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Heliarc® 252 ac/dc and Heliarc® 352 ac/dc

1. SECTION 6 T pss 57 pr EE 8 8 zi 8 9p 55 58 60 alg S 59 EN CE s Lum 7 See View A 62 53 54 63 gt Miss 64 52 E 65 66 67 aro 7 13730469 17240075 950255 950254 36049M 647361 36048M 36132 32221 32243 23604891 36242 952073 674971 950710 38074 36188 36191 674216 36185 36186 673579 673578 37246 951342 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 2 6 1 1 2 2 1 2 69 Bridge Diode Resistor 25W Capacitor 60uf 370 Vac Bracket Capacitor Lifting Bail Lug Term Ground 2 8 Wire Leg A Frame Input Term Board 230 460 V Input Term Board 230 460 575 V Input Term Board 220 400 50 60 Hz Label Danger High Voltage Filter Ass y 50 Hz CE Label Units Only Terminal Block 12 Pos Filter PC board Ass y Thermal Switch 12A 120 V Q D Snubber PC Board Ass y Angle Glastic Heatsink Dual SCR Assembly Capacitor 0 02uf 1 KDVC Busbar Anode Busbar Cathode Heatsink Spark Gap Point Spark Gap Spark Gap Ass y Includes No 70 71 73 Capacitor CER 2500 PF 15 KV 46 53 REF 009 i
2. 6 Y 2 OF 5 19 1804 8 1 18 6 2 09 M8 7 48 6 1 84 1809 L me 8 01 8 0 i d ma 1 14 2808 9 IHM 1 05 L 1 5 0 2 15 L 508 2825 5 NO 5 01 9 MB 9 55 61 030 5 15 9 tld 2839 y TA ra 5 IHM 1 27 8 NYO S 58 405 sa y 03 1 5 Lt M9 1 44 189 7 033 5097829 10 2 55 91 034 1 20 1 49 1824 489 2 18 2 s t 508 SH 2805 Wu TBA 1 9 1 53 1833 19 1804 TANVd 1081802 8 4 6c9 40 ud ZH 09 009 022 DA DV 292 292 uej6eiq 6 6 4 r Wig 01 KINO NI 03 1 15 1 430123 08 71 14 TOULNOD 1824 Ya 7 4 tva ms 7 14 41 aoor ozz xev 4 200 99 NO mis I 04 2 31 8196 a u 1 dl OJTIVISNI 119 92 S0Y31 3135 5310030 I ILON 0 1 KINO 536 39 HUM SINIHOVA NO X uu vie z im 8 W130 335 n X W130 335 0 1030 3 ud ZH 06 0091022 DA DV 256 052 9 6 e1nBr4 1 4 1824 151
3. 4 als a O Fig 3 1 Heliarc 252 352 Controls Locations 25 SECTION 3 OPERATION 3 4 2 6 AC WAVE 1 ALANCE CONTROL 7 0 8 10 8 MAXIMUM STRAIGHT POLARITY MINIMUM TUNGSTEN HEATING BALANCED Ed A A Figure 3 2 Square Wave Operation IMPORTANT When using Maximum Penetration in AC Tig the duty cycle will be reduced 50 and input current will increase approximately 40 Also when DCTig welding the Balance Control should always be set to the Maximum Cleaning balanced wave position NOTE Square wave power sources generally offer better cleaning in AC tig welding than conventional saturable reactor machines The extra clean ing results from more reverse polarity which decreases the maximum current for a given electrode The following may help to resolve this situation 1 Adjust the balance control for less cleaning 2 use a larger electrode and 3 use 2 thoriated tungsten 26 SECTION 3 PIN WARNING ELECTRIC SHOCK CAN KILL Do not use AC output in damp areas if movement is confined or if danger of falling exists Use AC output only if required for the welding process A Never under any circumstances operate the power source without its panels in place In addition to the safety hazard improper cooling may cause overheating which will damage the internal components Also make sure yo
4. Erg a VIEW 6 7 8 2 4 TS1 PCB2 SCR1 2 3 4 C2 3 4 5 9 10 SECTION 6 REPLACEMENT PARTS 86 85 83 84 81 82 Fig 6 4 Heliarc 252 352 Right Side View Qty Circuit Req Description Symbol M1 2062334 Fan Motor 36173 Fan Blade 36043M Fan Bracket 13735508 Fan Shroud 950708 Support Board Locking 38055 Control PC Board Ass y 60 Hz 38089 Control PC Board Ass y 50 Hz 36226 Dig Meter PC Board Ass y H 352 Opt H252 36176 Selector Switch 36415 Air Core Transformer 36187 Busbar Output 951179 HI Freq Transformer 997887 Hose 1 4 ID 997887 Hose 1 4 ID 951634 Solenoid Valve 24 V 36147 Inductor H 252 36142 Inductor H 352 36150 Main Transformer H 252 230 460 V 36148 Main Transformer H 252 230 460 575 V 36149 Main Transformer H 252 220 400V 50 60 Hz 36145 Main Transformer H 352 230 460 V 36143 Main Transformer H 352 230 460 575 V 36144 Main Transformer H 352 220 400 V 50 60 Hz Fe cS CA IS cA EE La ee Original Hel 252s used smaller 13730124 Fan Motor and 13730125 Fan Blade See page 31 47 NOTES 48 NOTES 49 NOTES 50 REVISION HISTORY INSTRUCTION MANUAL CHANGES The A Edition 9 96 of this manual covers the following changes 1 The 50Hz units originally designed for single 400V input power now have 220 400 input capability Input Terminal Board 36218 was replaced by 32243 No 58 in Fig 6 3
5. MANEJO DE CILINDROS Los cilindros si no son manejados cor rectamente pueden romperse y liberar violentamente gases Rotura repentina del cilindro v lvula o v l vula de escape puede causar da o o muerte Por lo tanto 1 Utilize el gas apropiado para el proceso y utilize un regulador dise ado para operar y reducir la presi n del cilindro de gas No utilice adaptadores Mantenga las mangueras ylas conexiones en buenas condiciones Ob serve las instrucciones de operaci n del manufacturero para montar el regulador en el cilindro de gas comprimido 2 Asegure siempre los cilindros en posici n vertical y am r relos con una correa o cadena adecuada para asegurar el cilindro al carro transportes tablilleros paredes postes o armaz n Nunca asegure los cilindros a la mesa de trabajo olas piezas que son parte del circuito de soldadura Este puede ser parte del circuito el lectrico 3 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 adec uado Evite el manejo brusco de los MANTENIMIENTO DEL EQUIPO Equipo de fectuoso mal mantenido puede causar da o o muerte Por lo tanto 1 Siempre tenga personal cualificado para efectuar a instalaci n diagn stico y mantenimiento del equipo No ejecute ning n trabajo el ctrico a menos q
6. 9 Power Factor Kit P N 36220 This kit when installed in power source will reduce input current draw at least 2096 It consists of 3 prewired power factor capacitors that installs easily inside the power source 22 SECTION 3 OPERATION 3 1 CONTROL FUNCTIONS Refer to Fig 3 1 Power On Off I O Switch S1 Switch is located on the rear panel In the OFF position the power source is electrically shut down In the ON position Power On light on front control panel will light and power is being provided to all circuits in the power source CONTACTOR Switch S3 This 3 position toggle switch sets the operational modes which can be used In the STICK position with the toggle UP the solid state contactor circuits immediately energize and welding power is continuously present at the output terminals In the TIG REMOTE position toggle at mid position the solid state contactor and other tig sequencing circuits are controlled by a remote device foot or torch switch through the Remote Control receptacle In TIG position toggle down the contactor is always on Current Control Panel Remote Switch S5 This 2 position toggle switch determines the location from which welding current will be oper ated PANEL position from the power source Weld Current potentiometer or REMOTE position from an optional foot or hand control that plugs into the Remote Control receptacle When the REMOTE position is selected the optional remote c
7. Heliarc 252 Ac pc and Heliarc 352 ac pc SQUARE WAVE POWER SOURCES Instruction Manual This manual provides complete instructions for the following power sources starting with Serial No TORI541008 November 1995 Heliarc 252 acoc Heliarc 352 Ac pc Item No Item No ESAB 230 208 460 Vac 60 Hz 1 Phase 736200 736210 ESAB 230 460 575 Vac 60 Hz 1 Phase 36201 36211 ESAB 220 400 380 415 Vac 50 Hz 1 Phase 736202 736212 ESAB 220 400 380 415 50 Hz 1 Phase 36205 36207 ESAB 220 400 380 415 Vac 60 Hz 1 Phase 736849 736850 Manufactured for export services only Discontinued F15 254 F 02 2006 BE SURE THIS INFORMATION REACHES THE OPERATOR YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER ATI These INSTRUCTIONS are for experienced operators If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment we urge you to read our book let Precautions and Safe Practices for Arc Welding 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 equipment 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
