindros si no son manejados correctamente pueden romperse y liberar violentamente gases Rotura repentina del cilindro valvula o valvula de escape puede causar dano muerte Por lo tanto Utilize el gas apropiado para el proceso utilize un regulador disenado para operar y reducir la presion del cilindro de gas No utilice adaptadores Ma
29. ntenga las mangueras y las conexiones en buenas condiciones Observe las instrucciones de operaci n del manufacturero para montar el regulador en el cilindro de gas comprimido Asegure siempre los cilindros en posici n vertical y am rrelos con una correa cadena adecuada asegurar el cilindro al carro transportes tablilleros paredes postes o armaz n Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura Este puede ser parte del circuito el lectrico Cuando el cilindro no est en uso mantenga la v lvula del cilindro cerrada Ponga el capote de protecci n sobre la v lvula si el regulador no est conectado Asegure y mueva los cilindros utilizando un carro o transporte adecuado Evite el manejo brusco de los 8 A Siempre tenga personal cualificado para efectuar Antes de dar mantenimiento en el MANTENIMIENTO DEL EQUIPO Equipo defectuoso o mal mantenido puede causar dano muerte Por lo tanto a instalaci n diagn stico y mantenimiento del equipo No ejecute ning n trabajo el ctrico a menos que usted est cualificado para hacer el trabajo interior de la fuente de poder desconecte la fuente de poder del suministro de electricidad primaria Mantenga los cables cable a tierra conexciones cable primario y cualquier otra fuente de poder en buen estado operacional No opere ning n equipo en malas condiciones No abuse del equipo y
30. of cylinders Locate cylinders away from heat sparks and flames Never strike an arc on a cylinder For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore A Always have qualified personnel perform the installation troubleshooting and maintenance work Do not perform any electrical work unless you are qualified to perform such work Before performing any maintenance work inside a power source disconnect the power source from the incoming electrical power Maintain cables grounding wire connections power cord and power supply in safe working order Do not operate any equipment in faulty condition Do not abuse any equipment or accessories Keep equipment away from heat sources such as furnaces wet conditions such as water puddles oil or grease corrosive atmospheres and inclement weather Keep all safety devices and cabinet covers in position and in good repair Use equipment only for its intended purpose Do not modify it in any manner ADDITIONAL SAFETY INFORMATION For more information on safe practices for elec tric arc welding and cutting equipment ask your supplier for a copy of Precautions and Safe Pra
31. or sparks can also cause fires and ex plosions Therefore 1 Remove all combustible materials well away from the work area or cover the materials with a protective non flammable covering Combustible materials include wood cloth sawdust liquid and gas fuels solvents paints and coatings paper etc 2 Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below Make certain that such openings are protected from hot sparks and metal 3 Do not weld cut or perform other hot work until the workpiece has been completely cleaned so thatthere are no substances on the workpiece which might produce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Havefire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use 5 Do not use equipment beyond its ratings For example overloaded welding cable can overheat and create a fire hazard After completing operations inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire Use fire watchers when necessary For additional information refer to NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Pro cesses available from the National Fire Protection Asso ciation Batterymarch Park Quincy M
