hefty ii stainless semiautomatic, solid state controlled voltage
Contents
1. STATEMENT OF WARRANTY erat conan pate pas cn aa et jm uae pe ac Nu tdg a cr commos EAT Tm 2 E ea rch etwa mala a ma o urs mA a nn e a lt cus Mads Tama dem ane Thema Eca January 1398 Troy 273 dum2. pp This page intentionally blank PRECAUTIONS DE SECURITE SOUDAGE A ER Se ia dv das Ps mie s a M DESCRIPTION OF EQUIPMENT General Te HEFTY LSTANLESS amp aperto lag cana a tm eve cb a contacta ande aus poa arde ue este gi The uique design ol fender tows op en constar o ape made won power and 1 sing wee ecd mode ue speed rag acea Product cd shorted gas vate 10 te Ten ld dam bone Wall curent imi o mota 2 onte ea tor nove voltage gun gr re o operator sale ara oro 035 D ter The HEFTY 1 STAINLESS has been designed o Si SATU REA E onn ions The stainiess steel case totally encloses the Voltage Pange welding wie wire ve Fruto Md My aces b the wo
3. the gun Clair te dumaged ee shortened use 5 2000 Revised Available Options ums Thefeowingoplonsareaestletrwsewihte 7 Teco Gun Adapter nus HEFTVIUSTANLESS Sone opions Remote Conta Rte iei bs EUR 100 229 19 in Ampnena 100 maso Sint iu TB T5941 Comncior Covenion Kl 87027 enem 4 Feed Ral Kt edie olage Motes See Dias Chap INSTALLATION Connections Ses System On 170091 in game choro mis ata ig thers acing or overeat 1 Connect cabe tom he por sue 2 Conecta weld cable rom power custo WARNING ELECTRIC SHOCK KILL DO NOT touch the metal portions of the voltage sensing lead when the power source output is on he proper as ine connection fom o he we ova 5 ah te gun o he vire 8 Connect waking gun sch leads See Figures 34 and 35 NOTE The are spool hub spied with he provide or a 30 pound fie mars are a so along a eo dra pour cola we lobe used umor ne spot by 2 Side ha spool ol wire over he wire spel hub sing e te alga pimenta eei e bch oft mre sol place wire spol hub not and om dock Eire
4. STAINLESS SEMIAUTOMATIC SOLID STATE CONTROLLED VOLTAGE SENSING WIRE FEEDER Far the Following Specs 191000527 IHERMAL A THERMADYNE Company OWNER S MANUAL Number 430429 456 Rev Fesdihosoinmucions belo opening of soning system THERMAL ARC INC TROY OHIO 45373 1085 U S A INTRODUCTION 1 ian 5 purum ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 2 DESCRIPTION OF EQUIPMENT Manns Se 8 Vari Sd E ternal Cons And Comectrs e prt Side rsen reaches seni Sec 37 Ai INSTALLATION Vi Wie Spel 2 Aut Spot en Sacto Ol rend ale ting Gun And eat OPERATION 5 Procedure E Vita Paar Vira CE Made Cade her ope esting Bumba Tine E hd Coca MAINTENANCE Or Te Unt Gang Orme Fe ote TROUBLESHOOTING 7 E E Bl testing ins blest E SRS OR PARTS LIST tor DIAGRAMS WARRANTY INTRODUCTION How To Use This Manual Owners Manual usua just ried scan et oi aan unos manu weeds WARNING NOTE spear iter 1o prove unde hase esa re est rc pee a iow
5. reas ends Benin eren let wi ne ed ol the tog gun he end 0 he urbes i mee wie rearing athe he weg gun ese WARNING ELECTRIC SHOCK KILL Make certain the power source and wire feeder fare both turned OFF before ginning the procedure 1 Usb a eo soekel remove he ar cover o expose conl Brod cut ou See 52 2 component runas on he or ora ped ard Fag e 52 The estos to ake aguatrars tl he amour tbo Corporat RO has go tum 2601 range o oven RGB doc To decrease burback in aus RG counter place he eter cover Calibrating Wire Feed Speed Meter camper hat pr ati ath wt dapayed aig mater ihe we i a a ea ve Cori e called th A wie lend speed meler td in fel a an opto The moter ono penes cct pon NT WARNING ELECTRIC SHOCK KILL While calibrating the viro feed speed meter voltages jas high as the open circuit volt lage of the power source will bo lexposed Use caution and fel low instructions accordingly pos 2 nul die or sock remove he ester cover o expose the motor co board gue 2 jus wire eed speed cort