8. the customer s disconnect switch INSTALLATION 2 3 SECONDARY OUTPUT CONNECTIONS Refer to Interconnection Diagram Figure 2 5 for typical secondary output process gas and water and torch connections that are required for this unit s welding application The proper operation of the welding machine depends to a great extent on the use of output cables that are insulated copper adequately sized in good condition and properly connected to the machine using UL listed pressure wire connectors It is recommended that the output cables be kept as short as possible this is particularly important for tig applications using high frequency AC and have adequate current carrying capacity The resistance of the output cables and connections causes a voltage drop which is added to the voltage of the arc Excessive cable resistance may result in overloading as well as reducing the maximum current output of which the power source is capable The welding output terminals are located on the front panel Table 2 2 will prove useful for selecting the recommended output cable size Table 2 2 Recommended Output Cable Sizes Welding Current Amps Total Length Feet of Cable in Weld Circuit 2 2 1 1 1 0 1 1 1 0 1 0 1 0 1 0 1 0 1 0 2 0 3 0 1 0 2 0 3 0 3 0 4 0 Total cable length includes work and electrode cables Cable size is based on direct current insulated copper conductors 40 duty cycle and a voltage drop of 4 or less volts The w
9. 2 110V Receptacles 952219 replaced 951033 No 18 in Fig 6 1 Air Core Transformer 36415 replaced 680024 No 89 in Fig 6 4 4 Capacitors C9 and C10 were added No 67 in Fig 6 3 e The B Edition 2 98 of this manual covers the following changes 1 Added Section 4 1 6 Dip Switch Settings of Main Control Board Assembly previously covered by an Insert dated May 1997 2 Clarified descriptions on the Contactor switch S3 in the Operation and Troubleshooting sections Added S2 connections and J2 pin functions in all schematic diagrams 4 Spark Gap Assembly 37246 was made available as a replacement part instead of just individual parts Fig 6 3 5 The Heliarc 252 power sources were equipped with small Fan Motor 13730124 and black plastic 4 bladed Fan Blade 13730125 up to late 1997 All power sources are now equipped with large Fan Motor 2062334 5 bladed metal Fan Blade 36173 The fan blades are not interchangeable but the large motor and fan blade combination can replace the small motor and fan blade combination Edition 5 99 of this manual covers the following changes 1 The green gray equipment originally designed for L TEC is now obsolete and no longer available 2 Changed the troubleshooting guide in section 5 to a table format 3 Added two 2 02uf 1kv capacitors C12 amp 13 across the S4 switch The D Edition 5 03 of this manual covers the following changes
10. ARC FORCE MAX ARC FORCE MAX AC or DC VOLTS 3 AC or DC VOLTS 3 2 204 20 ARC FORCE MIN 4 i t 1 t t 1 0 50 100 150 200 250 300 350 380 9 50 100 150 200 250 300 350 400 450 480 or DC AMPS AC or DC AMPS Figure 1 2 Volt Amp Curves Heliarc 352 Ac pc MAX OUTPUT MAX OUTPUT 320 nm RATED OUTPUT 5 300 BALANCE CONTROL AT RATED OUTPUT AT CLEAN POSITION 0 50 TIME BALANCE 250 BALANCE CONTROL AT 300 2 MAX CLEAN POSITION 2 ul 50 50 TIME BALANCE a 200 200 5 5 BALANCE CONTROL 100 5 MAX PENETRATION 100 e BALANCE CONTROL amp MAX PENETRATION 0 0 0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100 DUTY CYCLE 10 min base period DUTY CYCLE 10 min base period Figure 1 3 Duty Cycle Chart Heliarc 252 ac pc Figure 1 4 Duty Cycle Chart Heliarc 352 ac pc 13 SECTION 1 DESCRIPTION SECTION 2 INSTALLATION 2 1 GENERAL Proper installation can contribute materially to the satisfactory and trouble free operation of the power source It is suggested that each step in this section be studied carefully and followed as closely as possible 2 1 1 Unpacking and Placement 1 Immediately upon receipt of the power source it should be inspected for damage which may have occurred in transit Notify the carrier of any defects or damage at once After removing the power source from the
11. DUTY CYCLE Duty cycle is defined as the ratio of load time to the total time Standard current ratings are based on a 10 minute cycle This machine is rated at 40 percent duty cycle which means the rated load is applied for a total of 4 minutes and shut off for a total of 6 minutes in a 10 minute period However if the welding current is decreased the duty cycle can be increased Conversely if the weld ing current is increased the duty cycle must be decreased Figure 1 3 or 1 4 enables the operator to determine the safe output of the power source at various duty cycles Note that the duty cycle of the unit is approximately 5096 less when Balance Control is in the max penetration position 11 SECTION 1 DESCRIPTION Table 1 1 Specifications Heliarc 252 AC DC Heliarc 352 AC DC Rated Output 0 250 Amps 30 Volts 350 Amps 34 Volts 4096 Duty Cycle ACIDC Tig Stick ACIDC Tig Stick Max Open Circuit Voltage 79 Volts AC 72 Volts DC 79 Volts AC 72 Volts DC Output Current Welding Range in Amperes Current AC DC 5 to 320 Amps AC DC 3 to 380 Amps Input Voltage AC 230 208 460 V 1 ph 60 Hz 230 208 460 V 1 ph 60 Hz 230 460 575 V 1 ph 60 Hz 230 460 575 V 1 ph 60 Hz 220 400 380 415 1 ph 50 Hz 220 400 380 415 1 ph 50 Hz MA 220 V 230 V 400 460V 575V 220V 230V 400 V 460V 575V Input Current 0 Rated Load in w o P F C 100 96 52 48 38 160 152 84 76 61 Amperes with P F C 88 70 3
12. 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 not in use keep cylinder valves closed Have valve protection cap in place if regulatoris notconnected Secure and move cylinders by using suitable hand trucks Avoid rough handling 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 1 Always have qualified personnel perform the installation troubleshooting and maintenance work Do not perform any electrical work unless you are quali fied 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 a
13. factory set 030 inches 002 in However if the high frequency intensity is not sufficient for your application open or close the spark gaps until the desired high frequency intensity is obtained Remember that high frequency radiation increases as the gap increases and this can cause interference in other electronic equipment 1 Loosenretaining screw A only enough to free electrode point C for adjustment 2 Place feeler gauge of proper thickness between gap 3 Apply slight pressure against loosened electrode point C so the feeler gauge is held firmly in the gap Tighten retaining screw A Figure 4 1 Spark Gap Adjustment 4 1 5 Testing and Replacing Bridge Assy Components SCRs are devices which allow current to flow in only one direction and block current in the other direction The SCRs used in this power source are de signed to provide long trouble free operation however should a failure occur they may require replacement The testing procedures to determine defective components are as follows 1 Silicon Controlled Rectifier Modules Disconnect the SCR wiring to break continuity and provide an open circuit across the component to be tested Using an ohmmeter set to the R x 1 scale check the resistance across the SCR in both direc tions A good SCR will read high in both directions If the reading is low or zero in either direction the SCR is defective When replacing defective SCRs make sure the m
14. hole free gloves before turning on the pow er Turn off the power before removing your gloves Refer to ANSI ASC Standard Z49 1 listed on next page for specific grounding recommendations Do not mistake the work lead for a ground cable ECTRIC AND MAGNETIC FIELDS May be dangerous Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding and cutting current creates EMF around welding cables and welding machines Therefore Welders having pacemakers Jai consult their physician before welding EMF may interfere with some TM pacemakers Exposure to EMF may have other health effects which are unknown 3 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 Never coil the torch or work cable around your body Do not place your body between the torch and work cables Route cables on the same side of your body Connect the work cable to the workpiece as close as possible to the area being welded Keep welding power source and cables as far away from your body as possible m UO 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 mech
15. ininflammable ad quat e Ne jamais omettre de porter des lunettes de s curit lorsque vous vous trouvez dans un secteur l on effectue des op rations de soudage ou de coupage l arc 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 projet es des distances consid rables Les personnes se trouvant proximit doivent gale ment porter des lunettes de protection f Le gougeage l arc et le soudage l arc au plasma produisent un niveau de bruit extr mement lev de 100 114 dB et exigent par cons quent l emploi de dispositifs appropri s de protection auditive 2 PR VENTION DES INCENDES Les projections de laitier incandescent ou d tincelles peuvent provoquer de graves incendies au contact de mat riaux combustibles solides liquides ou gazeux Aussi faut il observer les pr cautions suivantes a loigner suffisamment tous les mat riaux combus tibles du secteur o ex cute des soudures ou des coupes l arc moins de les recouvrir compl tement d une b che non inflammable Ce type de mat riaux comprend notamment le bois les v tements la sciure l essence le k ros ne les peintures les solvants le gaz naturel l ac tyl ne le propane et autres sub stances combustibles semblables Les tincelles ou les projections de m tal incandescent peuvent tomber dans des fiss