32. ou endommag s Ne surchargez jamais le c ble Utilisez toujours un quipement correctement entretenu Mettez l quipement hors tension lorsqu il n est pas en service une mise la masse accidentelle peut en effet provoquer une surchauffe de l quipement et un danger d incendie Ne pas enrouler ou passer le c ble autour d une partie quelconque du corps V rifiez si le c ble de masse est bien reli la pi ce en un point aussi proche que possible de la zone de travail Le branchement des cables de masse l ossature du b timent ou en un point loign de la zone de travail augmente en effet le risque de passage d un courant de sortie par des cha nes de PRECAUTIONS DE SECURITE levage des cables de grue ou divers chemins lectriques Emp chez l apparition de toute humidit notamment sur vos v tements la surface de l emplacement de travail des c bles du porte lectrode et du poste de soudage coupage R parez imm diatement toute fuite d eau VENTILATION La respiration prolong e des fum es resultant des op rations de soudage coupage a l int rieur d un local clos peut provoquer des malaises et des dommages corporels Aussi convient il d observer les pr cautions suivantes Assurez permanence une a ration ad quate de emplacement de travail en maintenant une ventilation naturelle ou l aide moyens m caniques N effectuez jamais de travaux de soudage ou de coupage sur de
33. ous Substances A SIGNIFICADO DE LOS SIMBOLOS Segun usted avanza en la lectura de este folleto Los Simbolos Significan Atenci n Est Alerta Se trata de su seguridad Significa riesgo inmediato que de no ser evadido puede resultar inmediatamente en serio dano personal o la muerte Significa el riesgo de un peligro potencial que puede resultar en serio dano per sonal o la muerte Significa el posible riesgo que puede resultar en menores danos a la persona PRECAUTIONS DE SECURITE AVERTISSEMENT Ces regles de s curit ont pour objet d assurer votre protection Veillez a lire et a observer les precautions ci dessous avant de monter x quipement ou de commercer l utiliser Tout d faut d observation de ces pr cautions risque d entra ner des blessures graves ou mortelles 1 PROTECTION INDIVIDUELLE Les br lures de la peau et des yeux dues au rayonnement de lectrique ou du metal incandescent lors du soudage au plasma ou l lectrode ou lors du gougeage peuvent s av rer plus graves que celles r sultant d une exposition prolongee au soleil Aussi convient il d observer les precautions suivantes Portez un Ecran facial ad quat muni des plaques protectrices et des verres filtrants afin de vous proteger les yeux le visage le cou et les oreilles des tincelles et rayonnement de l arc lectrique lorsque vous effectuez des
34. pieza de trabajo est totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores t xicos No trabaje dentro o fuera de contenedores o tanques cerrados Estos pueden explotar si contienen vapores inflamables 4 Tenga siempre a la mano equipo extintor de fuego para uso instant neo como por ejemplo una manguera con agua cubeta con agua cubeta con arena o extintor port til Aseg rese que usted esta entrenado para su uso 5 No use el equipo fuera de su rango de operaci n Por ejemplo el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego 6 Despu s de termirar la operaci n del equipo inspeccione el rea de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego m s tarde Tenga personal asignado para vigilar si es necesario 7 Para informaci n adicional haga referencia a la publicaci n NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Processes disponible a trav s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 CHOQUE ELECTRICO El contacto con las partes el ctricas energizadas y tierra puede causar da o severo o muerte NO use soldadura de corriente alterna AC en areas humedas de movimiento confinado en lugares estrechos o si hay posibilidad de caer al suelo 1 Aseg rese de que el chasis de la fuente de poder est conectado a tierra atrav s del sistema de electr
35. put 35 160 amps 26 0 v Options amp Accessories Open Circuit Voltage nnn nennen nenene 50v R 33 FM 580 Reg Flowmeter rer 21557 Arc Voltage Electrode 20 2 26 4 Primary Extension Cord 25 ft 50 37833 Arc Voltage 10 2 16 4 FC 5B Foot Control 33646 Regulation Range monito nadaaconedsinsantammacatennmeanpecmedniadenteses 5 160A WOK Cable in 35881 EES A EE Automatic built in Gas HS E06 a eme te mc 31503 o Automatic built in Gas Hose AP 40V77 Ignition Electrode Scratch Gas Hose 25 34V 38 ignition TIG Reever E UE ES E HF AW 17V TL 12 1120 nennen 35857 rater enc tentes 0 20 sec Slope DOWN ir 0 10 sec ESO Trigger Momentary or Trigger Latch Electrode Holder 15 175 0558001791 Weight 28 7 lbs 13 kg Tee Connector 1 Male 2 13792804 e SS Torch Adaptor HW 17 Std to Twist Lock 0558002692 WxLxH 8 0in 200mm x 14 4in 360mm x 16 4in 410mm This adaptor