6. 4 Cu of welding wire at Vp at lng ge Ding gun or ect 15 Bacon Cul welding wire at tp ot elo gn nd stato e pn inch por mt PM Wie Long Messuredin step For Example I 26 ches ol re teed in 15 Seconds 125 X4 500 mes bot minae 8 New wihihe hehe guns depressed ul cora cnr Pes creat bord und ie meer PH n Step 97 Se Powe 52 8 Replace e eter cove 16 Pace ne COICV mode eich inne proper Pera estan rama m Protection And Safety Circuits folowing protection and salely cis standard vi the eed designed io Pra by doing he wr eed agua ant rae operator andor equipment nape 1 Underotage Proleeton ip stage beam specta vlog ange ot pei Scheie et ers dn accepte tange 2 Oneotago Protection V he votage e abate seco vago age tor dd prios d ti a scone el cea Their poem or era tn accepte tange Wine noa curet peti per lt pul ul beaker wil ip wie stra oprah ee ave to be manual orl were o p aspera Vois corte prt ce sal Fa E wirt on e Faure 2 T lo cron polca crc wil have SE on re eden of poston CAUTION thie protection cit SA MI
7. NOTE Inst meg posto he er om he BORN e wre gutle Adjustment Of Spool Tensi Ads e wie poa arin s te we declino We re re 9488 However e spot wie ust nec an wie ecd Sep To e re spo asin tien or Jog o tin tecno pre hr more Input And Output Wire Guide Installation Figure 35 Gui TS En Selection And Installation Of Feed Rolls NOTE See ro diving pie Diagrams cape o oder eed rat scusa team o neo input and wie us or spate te and led rol Fur 33 Forsebctonol teed rol es 4 1 So 1 teed coral fal smoot bang 2 eed ol const ot Ral Are obama dou sooth vee trad dive of heyteed 030 wee Sie 3 e rol cori oa ul rue voc faved Bearing Yl nl voc md 4 eed rots ol double bearing rds They toed 045065 bute 5 lend duto eating ana ave roi They lend 038 28 20 NOTE Al grooved led rote have het o range stamped on esd of Grate cron groove ne stie when nate stamped Hie ate he prove n use Bearing inte by usc lang ind temovi Pe
8. WARNING gives information garding possible personal in jury Warnings will be enclosed i a box such as this CAUTION reer o possible equipment damage Caution wi be shown in bold ee NOTE conca oct crer ocre Nico Equipment Identification The unte eration ruber pecan rumba and seal somber usualy on ataca to he contos Bona coa ease a may be ceo merear Equipment ih does rot ves ta gran cate saz les e dane by e specicalon or par ese minar rre Receipt Of Equipment use cre cc Np bore he ned air d cm Pur torte lomaion intem damage dams ereto Thermal Orr 2200 Binoy ho 487 a Move he equipment toe slt se ureatog he unt Use ce aid duragag hen vog bu fumme e chases by Thermal Ae tr atas gue stove e Owners rua number doen This page intentionally blank ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS sp o uv Ara ar Mu NOISE Cam ma a heat v r pir e uu iue 58 DIXI
9. ere alte weli fe wil drea in e a ed rper Turn Me wet machine and wie leder ON anil marae See 22 Remove contact hon wel pn See Manus Pret he gun tar NER selos pez gv sie ignes GA WARNING The welding wire is electrically wire is fed by depressing gun switch Electrode contact to work piece will cause an are with gun switch depressed Iram NOTE Number stamped on Sie ieciesle he wre se of Grove ie vera Figure 4 1 Feed Roll styles This page intentionally lett blank Prewelding Procedure owe walang gu onde HEFTY I STAINLESS lender string a been made haer Corsecons api o Pis mar 2 Ton ON e power source ane lode sine poa post CEE d Su 4 Liang ga wie depres ma purge sicher gu ne ow ol ga WARNING the gun switch depressed the wire feeder wi feed electrically hot welding ie f this hot welding wie touches the work piece a ling arc will be established 5 Depres inch or gun Sad ay peed control cn be ung sep rhe pr WARNING If the gun switch is deprossed the wire feeder w
10. ane 2000 Revised TROUBLESHOOTING Scope The voubieshoning guide lended lo be used by enc ing cante beso lise and cei instar ar faco he components ane violar Enc by a li re ar e pc tte io Safety To ensure sale and sei read moche The serve may be hd voltage eves do machine red no Troubleshooting Hints Exarine proper assembly sad component or Eca wi lente Condor shoud ia contei hdd e canard Bele replacing a suspect port cru ab vt pg cic Boa fones al wre pos to be fied creu bor le e macia Ee per Faidyconecions rian a cu Do not put on dleatsemale connections rem each ug comeco when ic Puig ira asse can dam Sent riy become ns caseiro Piero or senieing he machine weg coveriors nthe machine shud ace wer e sum Jaca sed rong receved Yon he cp ies and end away prs and praem ol e reed ret boards he machine vinis sa devices Use a goundng Sap ore bore templo lo s