16. last position is normal for most DC Tig welding applications Post Flow Control R2 This control provides a timed from 3 to 30 sec onds post flow of shielding gas after the welding arc is broken 23 SECTION 3 OPERATION NOTE The power source also has 0 to 5 seconds preflow capability which is factory set to zero seconds If preflow is desired locate R37 trim pot on the Control PC board assembly mounted behind the front control panel and then turn trim pot clockwise to desired position with a small screwdriver Auxiliary 115 Volt Receptacle This receptacle can be utilized to source 115 volt power for auxiliary equipment grinder coolant circulator etc and is protected by a 10 amp circuit breaker Arc Force Control R5 This control is used in the STICK mode only The lower settings provide less short circuit current and a softer more stable arc The higher settings provide more short circuit current and a forceful more penetrating arc For most Stick welding set the knob at 3 or 4 and readjust up forceful or down softer as desired Balance Control R4 This control changes the wave balance for Tig welding operations see Fig 3 2 It is not operative in Stick welding opera tions With the dial set in its extreme counterclockwise or Max Cleaning position the power source is set up for balanced wave operation equal portions of reverse and straight polarity 50 50 for use in DC and AC Tig with Maximum Cle
17. shipping container check the container for any loose parts Remove all packing materials Check air passages at front bottom and rear of cabinet for any pack ing materials that may obstruct air flow through the power source If the machine is not to be installed immediately store it in a clean dry well ventilated area Thelocation ofthe power source should be carefully selected to ensure satisfactory and dependable service Using the lifting eyebolt or a fork lift truck place the power source in the desired location Choose a location relatively close to a properly fused supply of electrical power The power source s components are maintained at proper operating temperature by forced air which is drawn through the cabinet by the fan unit on the rear panel The power source is designed to operate up to a 40 C 104 F ambient temperature For this reason locate the machine in an open area where air can circulate freely at front bottom and rear openings Leave atleast 2 feet of clearance between the rear of the power source and wall or other obstruction IMPORTANT Donotuse filters on this unit Outputratings are designed and based on an unobstructed supply of clean cooling air drawn over its internal components If cooling air is dirty e g laden with conductive dust the interior should be cleaned using low pressure air see Maintenance 15 SECTION 2 A TEE ELECTRIC SHOCK CAN KILL Before making electrical in
18. sultant d une exposition prolong e au soleil Aussi convient il d observer les pr cautions suivantes a Portez un cran facial ad quat muni des plaques protectrices et des verres filtrants appropri s afin de vous prot ger les yeux le visage le cou et les oreilles des tincelles et du rayonnement de l arc lectrique lorsque vous effectuez des soudures ou des coupes ou lorsque vous en observez l ex cution AVERTISSEZ les personnes se trouvant proximit de fa on ce qu elles ne regardent pas l arc et ce qu elles ne s exposent pas son rayonnement ni celui du m tal incandescent b Portez des gants ignifug s crispins une tunique paisse manches longues des pantalons sans rebord des chaussures embout d acier et un casque de soudage ou une calotte de protection afin d viter d exposer la peau au rayonnement de l arc lectrique ou du m tal incandescent Il est galement souhaitable d utiliser un tablier ininflam mable de fa on se prot ger des tincelles et du rayonnement thermique c Les tincelles ou les projections de m tal incan descent 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 d Prot gez des tincelles et du rayonnement de l arc lectrique les autres personnes travaillant prox imit l aide d un cran
19. that when using Maximum Penetra tion mode your duty cycle AC welding arc time must be reduced see Fig 1 3 or 1 4 Duty Cycle chart Also remember that for DC welding applications this control should always be set for Maximum Cleaning Adjust the Current Control potentiometer for the approximate welding current desired Remember that the setting placed on this potenti ometer will be the maximum current which can be regulated from a Remote Foot or Torch Control Depending on the type of current regulation desired place the PANEL REMOTE Current Control switch SW5 as follows PANEL Position permits full range current regulation only from the power source s Current Control potentiometer REMOTE Position permits current regulation from a remote location by connecting either the Foot or Torch control options to the Remote Control receptacle J2 Note that welding current regulation from the remote control option is always limited to the maximum cur rent that you preset on the power source main Current Control dial For example if the main Current Control dial is set at 50 the remote control will provide full range finer tuned current values up to the equivalent setting of 50 on the main Current Control dial however if you want complete remote current control operation the main Cur rent Control dial on the power source must be set at the maximum 28 SECTION 3 OPERATION Depending on your welding applicati
20. 1 Updated the schematic diagrams and updated the format of the manual The E Edition 3 05 of this manual covers the following changes 1 Revised gray items in Replacement Parts from GY to M Added black overlay part numbers The F Edition 2 06 of this manual covers the following change 1 Revised Input Terminal Board configuration in Section 2 Installation 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 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 F 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 Tele
21. 6 6 INO ZSSH NI OSTIVISNI AYOLOW3 wae 5804 138 2H09 V as s ogv osz 26296 39 ud ZH 09 G 6 09 0 2 OG OV ZSE ZSZ 6 SON 135 5310890 LON T3A_ti d 1824 KINO 252 310N 2 1 KINO ZSS 310N TH 1824 OA 151 sna 114100 D K 35 NO 0319001 39018 104110 OA 04 18 189d JHA 81 14 189d S i S U TA 0 s val ma 9 55 8 1130 335 n 3 W130 255 35 u SINISIVIR VOS B Ye 7 18 0 WS 1 INVA YVJ 358 JA WO 1894 A 4 8 8d Y MB 8 78 1804 MB 2 08 180d 2 OA 9 08 188 1 naa 1095 4d 8 2 g 8 34 5 4 1804 TA 1 84 1899 ex n H 9 3 3 8 Y TIANYA 18083 318455 825 3 1130 KINO NI GSTIVISNI 1801243 8 1 d 1824 038 9 14 1894 039 3 7 ni 5 1 14 1808 214 1804 9 ires T3NVA 18093 08 24 WA 21 59 1824 Wa cis rl 038 1 15 l Wig fl 8 4 1809 8 5 55 SZ IHM 8 ti TA UU BA 2 09 2 OA I 58 Ib 0
22. 69 CHOQUE ELECTRICO El contacto con las partes el c tricas energizadas y tierra puede causar da o severo o muerte NO use soldadura de corriente alterna AC en reas h medas de movimiento confinado e 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 electri cidad primario 2 Conecte la pieza de trabajo a un buen sistema de tierra f sica 3 Conecte el cable de retorno a la pieza de trabajo Cables y con ductores 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 Reem plaze 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 No se pare directamente sobre metal o tierra mientras trabaja 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 249 1 listado en la pr xima p gina para recomendaciones espec
23. 9 35 29 145 110 64 55 43 Power Factor wlo P F C Approx 55 Approx 55 Rated Load with P F C Approx 76 Approx 76 65 on 220 V 65 on 220 V Auxiliary Power Output 115 V AC 10 Amp 60 Hz 115 V AC 10 Amp 60 Hz Dimensions 18 8 in 463 mm 18 8 in 463 mm 32 5 in 826 mm 32 5 in 826 mm 25 in 635 mm 25 in 635 mm Weight Net Weight Shipping 375 lbs 170 kg 385 lbs 175 kg 432 Ibs 196 kg 442 Ibs 201 kg For 208 Vac 60 Hz or 380 Vac 50 Hz derate output current by 10 indicates with or without optional power factor correction kit The input currents listed are for balance control in the max clean 0 position When balance control is set in the max penetration 10 position input current will increase approximately 40 For 50 Hz models add 40 Ibs 18 kg 12 SECTION 1 DESCRIPTION HELIARC 252 HELIARC 252 ii TIG MODE 5 STICK MODE MAX OUTPUT MAX OUTPUT 8 MIN OUTPUT ARC FORCE MAX ARC FORCE MAX AC or DC VOLTS 5 AC or DC VOLTS ES 20 ARC FORCE MIN 4 9 50 100 150 200 250 300 320 9 50 100 150 200 250 300 350 400 420 AC or DC AMPS AC or DC AMPS Figure 1 1 Volt Amp Curves Heliarc 252 Ac pc HELIARC 352 HELIARC 352 TIG MODE STICK MODE 70 69 MAX OUTPUT MAX QUTPUT a MIN OUTPUT