36. quipements accessoires Gardez les l cart des sources de charleur notamment des fours de l humidit des flaques d eau maintenez les des traces d huile ou de graisse des atmosph res corrosives et des intemp ries Laissez en place tous les dispositifs de s curit et tous les panneaux de l armoire de commande en veillant a les garder en bon tat Utilisez le poste de soudage coupage conform ment son usage pr vu et n effectuez aucune modification INFORMATIONS COMPL MENTAIRES RELATIVES LA SECURITE Pour obtenir des informations compl mentaires sur les r gles de s curit observer pour le montage et l utilisation d quipements de soudage et coupage lectriques et sur les m thodes de travail recommand es demandez un exemplaire du livret N 52529 Precautions and Safe Practices for Arc Welding Cutting and Gouging publi par ESAB Nous conseillons galement de consulter les publications sui vantes tenues votre disposition par l American Welding Soci ety 550 N W LeJuene Road Miami FL 32126 Safety in Welding and Cutting AWS 249 1 Recommended Safe Practices for Gas Shielded Arc Welding AWS 1 Safe Practices for Welding and Cutting Containers That Have Held Combustibles AWS A6 0 Recommended Safe Practices for Plasma Arc Cutting AWS A6 3 Recommended Safe Practices for Plasma Arc Welding AWS CS5 1
37. r instalaci n o procedimiento de operaci n aseg rese de leer y seguir las precauciones de seguridad listadas a continuaci n as como tambi n todo manual hoja de datos de seguridad del material calcomanias etc El no observar las Precauciones de Seguridad puede resultar en da o a la persona o muerte PROTEJASE USTED Y A LOS DEMAS Algunos procesos de soldadura corte y ranurado son ruidosos y requiren protecci n para los o dos El arco como el sol emite rayos ultravioleta UV y otras radiaciones que pueden da ar la piel y los ojos El metal caliente causa quemaduras EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes Por lo tanto 42 1 Utilice gafas seguridad con protecci n a los lados siempre que este en el area de trabajo aun cuando est usando careta de soldar protector para su cara u otro tipo de proteccion 2 Use una careta que tenga el filtro correcto y lente para proteger sus ojos cara cuello y o dos de las chispas y rayos del arco cuando se est operando y observando las operaciones Alerte atodas las personas cercanas de no mirar el arco y no exponerse alos rayos del arco el ctrico o el metal fundido 3 Use guantes de cuero a prueba de fuego camisa pesada de mangas largas pantal n de ruedo liso zapato alto al tobillo y careta de soldar con capucha para el pelo para proteger el cuerpo de los rayos y chispas calientes provenientes del metal
38. rer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased This equipment or any of its parts should not be altered without the prior written approval of the manufacturer The user of this equipment shall have the sole responsibility for any malfunc tion which results from improper use faulty maintenance damage improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer TABLE OF CONTENTS SECTION TITLE PAGE SECTION 1 GENERAL sonar em Teer 11 SECTION 2 INSTALLATION ara AS 13 SECTION 3 OPERATION sonar inercia 17 SECTION 4 MAINTENANCE nao aa eee 21 SECTION 5 TROUBLESHOOTING an ea EEE ge 23 SECTION 6 REPLACEMENT PAR State 25 TABLE OF CONTENTS SAFETY PRECAUTIONS WARNING These Safety Precautions are for A your protection They summarize precaution ary information from the references listed in Additional Safety Information section Before performing any installation or operating procedures be sure to read and follow the safety precautions listed below as well as all other manuals material safety data sheets labels etc Failure to observe Safety Precautions can result in injury or death PROTECT YOURSELF AND OTHERS Some welding cutting and gouging 2 processes noisy and require ear 7 protection The arc like sun emits ultraviolet UV an
39. s materiaux de zinc de plomb de beryllium ou de cadmium en l absence de moyens m caniques ventilation capables d emp cher l inhalation des fum es d gag es par ces mat riaux N effectuez jamais de travaux de soudage ou de coupage proximite de vapeurs d hydrocarbure chlor resultant d operations voisines de degraissage ou de pulverisation La chaleur degagee ou le rayonnement de peut d clencher la formation de phosgene gaz particulierement toxique et d autres gaz irritants a partir des vapeurs de solvant Une irritation momentanee des yeux du nez ou de la gorge constat e au cours de l utilisation de l quipement d note un d faut de ventilation Arr tez vous de travailler afin de prendre les mesures saires a l am lioration de la ventilation Ne poursuivez pas l op ration entreprise si le malaise persiste Certaines commandes comportent des canalisations o circule de l hydrog ne Larmoire de commande est munie d un ventilateur destine a emp cher la formation de poches d hydrogene lesquelles presentent un ger d explosion ce ventilateur ne fonctionne que si l interrupteur correspondant panneau avant se trouve place en position ON Marche Veillez manceuvrer cette commande en verifiant si le couvercle est bien en place de fa on a assurer l efficacit de la ventilation ainsi realisee Ne jamais debrancher le ventilateur Les fum es produites par l op rat