11. Fe mica enar viue bye gas nes are alowed to cone io iat whe oor o bare bong com edad or recent tha ae va ui eperaion andor ga leakage a vane ron ob leaned ay Todes he gas ve teal obw mese poo vao ae ote a e orato fat aut pot wi respec e as wae shut have e seme orent 1 Remove inl power rom he wi o and depresso val 3 Remove he 2 bracel ares rom yoke c Be qa va Sipe oe craig cat ep 5 Remove ho piugnulcore ube sub assembly ai bay 8 Remove he coe and core sore 2 pate nod ob or soa cl e ve he gas va in reverse order t issertiy paye eran Fue 62 NOTE 2 bractel seres evenly 1o nere propr body gestat compression Torque bach are nh pound Assemble he gas valve othe wie NOTE N may be acere o compound o gat ater me Ive Do api compound 16 torte of gas wae ist vo esd ol mie re male suele une 5 2000 Revised por pred Nae oe gas he mangas sup chor Mas vao aa woe FS ener sena a Ria valve Te ur ovo operate Ie go va ins sho gre opcion gaze he Terao seve Figure 62 Ga Valve Assembly
12. R s sation fia manas ccr or stone ita and que aba vira pente ied wl non ede te 1003 peso laa CAUTON H Na protection circuit the contacto gar Vae most ley shorted ind MAINTENANCE Cleaning Of The Ui o epa pred citu sda th ponens Using vacuum ane o clan impressed a ad mee Ran 26 pre Cleaning Of The Feed Rolls Aout every 3 manta lan on tools ung we ah eed ll Stace pe a he eed rl cla ey ch Alter clearing he bon Upper loner Ta retain hobs Er Feedhead Maintenance See Figure 6 lor Figure 61 The pit ol maintenance assay heze very 400 hot When ro 38 haud De CAUTION Neglet in brush mainte ance may cause Gamage t he drive resul ngin molo operating Contactor Maintenance Regular examine contate contacto ay crac wom down o he copper bos ene diac au be race Gas Valve Maintenanc See Fur te delale Foreign ate he a boda ha major ga valve aure e inpr opera
13. aio mate measurement on predio AM signal in tou tecno canbe vi doll met OMM Te 5 2000 Revised Troubleshooting Guidi eira E trance in most cese resistance and voltage made wih a le geni par A Unit is completely nothing functions B Wire feed motor operates but wire does not feed or feeds erratically 2800 Revised pesar Toe no hne he Dein Assembly selon ot Check or correct td size lor eid being used Check see spa enon too great Cheek lor resin in welding ie Cheek or oc gun iner and contact is or wet wire being C Wire wraps around the feed rolls Cheek or lao much pressure ta teed rt Seo arg lenin rd he Dein na Assembly cn ot Check ol nd Cheek or oc gun iner and ont or wet wire being used D Wire does not feed with gun switch depressed Check tor cor ol the gun rigger ead wh ger depressed cota ep or replace the wet o Check gun TE eed motor 87 and gt he corel p baud for loe or fy comes Jo electronic protection lt may have scite so by placing poser aih in olf pasion lor a ss 60 seconds See Mainte
14. be nes OFF 1g In CC Mode vs CV Mode When welling constant current CC power changes vire a pet tl wa p diet e amour ol welding om S one ac reduces he il vire Vd thon operating wil 3 CC power sure Tas editos ireland spe corona ore Tropa exe acc CC power nerve ue tn Wen wong vago OV power el ing curent Changes led spa can be e o disi wi ed corii Te aa he amount ol welding ron the ota 1013 03 Theory Of Operation ee o e Connection Senema Dam ste Diagrans chap o a menu power ie supped tous he ent etch Si ar ig cre testo 0817 o ensures al mo prope platy ed i ha pe bond depender 2222 When gun ah ma wating gun is gun eh cage cui wee lead 81 tum eng ee a gus ve oop sawing gas sie contacter he meg Ve ci Wan the gun on qun leased a So on e gun sl a causing he is met lad ng ir be gas vae dose og ge SRS cmd pn mia ad mee Adjusting Burnback Time cae ped toa bard crai a component hal ports na Burnback ine ele o te amount ol wee rang al end of e gn der he