24. BA KINO ZSZ 310N M8 IN 9824 358 AJ d 1839 7 NB 8 79 1804 2 44 104 7 OA 9 4 1894 5081300 1 2 1325 039 030 5 24 A 10130 335 FIENISSY ANISIV3R 825 1804 ii d 1824 N SO KINO 256 310N TH NUS 825 IHM 182 ms OS 01 14 1808 Y AWM 81 12 1829 7 1f H 5 74 9 BA 1 3 03 s a 3 ma 9 55 80 Yi s is v 11083 5 14 289d 1 74 1804 508 SH 2805 Td 1804 Nin oro 11 54 i ax 1804 15 HS 4 130 335 1854 0 5 4 1804 28 25 508 SH 300NY 2305 TA 1 84 189d pj DEE 508 300 ANISIVIN 89S ma 8 d 1824 KINO O3TIVISNI 1840124 08 5594 18083 24 NNO 9 d 1824 d 1824 TANYd 1081802 P 61Z9 42 SECTION 6 REPLACEMENT PARTS 6 1 GENERAL 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 6 2 ORDERING To assure proper operation it is recommended that only genuine ESAB parts and products be used with this equipment The use of non ESAB parts may void your warranty Replacement parts may be ordered from your local dis
25. INSTALLATION em 15 EE 15 Unpacking and 15 Primary Input Electrical Connection 0 24 00000 nana ca 16 Secondary Output Connection us 20 ACCOSSOL OS un ea dot oe cep ed Lp E To ee tt 20 ERE 23 Control Function bene recor aie esi 23 Sequence of nte ede eive ed ete 27 Stick Electrode Shielded Metal Arc Welding 27 dtt eae teca ens ette Merge ar e d 27 MAINTENANCE a a 31 egre ier aee edited Ue te 31 Gleanifig era A Etre nn 31 LUBrICAUON EEE E 31 Spark Gap Servicilig ecc Hei 31 Spark Gap Adjustment si 32 Testing and Replacing Bridge Assembly Components 32 Dip Switch Settings of Main Control Board 33 5 35 Erici 35 REPLACEMENT PART S a 43 General end tiet n au i ante RE ie 43 9er 43 TABLE CONTENTS SAFETY PRECAUTIONS WARNING These Safety Precautions are for your protection They summarize precaution ary information fro
26. Requirements Input amp Gnd Conductor CU AWG Time Delay Fuse Size Amps Volts Amps 230 400 460 575 230 Sized per National Electric Code for 75 C rated 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 Wire per National Electric Code Table 310 16 using 90 C rated conductors e g THW 2 THWN THHN Heliarc 352 only 3 Whenusingthe provided strain relief referto Figure 2 1 for proper cable strip lengths It is important to follow the cable strip guide to ensure that if the primary input cable is ever pulled from the strain relief the input conductors will be pulled from the ON OFF power switch before the ground lead is pulled from the ground lug Once stripped thread the input and ground conductors through the large strain relief in the rear panel of the power source Connect the ground wire to the termi nal lug located on the right rear A frame leg inside the power source Connect the primary power leads to terminals L1 and L3 on the input power switch Secure the strain relief on the input cable Check all connections for proper tightness Ensure all connections are correct and well insulated 16 SECTION 2 Strain Relief Rear Panel Inside View 2 Power Leads Ground Lead Green or Green w Yellow Stripe Connect to Ground Lug GND1 Located on A Frame Rig
27. WARNING result in personal injury or loss of life Means hazards which could result in CAUTION minor personal injury PRECAUCION DE SEGURIDAD ADVERTENCIA Estas Precauciones de Seguridad son para su protecci n Ellas hacen resumen de infor maci n proveniente de las referencias listadas en la secci n Informaci n Adicional Sobre La Seguridad Antes de hacer cualquier 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 mate rial calcomanias etc El no observar las Precauciones de Seguridad puede resultar en dafio a la persona o muerte PROTEJASE USTEDY ALOS DEMAS Algunos procesos de soldadura corte y ranurado son ruidosos y requiren protecci n para los o dos El QE arco como el sol emite rayos ultravioleta UV y otras radiaciones que pueden da iar 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 1 Utilice gafas de seguridad con protecci n los lados siempre que est en el rea de trabajo a n cuando est usando careta de soldar protector para su cara u otro tipo de protecci n 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
28. ained in its use Do not use equipment beyond its ratings For example overloaded welding cable can overheat and create a fire EL 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 Processes available from the National Fire Protection Association Batterymarch Park Quincy MA 02269 ECTRICAL SHOCK Contact with live electrical parts and ground can cause severe injury or death DO NOT use AC welding current in damp areas if movementis confined EL or if there is danger of falling 1 Be sure the power source frame chassis is connectedtothe 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 Use well maintained equipment Replace worn or dam aged cables Keep everything dry including clothing work area cables torch electrode holder and power source Make sure that all parts of your body are insulated from work and from ground Do not stand directly on metal or the earth while working in tight quarters or a damp area stand on dry boards or an insulating platform and wear rubber soled shoes Put on dry
29. anical 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 Donotoperate near degreasing and spraying operations The heator 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 operating this is an indication that ventilation is not adequate Stop work and take necessary steps to improve ventilation in the work area Do not continue to operate if physical discomfort persists Referto ANSI ASC Standard Z49 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 1 Usethe proper gas forthe 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 regulator to a compressed gas cylinder Always secure cylinders an upright position
30. aning and minimum penetration This will be the normal counterclockwise position for most applications As the potentiometer is turned clockwise toward Max Penetration cleaning action will lessen and penetration will increase This unbalanced wave output more straight than reverse polarity should only be used for AC Tig applications when needed Volt Amp Switch and Digital Meter Optional on Heliarc 252 With toggle switch in AMP position digital meter will display preset current and then actual current after the arc has been struck With toggle switch in VOLT switch actual output voltage will always be displayed on the digital meter Over Temperature Light When this lights up the power source has over heated exceeded duty cycle The contactor will deenergize shutting down all operations but the fan will continue to run When the light goes off operations can be resumed 24 Circuit Breaker CB1 The 24V resettable circuit breaker CB1 protects the solenoid valve and torch trigger circuitry against overcurrent Section 5 2 provides trouble shooting information 115V Circuit Breaker CB2 The 115V resettable circuitry breaker CB2 protects the 115 volt auxiliary receptacle circuitry against overcurrent Section 5 2 provides troubleshoot ing information 24 SECTION 3 OPERATION Location For Optional L F Current Control Module P N 36228 Location For Optional Pulse Control Kit P N 36227
31. arbon Arc Gouging and Cutting 5 AWS C5 5 Recommended Practices for Gas Tungsten Arc Welding 6 AWS C5 6 Recommended Practices for Gas Metal Arc Welding 7 AWS SP Safe Practices Reprint Welding Handbook 8 ANSI AWS F4 1 Recommended Safe Practices for Weld ing and Cutting of Containers That Have Held Hazardous Substances seguridad Significa riesgo inmediato que de no ser A PELIGRO evadido puede resultar inmediatamente en serio da o personal o la muerte SIGNIFICADO DE LOS SIMBOLOS Seg n usted avanza en la lectura de este folleto Los S mbolos Significan Atenci n Est Alerta Se trata de su Significaelriesgo de un peligro potencial que puede resultaren serio dafio personal o la muerte Significa el posible riesgo que puede AU sultar en menores da os a la persona PN ADVERTENCIA PR CAUTIONS DE S CURIT AVERTISSEMENT Ces r gles de s curit ont pour objet d assurer votre protection Veillez lire et observer les pr cautions nonc es ci dessous avant de monter quipement ou de commercer l utiliser Tout d faut d observation de ces pr cautions risque d entrainer des blessures graves ou mortelles 1 PROTECTION INDIVIDUELLE Les br lures de la peau et des yeux dues au rayonnement de l arc lectrique ou du m tal incandescent lors du soud age au plasma ou l lectrode ou lors du gougeage l arc peuvent s av rer plus graves que celles r
