DRAGSTER 80 - Victor Technologies
Contents
1. Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publica tion P 1 de la CGA identifi e dans la liste de documents ci dessous Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue Si c est possible laissez le moteur refroidir avant de faire le plein de carburant ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur 8 V 96 PRECAUTIONS DE SECURITE EN SOUDAGE L ARC Instruction 830002 DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avantd installer ou de connecter un syst me arr tez le moteur DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives LA VAPEUR ET LE LIQUIDE DE REFROID2. This page intentionally left blank 2 4 May 8 1996 PRECAUTIONS DE SECURITE EN SOUDAGE L ARC Instruction 830002 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC MISE EN GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NILES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et ne prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite l exp rience pass e Ces pratiques doivent tre apprises par tude ou entra nement avant d utiliser l equipement Toute personne n ayant pas suivi un entra nement intensif en soudage coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 249 1 National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires sui
3. sinon portez un respirateur adduction d air Les gaz protecteurs de soudage peuvent d placer de l air et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respiration Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones souder ont t gratt es fond que sil espace est bien ventil si n cessaire portez un respirateur adduction d air Car ces rev tements et tout m tal qui contient ces l ments peuvent d gager des fum es toxiques au mo ment du soudage 8 V 96 PRECAUTIONS DE SECURITE SOUDAGE L ARC Instruction 830002 LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit o des particules volantes ou des projections peuvent atteindre des mat riau
4. 200 FEET Table 5 1 430429 440 DRAGSTER 80 This page intentionally left blank 5 2 DRAGSTER 80 430429 440 1 Connect the welding leads to the Dragster 80 with the correct polarity Figure 6 1 shows a typical connection for electrodes such as 6013 that require a positive connection This is called DCEP Direct Current Electrode Positive For electrodes that require a nega tive connection DCEN simply switch the ca bles 2 Turn the unit ON Set the Control Knob to the desired output The unit is now ready to weld After the weld is complete turn the unit OFF to remove open circuit voltage from the out put terminals CLOTHING AND GLOVES WARNING ONCE THE UNIT IS TURNED ON THERE WILL BE OPEN CIRCUIT VOLTAGE ON THE OUTPUT TERMINALS OF THE MACHINE TO AVOID ELECTRIC SHOCK DO NOT HANDLE EXPOSED CONDUCTORS ATTACHED TO THE POWER SOURCE TERMINALS WITHOUT PROPER PROTECTIVE Figure 6 1 RECOMMENDED ELECTRODE 6013 3 32 DIA 6 1 430429 440 DRAGSTER 80 This page intentionally left blank 6 2 DRAGSTER 80 430429 440 TROUBLESHOOTING WARNING DISCONNECT THE INPUT POWER CORD BEFORE CARRYING OUT ANY SERVICE OR REPAIR WORK HAZARDOUS VOLTAGES ARE PRESENT IN THE MACHINE WHENEVER INPUT POWER IS CONNECTED WARNING ALL SERVICE SHOULD BE PERFORMED BY TRAINED PER S
5. com pletely covers the CONNECTOR such that when the CONNECTOR is attached to the Dragster 80 there is no exposed metal at the joint Set Screw Brass Connector Insulator 95 Rolled Up Pd lt Copper Strip Figure 4 1 430429 440 DRAGSTER 80 Electrode Holder 3 Tighten the SET SCREW down against the LUG LUG should be positioned so when The Electrode Holder goes on the 15 Ft cable SET SCREW is tightened it will engage into on the end that has a lug crimped on it see Fig ure 4 2 the crimping indentation on the LUG 4 Align the SMALL HOLE in the PLASTI 1 Slip the PLASTIC HOUSING supplied with Sorc aE Ge ce ene fe ae ELECTRODE HOLDER onto PLASTIC HOUSING onto the ELECTRODE HOLDER until it snaps locks into position 2 Insert the lugged end of the CABLE into the ELECTRODE HOLDER Plastic Housing Small Hole Cable Lug Set Screw Snap Pin Electrode Holder Figure 4 2 4 2 DRAGSTER 80 430429 440 Carry Strap Figure 4 3 shows how to attach the carry strap WARNING DO NOT OPERATE THIS UNIT WHILE CARRYING IT ALWAYS PLACE THE UNIT ON THE GROUND OR OTHER SOLID STRUCTURE BE FORE OPERATING NOTE The carry strap is only intended to aid in transporting the unit from job to job Make sure the strap kept clear from the unit while operating it Never operate the unit while holding it Read and understand all warnings in this manual THREAD T