15. davis Prece hosed gas vae cl ie ay access ordi o reach jobs CENTER d caring menale Promos penay 17 Quis change Rots als gear dren e beter teed ol wie Aon prio secure weg Alon ea ol pesa whoa he change ac ae or wee ai Meanings Of Markings And Graphical Symbols o O SA o o Tne 5 2000 Roses Front Panel Controls And are conto can be atos Connections tog seu raca lang See Figure NOTE The power source bei he 1 WELDING GUN CABLE CONNECTION The uncon to gun ade carece 10 e wire ARC VOLTAGE METER OPTIONAL The poi Consecons be ight eres ar voagerneier aa vota dig Borba con es arte power source 2 WIRE FEED SPEED CONTROL 5 WIRE FEED SPEED METER OPTIONAL wire Thewre Te tpm da asas tod cio cane aussi ator cas te 8 POWER ONOFF SWITCH eh ARO VOLTAGE CONTROL OPTIONAL put poner ha rd na ho cont are om power the poner source inte
16. er ce leder nd et fo te plc Ve an he wre war hang lat 20 INPUT WIRE GUIDE Tis quide reque Te veto vis ton he mre spa he 21 INPUT GUIDE Then Sete see opu vr ud ation tb he roi Tree ME Bening eae on he eg ure bearing ed Remove change bear est OUTPUT GUIDE LOCKSCREW Tin ie are o sur he ope pd Figure 35 Feedbesd Assembly 25 GUN CLAMP KNOB ho lo wong qu ole nt ar OUTPUT WIRE GUIDE is quide te e vela wre om eed mai qu ca Power Source Compatibility Since the HEFTY STAINLESS operates cor wr with constant crer GV OC ype por sources lowed opem crua vage poser saute 100 VOC Open teat Sig a UDC ul Ld NOTE Because ol e high open lage CC power scarce recommended o place HEFT 11 STAINLESS power ate nte OFF postion po we co mt poe hele sere art Bonent comecei the power pines When te HEFTY 1 STARLESS there mut alte 15 VOC between he ut tri at lh power surce aug sandy and le er unt wll at have ech vago rope A contatos is standard component ofthe HEFTY I STANLESS anf aloes wein we do
17. er Se Thetearag lodo tang evene om he die and the bong iced pec oe an he der gea The and a nen Dive onte talo removing loner pacing the led tal ver Totes ot ge nd secu ih lower pedes forts ed tta a Pelr to Figures 34 and 35 qned guns sme ts special adap may be euro To etal met gun gun amo and rudi gun eee lh The ne gun clamp kr wang uns recta NOTE welding gun the leedheod make ture te my does rot exter e loca wating pun camel ege pon Threading Wire Into Feedhead metr to Figure 35 WARNING ELECTRIC SHOCK KILL Make certain the power source and wire feeder are turned OFF Do not tum the until told to do so in instructions CAUTION Use care when handing the pooled we este tends to un Tav when loosened spo end ire fimi and iai gt om you Make sre hat end ot a wre e and 1 Pic notte welsng wire ito e ie ute reed ough be rd ovr ve llores cases ia 2 Passihe wie guide and one wating gun asse 2 Leek palio he ep tension oc ro ag toe he Ei eed ol o camer o or aee NOTE
18. ill feed electrically hot welding wire f this hot welding wire louches the work piece a ing arc will be established are na mec Aue Te o conet core cn ba ted dig et we 7 sing a CV power source cont the Sowa ice il ai o be ener du eque a aos Tone pone source ora scone powe sura o Ba on ad he power source cer rama proper conection ratings agus Gun sun ewe We Fees a Figure Funcional Timing Diagram WARNING in semiautomatic automatic wire welding welding wire wire reel used input guide feed rolls output jauide feodhoad to Fiore 5 1 1 To dar wel the welding gun aive e dares gun Sch gpa The conl ien eras e gas Va re ec tmd powe arte 2 Toenttewed rens qun aie tiger vhi wang gun avay e work Te Gold site coal han able ia te feed mol power tue recommended wir gun away from the we aang Qui vit Ti alla arci par ily Me work piece with hearing at e ental con tats Using procure of contactor contacts hen weg af ih amperage 3 he work yo hen SNOT sto ard e Wee la o id power tua
19. king wie Wo Soco Range assembly that features quick change gear driven Papo na ru UD ear wanna a li ur obe lean Te HEFTY 11 STAINLESS comes wi abun skin We SRR 004801 inc 9 features wich ESE 1 EI onis acer aun 2 wir teed sped tonta Feed li Bom Gear Dive S ij roe Duy 8 qas vate 7 mode sich Gun Dam SY Nonna Big ceu selen pler Maxim Sting Gs ie Piastre JS PSI icone conta pecia cry o Weipi Lese Wie Satis 725 past undevotge ovenotage CSA NATL ag o a soro e ct met a shed EMA Ewa s rra 224 usc 5 2000 Revised E FeaturesiBenefits E ETT TETTE ET NE ERES penas trot ead Genes en eer raia Ernane performance wih power amoo o even e hows he wang re remain vi ni e qu Su ge 22202277 Cart ono Now o gar Power Permanent DC Dive he speed ightorue demand gemea 11 Beato Consructon tr eg basin over 2 wou rer Frau corpete