32. bon tat de fonctionnement les c bles le c ble de masse les branchements le cordon d alimentation et le poste de soudage coup age 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 quipements accessoires Gardez les l cart des sources de charleur notamment des fours de l humidit des flaques d eau maintenez les l abri 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 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 S CURIT Pour obtenir des informations compl mentaires sur les r gles de s curit observer pour le mon tage et l utilisation d quipements de soudage et de 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 Society 550 N W LeJuene Road Miami FL 32126 Safety in Welding and Cutting AWS Z49 1 Recommended Safe Practices for Gas Shielded Ar
33. c Welding AWS A6 1 Safe Practices for Welding and Cutting Containers That Have Held Combustibles AWS A6 0 Recommended Safe Practices for Plasma Arc Cut ting AWS A6 3 Recommended Safe Practices for Plasma Arc Weld ing AWS C5 1 Recommended Safe Practices for Air Carbon Arc Gouging and Cutting AWS C5 3 SECTION 1 DESCRIPTION 1 1 INTRODUCTION The Heliarc 252 and Heliarc 352 welding power sources are constant current AC DC welding power sources for high quality tig and stick welding in both the AC and DC mode The unique characteristics of the magnetic and solid state circuits provide excellent arc conditions for all tig welding as well as high alloy stick electrodes The non saturating current limiting reactor and electronic feedback control prohibits high current surges inherent with saturable reactors or solid state SCR control alone therefore reducing spatter on stick electrodes as well as tungsten spitting when tig welding The electronic firing circuit utilizes a voltage compensating circuit which compensates for line volt age variations of 10 percent Through its unique design the Heliarc 252 and Heliarc 352 Ac pc combines all of the latest state of the art magnetic and solid state concepts to provide the wide range volt ampere curve characteristics needed for a constant current AC DC power source see Figure 1 1 or 1 2 Refer to Table 1 1 for technical specifications 1 2
34. e Contactor switch 53 and or wiring Check continuity and replace if necessary Defective Control PC board Defective Current Selector switch S2 and or wiring Check continuity of S2 and ensure that all connections are secure and correct Replace S2 if defective Defective Current Control potentiometer R3 Current control pot set too low for welding application Increase setting of R3 Defective SCR in main bridge Check the resistance across the SCR on the R x 1 scale If the reading is high the SCR is good If the resistance is low or zero the SCR is defective To check the gate connect the gate lead to the anode of the SCR and read the forward resistance across the SCR anode to cathode If the internal voltage of the meter is high enough the meter should read a low resistance Defective Current Selector switch S2 and or wiring See Condition 2 E Defective Control PC board Intermittent shunt connections Check connections to shunt Defective SCR in main bridge See Condition 3 B Defective Control PC board Replace PC board Excessive high frequency Check spark gaps and adjust if necessary see Maintenance Section Check all connections and components in high frequency bypass circuit and replace any defective components Check for defective Current Control potentiometer R3 Open shunt connection Check connections to shunt Defective Control PC board Replace if defective Control PC board may be defective Replace i
35. elding cable insulation must have a voltage rating that is high enough to withstand the open circuit voltage of the machine 2 4 ACCESSORIES 1 FC 5B Foot Current Contactor Control P N 33646 or FC 5BEHD Foot Current Contactor Control P N 33841 This device provides the opera tor with remote control of current and contactor operation at the welding station Interconnection of these functions to the main unit is provided by a mating 30 foot cable plug assembly By depressing the foot pedal the weld start sequence circuit will energize and the welding current will increase or decrease within the range preset on the power source Current Control potentiometer TC 2B Torch Current and Contactor Control P N 33839 30 Ig This remote fingertip control is designed to be taped to any Tig torch handle and to provide the operator with complete contactor control and variable control of the welding current By simply rotating the knob clockwise off of zero the integral switch will energize the contactor Further rotation clockwise will increase the output current up to the limit preset on the power source main control HC 3B Current Hand Control P N 33838 This accessory operates in se ries with the power sources main current control potentiometer to provide remote up to 25 ft current regulation The hand control potentiometer s current adjustment is always controlled by and limited to the range that is preset on the main current con
36. f defective High frequency switch in the OFF position Check S4 and place in START or CONTINUOUS posi tion Improper spark gap Clean and adjust spark gaps if necessary See Spark Gap Servicing Defective S4 and or wiring Make continuity check and replace if necessary Defective Control PC board 36 ud ZH 09 099 082 DA DV 292 292 uej6eiq L G 4 08 5804 KINO ZSEH NI G3TIVISNI AYOLOW3 5 7425 y OIA 01 98 3 01 8 ev 1041802 NIV 1808 NO SIL Oi e Nous I e 209 A0917 087 4 4 134 01 59 25 9 15 S3HOLINS ad 37 ud ZH 09 099 082 ZGE ZGZ DuulM 2 6 4 BA 1 44 1824 nm Te Ta E e 8 3 WIN LT d 1824 08 Y313h WUN 8 3 9030 35 18 355 05 Y 1030 335 OA 01 14 1894 X li We 2 10 TANYA 3SV8 TANYA 1081802 A9 v Yd 1804 8 74 1804 ma 2 79 18929 OA 9 74 189d came 8 2 Fa Wadd oa 180d 18 184 H 9L9 38 yd ZH 09 629 097 022 DA DV 292 292 2neuieuos
37. face 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 us s ou endommag s Ne surchargez jamais le c ble Utilisez toujours un qui pement 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 c bles de masse l ossature du b timent ou en un point loign de la zone de travail augmente en effet le risque de passage PR CAUTIONS DE S CURIT 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 diate ment toute fuite d eau VENTILATION La respiration prolong e des fu m es r sultant des op rations de soudage coup age l int rieur d un local clos peut provoquer des malaises et des dommages corp
38. ficas de como conectar el equipo a tierra No confunda el cable de soldar a la pieza de trabajo con el cable a tierra CAMPOS ELECTRICOS Y MAGNETICOS Son pelig rosos La corriente el ctrica fluye atrav s de cualquier conductor causando a nivel local Campos El ctricos y de corte y soldadura crean EMF alrrededor de los cables de soldar y las maquinas Por lo tanto 1 Soldadores u Operadores que use marca pasos para el coraz n deber n consultar a su m dico antes de soldar El Campo Electromagn tico EMF puede 2 Exponerse a campos electromagn ticos EMF puede causar otros efectos de salud a n desconocidos 3 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 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 e Magn ticos EMF Las corrientes en el rea interferir con algunos marca pasos junto al otro con cinta adhesiva cuando sea posible posible de su cuerpo PRECAUCION DE SEGURIDAD HUMO Y GASES El humo y los gases pueden causar malestar
39. ht Side ON OFF Power Switch S1 PRIMARY INPUT INSTALLATION Recommended Cable Strip Lengths u __ GREEN X 19 GREENYELLOW gt EARTH Figure 2 1 Connecting Primary Power Leads 17 3 PRIMARY 17 CONDUCTORS WHITE 112 BLACK RED gt t GREEN SECTION 2 Figures 2 2 thru 2 5 illustrate the input voltage ter minal board and the input voltage link connections The particular voltages from which this power source may be operated are stated on the rating plate The voltage links were factory set for highest voltage stated on the rating plate If the power source is to INSTALLATION be operated on another stated input voltage the links must be reset for that particular input voltage Always verify the input voltage and check the link arrange ment regardless of factory setting The voltage links are set up by reconfiguring the copper link bars to the voltage designations for the desired voltage For 230 460 575V Models Figure 2 2 Input Terminal Board Configuration for 230V Input SER af mS 5 m N S 1 2 Figure 2 3 Input Terminal Board Configuration for 460V Input Figure 2 4 Input Terminal Board Configuration for 575V Input SECTION 2 INSTALLATION For 220 400V Models Figure 2 5 Input Terminal Board Configuration f