6. de s curit approuv es Des crans lat raux BRULER LES YEUX ET LA PEAU LE sont recommand s BRUIT PEUT ENDOMMAGER L OUIE Entourez l aire de soudage de rideaux ou de cloisons pour prot ger les autres des coups d arc ou de l blouissement L arc de soudage produit une chaleur et des avertissez les observateurs de ne pas regarder l arc rayons ultraviolets intenses susc ptib es de Portez des v tements en mat riaux ignifuges et durables laine br ler les yeux et la peau Le bruit caus par i TAUL et cuir des chaussures de s curit certains proc d s peut endommager RES 7 5 Portez un casque antibruit ou des bouchons d oreille approuv s 1 Portez une casque de soudeur avec filtre oculaire de nuance lorsque le niveau de bruit est lev appropri e consultez la norme ANSI Z49 indiqu e ci apr s 8 V 96 2 5 1 2 3 4 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Instruction 830002 SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE selon AWS A 8 2 73 Op ration Coupage ou soudage Brasage tendre au chalumeau Brasage fort au chalumeau Oxycoupage mince moyen pais Soudage aux gaz mince moyen pais Soudage a avec electrode enrob es SMAW Soudage sous gaz avec fil plein GMAW m taux non ferreux m taux ferreux Soudage sous gaz avec lectrode de tungst ne GTAW So
7. receptacle CAUTION Consult nameplate for proper input voltage and input amper age The method of installation conduc tor size and overcurrent protection shall conform to the requirements of the local electrical code All installation wir ing and machine connection shall be done by a competent electrician The National Electrical Code Article 630B 1984 Edition provides standards for amperage han dling capability of supply conductors based on the duty cycle of the welding power source This unit has a 10 duty cycle 1 minute of every 10 minutes can be used for welding therefore the cord supplied with this unit complies with these standards Ensure that the building supply and receptacle comply with NEC standards and any additional state and local codes NOTE The supply wiring for the welding power source must be capable of handling a minimum of 20 amps The welding power source must be the only load connected to the supply circuit Poor unit performance or frequently opening line fuses or circuit breakers can result from an inadequate or improper supply NOTE Use Table 5 1 for selection of the minimum wire size for extension cords CAUTION Do not connect the DRAGSTER 80 to an input power supply with a rated voltage that is greater than 125 volts WARNING Do not remove the power cord ground prong SE LENGTH OF EXTENSION CORD IZE 4 50 FEET OR LESS 12 50 FEET
8. DRAGSTER 80 80Amp Inverter Power Source For the Following Specs 100040 1 THERMAL THERMADYNE Company RECOMMENDED 6013 3 32 DIA OWNER S MANUAL Number 430429 440 Rev AA Revised November 29 1999 THERMAL ARC INC TROY OHIO 45373 1085 U S A DRAGSTER 80 430429 440 TABLE OF CONTENTS INTRODUCTION How To Use This Manual Equipment Identification Receipt Of Equipment ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS PRECAUTIONS DE SECURITE EN SOUDAGE L ARC DESCRIPTION OF EQUIPMENT SR hus ites ar annuos festa Bek fautes d Ratings uic E A ete a Aa 4n ae Y ASSEMBLY Twist Lock Electrode Holder 5 2 a Jus EA LEER WAGE GA eee tae sas a Evo a DCN ar de e ote es eae INSTALLATION Gro nding iv oe de he de lve dp ede be dL Re ped Electrical Input Requirements OPERATION TROUBLESHOOTING Troubleshooting guide PARTS LIST DIAGRAMS STATEMENT OF WARRANTY 8 1 8 1 10 430429 440 DRAGSTER 80 This page intentionally left
9. HRU SLOTS IN EACH END OF WRAPPER sp Figure 4 3 4 3 430429 440 DRAGSTER 80 This page intentionally left blank 4 4 DRAGSTER 80 430429 440 INSTALLATION Location For best operating characteristics and longest unit life take care in selecting an installation site Avoid locations exposed to high humidity dust high ambient temperature or corrosive fumes Moisture can condense on electrical compo nents causing corrosion or shorting of circuits Dirt on components helps retain this moisture and also increases wear on moving parts Adequate air circulation is needed at all times in order to assure proper operation Provide a mini mum of 12 inches 305 mm of free air space at front rear and sides of the unit Make sure that the ventilator openings are not obstructed Safety Refer to additional installation instructions under the SAFETY INSTRUCTIONS AND WARNINGS chapter included in this manual Grounding The internal frame of this welding machine is grounded for personnel safety Where grounding is mandatory under state or local codes it is the responsibility of the user to comply with all cable rules and regulations Where no state or lo cal codes exist it is recommended that the National Electrical Code be followed Electrical Input Requirements Plug the input cord into a properly grounded and protected fuse or circuit breaker 115 V AC 20 amp
10. ISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression Seules des personnes qualifi es doivent d monter des protecteurs ou des capots pour faire l entretien ou le d pannage n cessaire Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative N approchez pas les mains ou les cheveux de pi ces en mouvement elles peuvent aussi accrocher des v tements amples et des outils R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur Portez toujours un cran facial en travaillant sur un accumu lateur Arr tez le moteur avant de connecter ou de d connecter des cables d accumulateur N utilisez que des outils anti tincelles pour travailler sur un accumulateur 4 N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi Mettez des gants et posez un torchon sur le bouchon pour l ter Laissez la pression s chapper avant d ter compl tement le bouchon PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting norme ANSI 249 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Stand