20. nance i Mabienanca chap manu esco mote cont board necessary E Wire food motor continues to run after gun switch has been released te hed wing avr aa he e lg gare or replace weg gun Cor a shana gun el receptacle 14 terminal si TB or J1 on the motor cna board esco meter board F No wire feed speed WFS contro on e molar ct pb er unc S 2000 Revised Win input power sped wire tede estu vage ror on bord fam tero sie RIZ erigi id ol R2 See rure 2 Whe vay Tg e e fond pet om inum e volg ecu chang m 025 semear baee 225 575 vage replace he wire eed speed motor cont pe bea necessary Wire feeds but no gas flows Cheek to gas ele is empty or he vale closed Make proper gat Pon rate has been a Check or a pesti n he In qas va Check wein gun nozzle is plugged Check gas valve 1 emia sip 787 plug J on he 12 VDC diver boa plug ani motor col toad lo uy contra anes corde a he gst eee esto coa eos Ar replace he gas vo Jo electronic protection ie may have setae so by placing poser sich opa fr a ss 00 seconds Pesca 12 VOC der noces Gas flows the time or leaks
21. ner tle Spectcalon or unter How To Use This Parts List Pre Numba anda comespendog at ot prs which cortina a reno o he and para Al Bay See Perro ui ach ar wie cab leg tna ci permanent a brancher par dessplons vay be i ered show lores he p number deseo or plan yo e mori corresponding Pare Li February 22000 Revised List for Figure 1 February 2 2000 vised Pate List for Figure 2 This page intentionally lett blanc February 2 2000 Revised DIAGRAMS any hose diagrams and thal are appeal CONNECTION amp MODEL SPECIFICATION schematic SYSTEM FEED ROLL NUMBER DIAGRAM OUTLINE CHART HEFTYI 1000524 970256 171435 STAINLESS NOUSSNNOS
22. rnal Controls And Connections Component Side See 33 or tal 7 COCV MODE SWITCH Tha paso po vies a voltage uta good modo oi pera or so contr cent CC power SBc The CU poston conan we mde apra uso vincent age CV power mode made of opera Je Eye por El pred crc board pirar response agar vue pied ret boars PCB pray oup sped a e mor cad eed e lang veis eat S0 amps or wei curent Dicesdng cumemar duly oj dl ring a or none he GAS VALVE The gat vale contol he ont tow sing gas rough wel on Component Sse usc S 2000 Revised Figure 34 internal Control Connections ire Spot Sie Internal Controls And Connections Wire Spool Side See gue ator a the d can em he power coa tte wie fed Conan oer rigor esta cre NOTE mat comete veis a e let nie ouves p SNR uns seed au Ie we spd ic ata recai rd o dut teca endi ce contra e NCHPURGE SWITCH Dogs ten dee E Cao Sa when ning ste be ea po on Ear gua ow ote e vel pura 212 17 GUN SWITCH RECEPTACLE gun tose sro e wang co Mie dase ne wee
23. ut all connections tah Cheek lor trigo ra nie he q va Mire feeds contactor closes but welding wire is not hot there is no are Make sure al connecian have bee made he power source and ie er sure the cable between he crac and properly conaecid using power mak sue conc has been ened See Procede secon ths manu Replace contactor J Wire feeds contactor does not close and welding wire is not hot there is no Cheek carat kt eins TET and plug an 12 VDC a pe board or or aut connection ie anc acc ton he ei mes he rele replace contato Jo electronic it have scatet ane 5 2000 Revised ag pt Replace e 2 VDC pe noi K Wire does not feed with inch switch depressed Checkinehpure mich S3 nd terminal tip ose connections Check or etc ich purge ste 59 1 Gas does not flow with purge switch depressed Checkirehpure mih 53 nd terminal ose connections Check or etc ste 53 M Meters do not function e melee end ne mo bo bos a ae usc 00 Revised 7s This page intentional let blank June 2800 Revised PARTS LIST Equipment Identification sion ester must furnished when mating nares Te amont usualy nct any dh e
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