40. sus accesorios Mantenga el equipo lejos de cosas que generen calor como hornos tambi n lugares h medos como charcos de agua aceite o grasa atm sferas corrosivas y las inclemencias del tiempo 5 Mantenga todos los art culos de seguridad y coverturas del equipo en su posici n y en buenas condiciones 6 Use el equipo s lo para el prop sito que fue dise ado No modifique el equipo en ninguna manera INFORMACION ADICIONAL DE SEGURIDAD Para m s informaci n sobre las pr cticas de seguridad de los equipos de arco el ctrico para soldar y cortar pregunte a su suplidor por una copia de Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 Las siguientes publicaciones disponibles atrav s de la American Welding Society 550 N W LeJuene Road Miami FL 33126 son recomendadas para usted 1 2 EE JUN ADVERTENCIA FN CUIDADO ANSI ASC 249 1 Safety in Welding and Cutting AWS C5 1 Recommended Practices for Plasma Arc Welding AWS 5 2 Recommended Practices for Plasma Arc Cutting AWS 5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting AWS 5 5 Recommended Practices for Gas Tungsten Arc Welding AWS C5 6 Recommended Practices for Gas Metal Arc AWS SP Safe Practices Reprint Welding Handbook ANSI AWS F4 1 Recommended Safe Practices for Weld ing and Cutting of Containers That Have Held Hazard
41. t es des distances consid rables Les personnes se trouvant proximit doivent galement porter des lunettes de protection Le gougeage l arc et le soudage l arc au plasma produisent un niveau de bruit extr mement lev de 100 a 114 dB et exigent par cons quent l emploi de dispositifs appropri s de protection auditive PR VENTION DES INCENDES Les projections de laitier incandescent ou d etincelles peuvent provoquer de graves incendies au contact de materiaux combus tibles solides liquides ou gazeux Aussi faut il observer les precautions suivantes Eloigner suffisamment tous les mat riaux combustibles du secteur ou ex cute des soudures ou des coupes a moins de les recouvrir completement d une bache non inflammable Ce type de materiaux comprend notamment le bois les v tements la sciure le kerosene les peintures les solvants le gaz naturel lac tylene le propane et autres sub stances combustibles semblables Les etincelles ou les projections de metal incandescent peuvent tomber dans des fissures du plancher ou dans des ouvertures des murs et declencher une ignition lente cach e Veiller a prot ger ces ouvertures des etincelles et des projections de metal N ex cutez pas de soudures de coupes d operations de gougeage ou autres travaux a chaud a la surface de barils bidons r servoirs ou autres contenants usag s avant de les avoir nettoyes
42. t should be carefully selected to ensure satisfactory and de pendable service Choose a location relatively close to a properly fuse source of electrical power The Heliarc 161 should be placed within easy reach of the object to be welded The machine components are maintained at proper operating temperatures by forced air which is drawn 12 GENERAL through the cabinet by the fan unit on the rear panel For this reason it is important that the machine be located in an open area where air can circulate freely at front and rear openings If space is at a premium leave at least 1 foot of clearance between the rear of the power source and wall or other obstruction The area around the unit should be relatively free of dust fumes excessive heat mois ture and corrosive vapors 1 2 RADIO INTERFERENCE A ESAB welding power sources have been designed to high standards of electromagnetic compatibility However arc welding by its very nature generates radio frequency energy and may cause interference By installing and using the equipment correctly in accordance with these instructions the problems of interference may be minimized B Before installing this welding equipment an assess ment should be made of potential problems that may occur It is good practice not to install welding equip ment next to computers or safety critical control cir cuits eg electronic machine guards unless they have been suitably protected Prim