11. ONNEL ONLY WARNING HAZARDOUS VOLTAGES MAY BE PRESENT INSIDE THIS MA CHINE FOR SEVERAL MINUTES AFTER POWER IS REMOVED WAIT 10 MIN UTES AFTER REMOVING POWER BEFORE REMOVING COVER NEVER OPERATE WITH THE COVER REMOVED Troubleshooting guide On Off switch light does not come on Unit unplugged Blown fuse or tripped breaker Make sure the proper size fuse or breaker is being used OVERTEMPERATURE LIGHT comes on Unit has overheated Let the unit cool down for at least 10 minutes Turn power off and back on Overtemperature light should then go off Observe cycle rating Erratic weld output Check all connections Check ground clamp connection to workpiece Check electrode connection in electrode holder Check twist lock connections to unit Check all cable connections Low open circuit voltage Line voltage too low Wrong size extension cord See Table 5 1 7 1 430429 440 DRAGSTER 80 This page intentionally left blank 7 2 DRAGSTER 80 430429 440 PARTS LIST Equipment Identification All identification numbers as described in the In troduction chapter must be furnished when or dering parts or making inquiries This information is usually found on the nameplate attached to the equipment Be sure to include any dash numbers following the Specification or Assembly num bers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and
12. TION SCHEMATIC NUMBER DIAGRAM DRAGSTER 100040 1 830579 430429 440 DRAGSTER 80 This page intentionally left blank 9 8 ZZ M3EADN _7 NOLWOOT Lava OMM Avuovia eee Ordres ANIS 1V3H OL LNdNI m IM HOLIMS 440 NO NIS LV3H ANNONS avoa 93N ANIS NOLLOANNOO SIVNINYIL Od 430429 440 DRAGSTER 80 This page intentionally left blank 9 10 DRAGSTER 80 430429 440 STATEMENT OF WARRANTY LIMITED WARRANTY Thermal Arc Inc Thermadyne Company warrants that its products will be free of defects workman ship or material Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed oper ated and maintained in accordance with Thermal Arc s specifications instructions recommendations and recognized standard in dustry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal Arc s sole opt
13. Turns the Dragster 80 on and off When on the switch will be lit up lock connectors allow for easy connection of the welding cables For most applications Such as 6013 electrodes the ground cable attaches to the terminal and the electrode cable attaches to the terminal To install cables simply insert the male connector into the female and twist clockwise until it tightens into place about 1 2 turn Overtemperature Light Switch Control 1 Knob RECOMMENDED ELECTRODE 6013 3 32 DIA 25mm Female Twist Lock Connectors p Figure 3 1 3 1 430429 440 DRAGSTER 80 This page intentionally left blank 3 2 DRAGSTER 80 430429 440 ASSEMBLY Twist Lock Connectors Assemble the male twist lock connectors to both the 10 Ft ground and 15 Ft electrode cables as follows see Figure 4 1 1 Slip the RUBBER INSULATOR onto the ca ble as shown 2 Wrap the piece of COPPER STRIP around a small rod such as a pencil then insert it into the end of the BRASS CONNECTOR 3 Remove the 3 4 in cut piece of insulation from the end of the cable Rubber d d Weld Cable Insert the stripped end of cable into the BRASS CONNECTOR making sure it is also inside the rolled up COPPER STRIP 5 Tighten the SET SCREW 6 Push the RUBBER INSULATOR over the BRASS CONNECTOR Make sure it
14. UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON AUTHORIZED PERSONS Except with regards to the products listed below this warranty shall remain effective three 3 years from the date Thermal Arc s au thorized distributor delivers the product to Purchaser but in no event more than 4 years from the date Thermal Arc delivers the product to the authorized distributor Shorter warranty periods apply to the products listed below On these products the warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser Notwithstanding the foregoing in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor PARTS LABOR DRAGSTER 80 POWER MAGNETICS 1 YEAR DRAGSTER 80 INPUT POWER RECTIFIER 1 YEAR DRAGSTER 80 PC BOARD 1 YEAR DRAGSTER 80 ALL OTHER CIRCUITS AND COMPONENTS 1 YEAR ELECTRODE HOLDER AND LEADS 180 DAYS REPAIR REPLACEMENT PARTS 90 DAYS Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc repair facility within thirty 30 days of the purchaser s notice of a warranty claim No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the p