40. 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 Malfunctioning 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 replacement become necessary the manufacturer 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 malfunction 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 SECTION PARAGRAPH SECTION 1 1 1 1 2 SECTION 2 2 1 2 1 1 2 2 2 3 2 4 SECTION 3 3 1 3 2 3 2 1 3 2 2 SECTION 4 4 1 4 1 1 4 1 2 4 1 3 4 1 4 4 1 5 4 1 6 SECTION 5 5 1 SECTION 6 6 1 6 2 TABLE OF CONTENTS TITLE PAGE SAFETY 5 10 DESCRIPTION sic de 11 Introductions a cnet na 11 Duty Cycle dne epi e Pate d tte Re i n ed ie n tcp 11
41. lding by touch or scratch starting If necessary readjust the Current Control potentiometer and or Arc Force control to obtain the exact welding condition required TIG Welding Make the necessary welding power and service connections as shown on the Interconnection Diagram Fig 2 3 Set the Power ON OFF switch to the OFF position Set the CONTACTOR switch to the TIG or TIG REMOTE down or middle position The REMOTE position requires that a torch switch or foot control be plugged into the Remote Control receptacle J2 in order to make and break the welding sequence Close the main wall disconnect switch or circuit breaker to provide input voltage to the power source Place the Current Selector switch in AC DCSP or DCRP position The AC position is primarily used for welding of aluminum and magnesium The DCSP position will normally be used to cover all of the remaining metals steel copper refractory etc and alloys The DCRP position produces a shallow weld which makes it suitable for joining thin sheets of metal e g magnesium foil etc 27 SECTION 3 IN WARNING ELECTRIC SHOCK CAN KILL Do not use AC output in damp areas if movement is confined or if danger of falling exists Use AC output only if required for the welding process Do not change the position of this switch while welding OPERATION Set the Balance control to the position which best suits your AC Tig welding condition Remember
42. m 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 ING PROTECT YOURSELF AND OTHERS Some welding cutting and gouging processes are noisy and require ear protection The arc like the sun emits ultraviolet UV and 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 any work area even if welding helmets face shields and goggles are also required 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 not 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 welding 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 Hot sparks or metal can lodge in
43. o da o particularmente en espa cios sin ventilaci n No inhale el humo o gases El gas de protecci n puede causar falta de ox geno Por lo tanto 1 Siempre ventilaci n adecuada en el rea de trabajo por medio natural o mec nico No solde corte o ranure materiales con hierro galvanizado acero inoxid able cobre zinc plomo ber lio o cadmio a menos que provea ventilaci n mec nica positiva No respire los gases producidos por estos materiales 2 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 3 Si moment neamente desarrolla inrritaci n de ojos nariz o garganta 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 4 Haga referencia a la publicaci n ANSI ASC Standard Z49 1 Vea la lista a continuaci n para recomendaciones espec ficas en la ventilaci n 5 ADVERTENCIA Este producto cuando se utiliza para soldaduras o cortes produce hu mos 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
44. observando las operaciones Alerte a todas las personas cercanas de no mirar el arco y no exponerse alos rayos del arco el ctrico o el metal fundido 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 delos rayos y chispas calientes provenientes del metal fundido En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas Chispas y part culas de metal caliente puede alojarse en las man gas 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 Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no flamable como divisi n Use careta 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 g y las chispas pueden causar fuegos y A explosiones Por lo tanto 1 Remuevatodo material combustible lejos del rea de trabajo o cubra los materiales con una cobija a prueba de fuego Materiales combustibles incluyen madera ropa l quid
45. on place the High Frequency Selector switch in the START or CONTINUOUS position Setthe POSTFLOW control to provide the desired interval of post flow shielding gas from 3 to 30 seconds after the welding arc voltage is broken Place the Power ON OFF switch to the ON position This will immediately energize the power source up to its solid state contactor To establish the welding arc position the torch electrode near the workpiece i e 1 8 typical and close the Remote Torch or Foot Control This will energize the solid state contactor and provide high frequency and welding current to initiate the arc If necessary readjust the panel or remote Current Control until you secure the exact condition desired 29 SECTION 3 OPERATION 30 SECTION 4 MAINTENANCE ATENTA Be sure that the wall disconnect switch or circuit breaker is open before attempt ing any inspection or work inside of the power source Always wear safety goggles with side shields when blowing out the unit with low pressure air 4 1 MAINTENANCE If this Equipment does not operate properly stop work immediately and inves tigate the cause of the malfunction Maintenance work must be performed by an experienced person and electrical work by a trained electrician Do not permit untrained persons to inspect clean or repair this Equipment Use only recommended replacement parts 4 1 1 Cleaning Since there are no moving parts other than
46. ontrol will vary the welding current but only within the range preset on the power source Weld Current potentiometer R3 Remote Control Receptacle J2 This receptacle allows you to plug in a remote accessory i e foot or hand control to provide remote current and or contactor control depending on the Panel Remote selection of panel switches described in Items B and C above Current Selector Switch S2 A 3 position switch offers a choice of AC DCSP or DCRP output current to suit your particular welding applications Placing the switch in its DCSP mode causes the output terminals to assume thefollowing polarities workis positive and torch electrode is negative Con versely when the switch is in DCRP work is negative and torch electrode is positive Do not change the position of this switch while welding or under load Current Control R3 This control provides adjustment of welding current The panel faced dial provides an accurate reference for presetting and or adjusting the control High Frequency Selector Switch S4 A 3 position toggle switch controls high frequency Thefunctional positions are Off no high frequency this is the normal posi tion for all stick welding or scratch start TIG Continuous high frequency is provided throughout the entire welding cycle this is the normal position for all AC Tig welding and Start high frequency initiates immediately and cuts off when the arc is established this
47. or Figure 2 6 Input Terminal Board Configuration for 220V Input 400V Input 19 SECTION 2 INSTALLATION Heliarc 252 Ac Dc AC Note Three power cable adaptors are supplied with the power source Use P N 19708 for connecting HW 9 amp HW 24 style torches Use P N 19709 for connecting HW 26 style torches Use P N 19710 for connecting HW 17 style torches DCSP 115VAUX DCRP Water to Torch Power Water from Torch Power Gas to Torch El 2 Hot power 22 see Note Sh ELECTRODE primary power before changing connec Y CoveredElectrode SMAW Holder REMOTE CONTROL WORK GasCooled Heliarc Tig Torch Water Cooled Work Heliarc Tig Torch Connect to approved earth ground by customer FC 5B Foot Control P N 33646 FC 5B EHD Foot Control P N 33841 Remote Contactor Current Control TC 2B Torch Control P N 33839 Notsupplied with power source HC 3B Hand Control P N 33838 Figure 2 7 Heliarc 252 352 Interconnection Diagram 20 SECTION 2 AN Verify that all electrical connections comply with local electrical codes and especially with requirements established in booklet F 11 831 High Frequency Stabilized Arc Welding Equipment which is packed with this power source ATEN Before making any connections to the power source s output receptacles make sure that all primary input power to the machine is deenergized off at