43. the control enables the operator to adjust the balance of the AC current to achieve either greater cleaning more positive or greater penetration more negative of the workpiece As the control is rotated clockwise the balance of the AC wave changes from more negative to more positive clockwise increases cleaning action in aluminum AC welding This control changes the AC wave balance from 91 straight polarity and 9 reverse polarity to 64 straight polarity and 34 reverse polarity 2 11 Start Current Enables the current at which the TIG arc is struck to be preset Useful when using small diameter tungstens Start current is set as a percentage of the main welding cur rent 2 12 Welding Current Sets the main welding current in the range 10 to 160A 2 13 Slope Down Time In order to allow the weld crater to fill up before extin guishing the TIG arc the current can be reduced slowly to a lower background level before the arc is turned off This control sets the time for the down slope between 0 10 seconds Set it to minimum when using a remote foot control unit SECTION 2 2 14 Post Gas Purge Time Sets the duration of the shielding gas flow after the TIG arc is extinguished Postflow time can be set up to 20 seconds 2 15 Over Temperature Light In the event the unit exceeds its duty cycle and internal component temperatures get too high an internal tem perature sensor will switch off welding output and the
44. uired 2 or 4 stroke HF or touch start TIG mode 4 Stroke inoperative if Foot Control is used AC or DC process AC balance if AC TIG welding 3 is a good starting point Start current Main current Slope down time If a remote current control is used set to minimum Gas post flow time 17 OPERATION IMPORTANT If a remote current control device is connected eg the FC 5B foot control the remote device will con trol the weld current from minumum to the maximum current setting on the front panel weld current con trol knob If the knob is set to 80 amps the maxi mum current of the remote device will be 80 amps The start current setting is a percentage of the weld current setting Flat Tip Straight Ground Y STABLE ARC ARC WANDER 5 Radial Ground Pointed Tip Figure 4 Proper Electrode Grinding 5 32 1 4 4 7mm Figure 5 Proper Electrode Stickout Electrode Stickout SECTION 3 Figure 6 TIG GTAW Welding Connection Diagram IMPORTANT Connect the TIG Torch to the Negative Output Terminal Set the Start Current Control 5 Set the AC Balance to 3 HELIARC TORCH WORK CABLE ASSEMBLY A WORK PIECE OPTIONAL FOOT CONTROL Figure 7 STICK SMAW Welding Connection Diagram IMPORTANT Connected the Electrode Holder to the Positive Output Terminal Set the Start Current Control 100 ELECTRODE HOLDER ASSEMBLY WORK CABLE ASSEMBLY ee 88858
45. w time Built into the unit is an electronic non contact arc ignition system note that the unit initiates the TIG arc in DC mode even when AC output is selected Once the arc is struck the unit alternates the output current in AC mode The AC frequency is not locked to main frequency 60Hz but is varied automatically depending on the preset out put weld current level Front panel AC balance control provides either greater AC cleaning action or penetra tion as desired The unit provides both 2 and 4 stroke torch switch op eration as well as Touch Start Non HF arc starting A 14 pin remote control socket enables a remote current or arc start control to be used Two axial fans mounted in the rear of the housing cool the internal semiconductor components A thermal sensor protects the components from excessive temperatures if the duty is exceeded 1 1 UNPACKING AND PLACEMENT A Immediately upon receipt of the equipment inspect for damage which may have occurred in transit Notify the carrier of any defects or damage at once B After removing the components from the shipping container s check the container for any loose parts Remove all packing materials C Check air passages of power source for any packing materials that may obstruct air flow through the power source D Ifthe equipment is not to be installed immediately store it in a clean dry well ventilated area E The location of the welding equipmen
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