15. a corresponding list of parts which contains a breakdown of the equipment into assemblies subassemblies and detail parts All parts of the equipment are listed except for commercially available hardware bulk items such as wire cable sleeving tubing etc and permanently attached items which are soldered riveted or welded to another part The part de scriptions may be indented to show part relation ships To determine the part number description quantity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item in the Parts List applies to all Specifications or As semblies the word ALL will be in the Applica tion Code column Refer to the following list to determine the appropriate Application Codes for the Specifications or Assemblies covered by this manual If only the assembly or specification number is listed the use of an Application Code does not apply to this manual SPECIFICATION NUMBER 100040 1 430429 440 DRAGSTER 80 Figure 8 1 8 2 DRAGSTER 80 430429 440 Item No Part Number 100040 1 830558 830561 830543 Parts List for Figure 8 1 Description Dragster 80 Strap Carry La
16. ards OSHA 29 CFR 1910 Superintendent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances Safe Handling of Compressed Gases in Cylinders document P 1 Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting norme CSA W117 2 Associ ation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protec norme AWS F4 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 tion norme ANSI Z87 1 American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme 51B NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 8 V 96 DRAGSTER 80 430429 440 DESCRIPTION OF EQUIPMENT General The Thermal Arc Dragster 80 is a light weight easy to use 80 amp stick electrode SMAW welder It is designed for welding thin gauge 1 8 in or less mild and stainless steels It comes standard with the following 10 Ft workpiece ground cable and clamp 15 Ft electrode cable brand el
17. bel Warning Wrapper Qty per Assy 8 3 DRAGSTER 80 430429 440 12 7 13 IHERMAL MOUNTED ON OPPOSITE HEATSINK RECOMMENDED ELECTRODE 6013 3 32 DIA 14 Figure 8 2 8 4 DRAGSTER 80 430429 440 Item No Parts List for Figure 8 2 Part Number 100040 1 375432 18 TRY 119 14 830629 830630 409554 2 830631 830545 204600 1 830567 203300 3 830484 2 10 6127 830562 830542 10 6128 830556 830559 Not Illustrated Description Dragster 80 Cord Power Bushing Strain Relief Package Fan Thermostat Bridge Diode Package Choke Potentiometer Spacer Knob LED Yellow W Lens Switch ON OFF Connector Female Foot Rubber Base Connector Male Cables Weld Output Clamp Electrode Holder Qty per Assy N A PP HAH H H KH KH Ss et Includes Electrode Cable And Work Cable With Ground Clamp 8 5 430429 440 DRAGSTER 80 This page intentionally left blank 8 6 DRAGSTER 80 430429 440 DIAGRAMS e Note the model and specification number shown on the equipment nameplate e Locate these numbers in the model and specification num ber columns below e Use only those diagrams and instructions that are applica ble CONNECTION amp MODEL SPECIFICA
18. blank DRAGSTER 80 430429 440 INTRODUCTION How To Use This Manual This Owner s Manual applies to the specification or part numbers listed on the cover To ensure safe operation read the entire man ual including the chapter on safety instructions and warnings Throughout this manual the word WARNING CAUTION and NOTE may appear Pay particu lar attention to the information provided under these headings These special annotations are easily recognized as follows WARNING A procedure which if not properly followed may cause injury to the operator or others in the operating area Warnings will be enclosed in a box such as this CAUTION A procedure which if not properly followed may cause damage to the equipment Cautions will be shown in bold type NOTE An operation procedure or back ground information which requires addi tional emphasis or is helpful in efficient operation of the system Notes will be shown in italics Equipment Identification The unit s identification number specification or part number model and serial number usually appear on anameplate attached to the machine Equipment which does not have a nameplate at tached to the machine is identified only by the specification or part number printed on the ship ping container Record these numbers for future reference Receipt Of Equipment When you receive the equipment check it against the invoice to ma
19. ectrode holder 2 25mm twist lock male connectors 5 Ft carrying strap Sample pack of Thermal Arc 3 32 in 6013 elec trodes Rating Table 3 1 shows the input and output ratings Input 115 VAC 60 Hz 1 Phase Maximum Open Circuit Voltage 50 VDC CSA 60974 Ratings Ratings Duty Cycle 100 60 10 20 Input Current 15 19 32 19 Output Amps 40 50 80 60 WARNING WHEN THE UNIT IS TURNED ON THERE WILL BE OPEN CIRCUIT VOLTAGE ON THE OUTPUT TERMINALS OF THE MACHINE TO AVOID ELECTRIC SHOCK DO NOT HANDLE EXPOSED CONDUC TORS ATTACHED TO THE POWER SOURCE TERMINALS WITHOUT PROPER PROTEC TIVE CLOTHING AND GLOVES OUTPUT TERMINALS These 25mm twist Output Volts 21 6 22 0 23 2 18 Refer to Figure 3 1 for the following descriptions CONTROL KNOB This knob controls the welding output current The current can be varied from approximately 10 amps setting 1 to 80 amps setting 8 1 16 inch rods should use a set ting of around 4 40 amps 3 32 inch rods around 6 60 amps OVERTEMPERATURE LIGHT This light will come on if the duty cycle of the machine is ex ceeded and overheats it If the light comes on it will turn off the welding circuit but leave the fan on The unit must be allowed to cool for at least 10 minutes The welding circuit will remain off un til the ON OFF switch is turned off then back on ON OFF SWITCH