48. orels Aussi convient il d observer les pr cautions suivantes Assurez en permanence une a ration ad quate de l emplacement de travail en maintenant une ventila tion naturelle ou l aide de moyens m caniques N effectuez jamais de travaux de soudage ou de coupage sur des mat riaux de zinc de plomb de beryllium ou de cadmium en l absence de moyens m caniques de 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 proximit de vapeurs d hydrocarbure chlor r sultant d op rations voisines de d grais sage ou de pulv risation La chaleur d gag e ou le rayonnement de l arc peut d clencher la forma tion de phosg ne gaz particuli rement toxique et d autres gaz irritants partir des vapeurs de solvant Une irritation momentan e 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 Ar r tez vous de travailler afin de prendre les mesures n ces saires l am lioration de la ventila tion 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 destin emp cher la formation de poches d hydrog ne lesquelles pr sentent un danger d explosion ce ventilateur ne fonctionne que si l interrupteur correspondant du
49. os y gases flamables solventes pinturas papel etc 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 No corte suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo est totalmente limpia y libre de substan cias 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 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 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 starde 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 As sociation Batterymarch Park Quincy MA 022
50. ounting surfaces are clean Make certain the polarity on the replacement SCR is the same as on the unit being replaced 32 SECTION 4 MAINTENANCE 4 1 6 Dip Switch Setting of Main Control Board Assembly Referring to the diagram below the dip switches on the Main Control PC Board assembly 38055 or 38089 are factory positioned as shown with no options on the Heliarc 252 and 352 power sources If a pulse and or slope control option is installed the dip switches must be repositioned as shown 7 vedi e 7 221 252 352 H 252 H 352 NO OPTIONS NO OPTIONS WITH PULSE WITH PULSE OR SLOPE CONTROL SLOPE CONTROL O O 38055 REV _ O 33 SECTION 4 MAINTENANCE 34 SECTION 5 TROUBLESHOOTING ANTENA Be sure that all primary power to the machine has been externally discon nected Open wall disconnect switch or circuit breaker before attempting inspection or work inside ofthe power source 5 1 General If power source is operating improperly the following troubleshooting informa tion may be used to locate the source of the trouble Check the problem against the symptoms in the following troubleshooting guide Table 5 1 The remedy may be quite simple If the cause cannot be quickly located open up the unit and perform a simple visual inspection of all the components and wiring Check for secure terminal connections loose o
51. panneau avant se trouve plac en position ON Marche Veillez man uvrer cette commande en v rifiant si le couvercle est bien en place de facon assurer l efficacit de la ventilation ainsi r alis e Ne jamais d brancher le ventilateur Les fum es produites par l op ration 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 limi ner du voisinage de l op rateur tout d gagement de fum e visible Consultez les recommandations particuli res en mati re de ventilation indiqu es l alin a 6 de la norme Z49 1 de l AWS ENTRETIEN DE L QUIPEMENT Un quipement entretenu de d fectueuse ou inad quate risque non seulement de r aliser un travail de 10 mauvaise qualit mais chose plus grave encore d entrainer des dommages corporels graves voire mortels en d clenchant des incendies ou des chocs lectriques Observez par cons quent les pr cau tions suivantes Efforcez vous de toujours confier un personnel qua lifi 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 quel conque l int rieur du poste de soudage coupage avant d avoir d branch l alimentation lectrique Maintenez en
52. phone 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 8 Support BD ESAB 9 ESAB Welding amp Cutting Products PO Box 100545 Florence SC 29501 0545 F15 254 F 02 2006
53. put connections to the power source Machinery Lockout Procedures should be employed If the connections are to be made from a line disconnect switch place the switch in the off position and padlock itto prevent inadvertent tripping If the connection is made from a fuse box remove the corresponding fuses and padlock the box cover If it is not pos sible to use padlocks attach a red tag to the line disconnect switch or fuse box warning others that the circuit is being worked on AMG The chassis must be connected to an approved electrical ground Failure to do so may result in severe electri cal shock causing severe burns or death INSTALLATION 2 2 PRIMARY INPUT ELECTRICAL CONNECTION This power source is a single phase unit and must be connected to a single phase power supply It is recommended that the unit be operated on a dedicated circuit to prevent impairment of performance due to an overloaded circuit 1 The primary power leads must be insulated copper conductors Two power leads and one ground wire are required Either rubber covered cable or conduit flexible or solid may be used Table 2 1 provides recommended input conductors and line fuse sizes Remove the top cover Identify primary power input connections on the power switch chassis ground lug on the A frame and primary input terminal board Refer to Figures 2 1 and 2 2 Table 2 1 Recommended Sizes for Input Conductors and Line Fuses Input
54. r burned wiring or components bulged or leaking capacitors or any other sign of damage or discoloration 35 SECTION 5 CONDITION 1 Unit completely Inoperative 2 No welding output Fan operative 3 Low or unstable open circuit voltage 4 Erratic output weld current 5 Minimum welding output 6 High weld output current control does not vary the output 7 Absence of High Frequency while selector switch S4 is in START mode only 8 Insufficient or absence of high frequency TROUBLESHOOTING Table 5 1 Troubleshooting Guide ACTION Open line fuses check the line fuses for continuity and replace if necessary If the fuses continue to open the jumper links may not be in proper position See Primary Electrical Connections No power input check position of line disconnect switch Improper jumper link placement on input terminal board See Primary Electrical Connection Defective power on off switch S1 on rear panel check continuity of 51 and replace if necessary Power source magnetics overheating thermal switch TS1 or TS2 tripped due to restricted cooling air flow or over extended duty cycle Allow unit to cool for at least 5minutes with fan running to let TS reset Contactor switch S3 in the TIG REMOTE middle position without a remote contactor control connected to the Remote Control receptacle J2 Place S3 in STICK up or TIG ON down position or make remote torch connection at J2 Defectiv
55. rolled up sleeves trou ser cuffs or pockets Sleeves and collars should be kept buttoned and open pockets eliminated from the front of clothing Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains Use goggles over safety glasses when chipping slag or grinding Chipped slag may be hotand canfly far Bystand ers should also wear goggles over safety glasses FIRES AND EXPLOSIONS Heat from A flames and arcs can start fires Hot 5 slag or sparks can also cause fires and explosions Therefore 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 Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smolder ing fire or fires on the floor below Make certain that such openings are protected from hot sparks and metal Do not weld cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce flammable or toxic vapors Do not do hot work on closed containers They may explode Have fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are tr
56. s 952133 gray Overlay Front Panel Black Heliarc 352 was 952154 gray 44 SECTION 6 REPLACEMENT PARTS 41 44 45 46 47 22e 2X gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt DDD gt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt y gt lt gt CC C gt C o Sy y y gt 22222222 lt 2525252525 1 25 252525 252 lt 39 43 C CX C X 33 34 38 42 36 37 36107 Switch Power 600 V 63A H 252 950945 Switch Power 600 V 100A H 352 950219 Strain Relief 58V75 Adaptor B A WF x 1 4 NPT 950510 Hose Nipple Barbed 631F02 Hose 1 4 ID 11N22 Hose Nipple B 3 16 136208 Hose Nut B I G 36057M Rear Panel Screened 36052YL Right Side Panel 36045YL Left Side Panel 36046YL Top Cover 36035M Base 13734588 Decal ESAB 954008 Label Danger High Voltage 9512240 Label Caution Lifting 2091514 Label Warning 954564 Label Schematic 230 460 V 60 Hz 954597 Label Schematic 230 460 575 V 60 Hz 954585 Label Schematic 220 400 V 50 60 Hz 1 1 1 1 1 1 1 2 1 1 1 1 Not factory assembled to the power source 45 REPLACEMENT PARTS