20. equipment Anyone not having extensive training in welding and cutting practices should not attempt to weld Certain of the practices apply to equipment connected to power lines other practices apply to engine driven equipment Safe practices are outlined in the American National Standard Z49 1 entitled SAFETY IN WELDING AND CUTTING This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions HAVE ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or auto matic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or im properly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers Disconnect input power or stop engine before installing or servic ing this equipment Lock input power disconnect switch open or remove line fuses so power cannot be turned on accidentally Properly install and g
21. fingers and hands and catch SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Batteries contain acid and generate explosive gases STEAM AND PRESSURIZED HOT COOLANT can burn face eyes and skin The coolant in the radiator can be very hot and under pressure not fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only qualified people remove guards or covers for mainte nance and troubleshooting as necessary Toprevent accidental starting during servicing disconnect nega tive battery cable from battery Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Do not remove radiator cap when engine is hot Allow engine to cool Wear gloves and put a rag over cap area when removing cap Allow pressure to escape before completely removing cap WARNING This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State
22. ilisez qu une bonne prise de masse pour la mise la terre quipement inad quatement install ou de la pi ce souder inad quatement mis la terre est dangereux Ne touchez pas l lectrode lorsqu en contact avec le circuit de Ne touchez pas des pi ces sous tension soudage terre Portez des gants et des v tements isolants secs et non trou s N utilisez que des quipements en bon tat R parez ou Isolez vous de la pi ce souder et de la mise la terre au moyen remplacez aussit t les pi ces endommag es de tapis isolants ou autres Dans des espaces confin s ou mouill s n utilisez pas de source D connectez la prise d alimentation de ou arr tez de courant alternatif moins qu il soit muni d un r ducteur de le moteur avant de l installer ou d en faire l entretien Bloquez le tension Utilisez plut t une source de courant continu commutateur en circuit ouvert ou enlevez les fusibles de Portez un harnais de s curit si vous travaillez en hauteur l alimentation afin d viter une mise en marche accidentelle Fermez solidement tous les panneaux et les capots Veuillez installer cet quipement et le mettre la terre selon le manuel d utilisation et les codes nationaux provinciaux et locaux applicables pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure LE RAYONNEMENT DE L ARC PEUT Portez des lunettes
23. ion of any components or parts of the product determined by Thermal Arc to be defective THERMAL ARC MAKES NO OTHER WARRANTY EXPRESS OR IMPLIED THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PAR TICULAR PURPOSE LIMITATION OF LIABILITY Thermal Arc shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customers of distributor hereinafter Pur chaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with re spect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal Arc whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based No employee agent or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS
24. ion by chaining them to a stationary support or equipment cylinder rack to pre vent falling or tipping amp WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases Read the Material Safety Data Sheets MSDSs and the manu facturer s instruction for metals consumables coatings and cleaners Workin a confined space only if it is well ventilated or while wear ing an air supplied respirator Shielding gases used for welding can displace air causing injury or death Be sure the breathing air is safe Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cad mium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals contain ing these elements can give off toxic fumes if welded Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums Connect work cable to the work as close to the welding area as practical to p
25. ke sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to file a claim Furnish com plete information concerning damage claims or shipping errors to Thermal Arc Order Depart ment 2200 Corporate Drive Troy Ohio 45373 1085 Include all equipment identification numbers as described above along with a full de scription of the parts in error Additional copies of this manual may be pur chased by contacting Thermal Arc at the address given above Include the Owner s Manual num ber and equipment identification numbers 430429 440 DRAGSTER 80 This page intentionally left blank 1 2 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUCTIONS READ OPERATING INSTRUC TION MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS EQUIPMENT Welding products and welding processes can cause serious injury or death or damage to other equipment or property if the operator does not strictly observe all safety rules and take precautionary actions Safe practices have developed from past experience in the use of welding and cutting These practices must be learned through study and train ing before using this
26. of California to cause birth defects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq NOTE Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 63 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments atthe cellular level and from studies with animals and peo ple which clearly establish that low frequency magnetic fields can interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single co herent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear sci ence based advice on strategies to minimize or avoid potential risks To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator About Pacemakers 3 Do not coil or drape cables around the body 4 Keep welding power source and cable
27. on 830001 FUMES AND GASES can be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to move welding fumes and gases If ventilation is poor use an approved air supplied respirator WELDING can cause fire or explosion Sparks and spatter fly off from the welding arc The flying sparks and hot metal weld spatter hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers FLYING SPARKS AND HOT METAL can cause injury Chipping and grinding cause flying metal As welds cool they can throw off slag CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pres sure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully 1 Protect compressed gas cylinders from excessive heat mechan ical shocks and arcs 2 Install and secure cylinders in an upright posit
28. pproved safety glasses Side shields recommended Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc Wear protective clothing made from durable flame resistant ma terial wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high Eye protection filter shade selector for welding or cutting goggles or helmet from AWS A6 2 73 Electrode Size Filter Electrode Size ilter Welding or Cutting Metal Thickness Shade Welding or Cutting Metal Thickness Shad Operation or Welding Current No Operation or Welding Current e No Torch soldering 2 Gas metal arc welding MIG Torch brazing 3or4 Non ferrous base metal All 11 Oxygen cutting Ferrous base metal All 12 Light Under 1 in 25 mm 3or4 Gas tungsten arc welding All 12 Medium 110 6 in 25 150 mm 40r 5 TIG All 12 Heavy Over 6 in 150 mm 5or6 Atomic hydrogen welding All 12 Gas welding Carbon arc welding All 12 Light Under 1 8 in 3 mm 4 0 5 Plasma arc welding Medium 1 8 to 1 2 in 3 12 mm 50r 6 Carbon arc air gouging 12 Heavy Over 1 2 in 12 mm 60r8 Light 14 Shielded metal arc welding Under 5 32 in 4 mm 10 Heavy stick electrodes 5 32 to 1 4 in 4 to 6 4 mm 12 Plasma arc cutting Under 300 Amp Over 1 4 in 6 4 mm 14 Light 300 to 400 Amp 9 Medium Over 400 Amp 12 Heavy 14 2 1 May 8 1996 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instructi
29. revent welding current from traveling long possibly unknown paths and causing electric shock and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at con tact tip when not in use Wear approved face shield or safety goggles Side shields rec ommended Wear proper body protection to protect skin Keep cylindersaway from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders asso ciated equipment and CGA publication P 1 listed in Safety Stan dards ENGINES can be hazardous 1 Use equipment outside in open well ventilated areas 2 If used in a closed area vent engine exhaust outside and away from any building air intakes May 8 1996 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ENGINE FUEL can cause fire or explosion Engine fuel is highly flammable 1 Stop engine before checking or adding fuel MOVING PARTS can cause injury Moving parts such as fans rotors and belts can cut