57. the fan in the power source maintenance consists mainly of keeping the interior of the cabinet clean Periodically remove the cover from the cabinet and blow accumulated dust and dirt from the air passages and the interior components using clean low pressure air It is imperative that the air passages to the interior of the unit be kept free of dirt accumulation to ensure adequate circulation of cooling air especially over the rectifier bridge plates and PC boards The length of time between cleaning will depend on the location of the unit and the amount of dust in the atmosphere 4 1 2 Lubrication Fan motors with oil tubes require lubrication after 1 year of service Motors with out oil tubes are permanently lubricated and do not require any attention 4 1 3 Spark Gap Servicing This component is part of the high frequency assembly It will probably be necessary to readjust these gaps after extended operation or if erratic high frequency operation is noted It is important that the gaps be adjusted with a feeler gauge rather than by eye Cleaning and dressing of spark gap points is not recommended since the points are tungsten and difficult to file Points P N 673578 should be replaced as a set 31 SECTION 4 MAINTENANCE 4 1 44 Spark Gap Adjustment Generally the high frequency output of the unit increases as the gap setting is increased Electronic instability in other equipment may occur if the gap is opened more than the
58. tmospheres 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 itin any manner ADDITIONAL SAFETY INFORMATION For more information on safe practices for electric arc welding and cutting equipment ask your supplier for a copy of Precautions and Safe Practices for Arc Welding Cutting and Goug ing Form 52 529 The following publications which are available from the American Welding Society 550 N W LeJuene Road Miami FL 33126 are recommended to you 1 2 3 ANSI ASC Z49 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 C5 5 Recommended Practices for Gas Tungsten Arc Welding AWS C5 6 Recommended Practices for Gas Metal Arc Welding AWS SP Safe Practices Reprint Welding Hand book ANSI AWS F4 1 Recommended Safe Practices for Weld ing and Cutting of Containers That Have Held Hazardous Substances MEANING OF SYMBOLS As used throughout this manual Means Attention Be Alert Your safety is involved Means immediate hazards which if not ALINE avoided will result in immediate seri ous personal injury or loss of life Means potential hazards which could
59. tributor Be sure to indicate any special shipping instructions when ordering replacement parts Refer to the Communication Guide located on the last page of this manual for a list of customer service phone numbers 43 SECTION 6 REPLACEMENT PARTS 11 6 14 13 41 12 4 26 27 10 15 8 9 7 8 16 6 5 6 22 17 21 18 1 19 E 2 3 36067 36189 13733935 13733936 36068 951511 13730611 672831 674216 951474 951815 13792157 13730632 950584 672786 2133514 636702 992804 950122 952219 951916 58175 954441 2062171 950510 36066 30612 954587 954589 1 1 2 2 1 1 3 1 2 3 1 1 2 1 1 10 1 1 2 1 1 1 1 1 1 1 1 1 1 Not factory assembled to the power source 2 3 20 23 25 24 FIG 6 1 Heliarc 252 352 Front View Panel Front Screened H 252 Panel Front Screened 352 Receptacle Cable 2 1 0 Connector Quick Not Shown Panel Control Potentiometer 2M 2W Knob Switch Toggle SPDT Capacitor 0 02uf 1KDVC Switch Seal Light Amber 12 V Lamp White 48 V Potentiometer 10K 2W Knob Eyebolt Lifting Hole Plug Switch Toggle DPDT 3 Pos 15A Potentiometer 250K 2W Circuit Breaker 10 Receptacle 110 V Receptacle 14 Pin Adaptor B A WF x 1 4 NPTM Warning Label Shock AC Knob Hose Nipple Barbed Box Gas Water Block Molded Output Overlay Front Panel Black Heliarc 252 wa
60. trol 21 SECTION 2 INSTALLATION 4 TR 23A Truck Kit P N 36224 Provides complete mobility for power source Includes handle 4 castors and gas cylinder bracket 5 AC DC Digital Meter Kit with Current Preset P N 36226 Optional for Heliarc 252 installed in Heliarc 352 This meter kit provides direct accurate reading of AC and DC open circuit and welding voltages as well as welding current The kit mounts directly to the front of the power source A plugged hole in the front panel of the unit provides access for the meter Allows pre set of welding current 6 WC 8C Coolant Circulator P N 33739 A self contained 1 5 gallon ca pacity water cooler suitable for most water cooled torch applications The unit circulates 1 gallon per minute at 60 psi and operates from 115 volt 60 Hz 1 phase 5 4 amp input The circulator fits in place of cylinder in the TR 23 Truck 7 Current Slope Control Module with Trigger Lock P N 36228 Allows setting of start initial current up slope time down slope time and final current as well as standard or latching torch trigger NOTE When using pulse and or slope control dip switch settings on main control board must be reset see 4 1 6 in the Maintenance section 8 Pulse Control Kit P N 36227 Allows independent setting of Peak Current 11 Peak Time T1 Background Current 12 Background Time T2 Has a three position switch for setting Peak 11 Background 12 and Pulse modes
61. u are adequately protected before you start welding welding helmet gloves and ear protection and safety glasses with side shields should always be worn A WARNING ELECTRIC SHOCK CAN KILL Do not use AC output in damp areas if movement is confined or if danger of falling exists Use AC output only if required for the welding process Am Do not change the position of this switch while welding OPERATION 3 2 SEQUENCE OF OPERATION 3 2 1 Stick Electrode Shielded Metal Arc Welding 1 3 2 2 Connect all welding cables to workpiece and electrode holder as shown on the Interconnection Diagram Fig 2 3 Place the power source s Power ON OFF and High Frequency Selector switches to the OFF position Close the main wall disconnect switch or circuit breaker to provide input voltage to the power source Place the Current Selector switch to AC DCSP or DCRP depending on your welding application Leave the High Frequency Selector switch in its OFF position Adjust the Current Control potentiometer for the approximate desired welding current Set the Arc Force control at 3 or 4 on the dial and readjust as neces sary to provide a softer or harder welding arc as described in Section 3 1 L Place the Power ON OFF switch to the ON position Place the CON TACTOR toggle switch to the STICK up position This will immediately energize the power source up to the output terminals and the electrode holder Commence we
62. ue usted est cualificado para hacer el trabajo 2 Antes de dar mantenimiento en el interior de la fuente de poder desconecte la fuente de poder del suministro de electricidad primaria 3 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 4 No abuse del equipo y 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 Ameri can Welding Society 550 N W LeJuene Road Miami FL 33126 son recomendadas para usted 1 ANSI ASC Z49 1 Safety in Welding and Cutting 2 AWS C5 1 Recommended Practices for Plasma Arc Weld ing 3 AWS C52 Recommended Practices for Plasma Arc Cut ting 4 AWS C5 3 Recommended Practices for Air C
63. ures du plancher ou dans des ouvertures des murs et y d clencher une ignition lente cach e prot ger ces ouvertures des tincelles et des projections de m tal N ex cutez pas de soudures de coupes d op rations de gougeage ou autres travaux chaud la surface de barils bidons r servoirs ou autres contenants usag s avant de les avoir nettoy s de toute trace de substance susceptible de produire des vapeurs inflammables ou toxiques En vue d assurer la pr vention des incendies il con vient de disposer d un mat riel d extinction pr t ser vir imm diatement tel qu un tuyau d arrosage un seau eau un seau de sable ou un extincteur portatif Une fois le travail l arc termin inspectez le secteur de fa on vous assurer qu aucune tincelle ou pro jection de m tal incandescent ne risque de provoquer ult rieurement un feu CHOC LECTRIQUE Le gougeage l arc et l arc au plasma exige l emploi de tensions vide relative ment 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 recu 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 sur

Heliarc® 252 ac/dc and Heliarc® 352 ac/dc

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Heliarc® 252 ac/dc and Heliarc® 352 ac/dc