30. round this equipment according to its Owner s Manual and national state and local codes ARC RAYS can burn eyes and skin NOISE can damage hearing Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin Noise from some processes can damage hearing Turn off all equipment when in use Disconnect power to equipment if it will be left unattended or out of service Use fully insulated electrode holders Never dip holder in water to cool it or lay it down on the ground or the work surface Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode Do not use worn damaged undersized or poorly spliced cables Do not wrap cables around your body Ground the workpiece to a good electrical earth ground Do not touch electrode while in contact with the work ground cir cuit Use only well maintained equipment Repair or replace damaged parts at once In confined spaces or damp locations do not use a welder with AC output unless it is equipped with a voltage reducer Use equipment with DC output Wear a safety harness to prevent falling if working above floor level Keep all panels and covers securely in place Wear a welding helmet fitted with a proper shade of filter see ANSI 249 1 listed in Safety Standards to protect your face and eyes when welding or watching Wear a
31. s as far away from body as practical PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances Amer ican Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Pro tection Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis High way Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Protec tion ANSI Standard 287 1 from American National Standards Insti tute 1430 Broadway New York NY 10018 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 May 8 1996 2 3 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001
32. s bouteilles endommag es peuvent exploser Comme les bouteilles font normalement partie du proc d de soudage traitez les avec soin Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support ou un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage MISE EN GARDE LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau de carburant ou de faire le plein Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s Portez des v tements appropri s pour prot ger la peau Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation
33. udage l hydrog ne atomique AHW Soudage avec lectrode de carbone Soudage l arc Plasma PAW Gougeage Air Arc avec lectrode de carbone mince pais Coupage Plasma PAC mince moyen pais LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses a respirer Eloignez la t te des fum es pour viter de les respirer A l int rieur assurez vous que l aire de soudage est bien ventil e ou que les fum es et les vapeurs sont aspir es l arc Si la ventilation est inadequate portez un respirateur adduction d air approuv Lisez les fiches signal tiques et les consignes du fabricant rela tives aux m taux aux produits consummables aux rev tements et aux produits nettoyants Dimension d lectrode ou de Epaisseur de m tal ou Intensit de courant toutes conditions toutes conditions moins de 1 po 25 mm de 1 6 po 25 150 mm plus de 6 po 150 mm moins de 1 8 po 3 mm de 1 8 1 2 po 3 12 mm plus de 1 2 po 12 mm moins de 5 32 po 4 mm de 5 32 1 4 po 4 6 4 mm plus de 1 4 po 6 4 mm toutes conditions toutes conditions toutes conditions toutes conditions toutes conditions toutes dimensions moins de 300 amp res de 300 400 amp res plus de 400 amp res Nuance de de filtre oculaire 5 Ne travaillez dans un espace confin que s il est bien ventil
34. urchaser All returned goods shall be at the purchaser s risk and expense This warranty supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermadyne Industries Inc Effective January 1 1999 10 1
35. vre Ce document ainsi que d autres guides que vous devriez connaitre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN ET D ESSAI L ELECTROCUTION PEUT ETRE 6 Arr tez tout quipement apr s usage Coupez l alimentation de MORTELLE l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser trainer par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de courant en m me temps Ne jamais toucher quelqu un d autre avec l lectrode ou le porte lectrode Une d charge lectrique peut tuer ou br ler gravement L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimentation et les circuits internes de l quipement sont aussi sous tension d s la mise en marche En soudage automatique ou A semi automatique avec fil ce dernier le rouleau ou N utilisez pas de cables lectriques us s endommag s mal la bobine de fil le logement des galets piss s ou de section trop petite d entrainement et toutes les pi ces m talliques en pas de cables lectriques autour de votre corps contact avec le fil de soudage sont sous tension Un N ut
36. x inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir ou un baril Connectez le c ble de soudage le plus pr s possible de la zone de soudage pour emp cher le courant de suivre un long parcours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube contact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et un casque Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de LES ETINCELLES ET LES PROJEC laitier TIONS BRULANTES PEUVENT CAUSER DES BLESSURES LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER Les bouteilles contiennent des gaz protecteurs sous haute pression De
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