Home

MEGA-ARC 5040DD 400 Amp Constant Current Diesel Engine

1. Figure 7 1 Control P C Board TEST TEST POINTS CALLOUTS VOLTAGE CONDITIONS REMARKS 1 TP N to TP E 2013 40 0 21 0 1800 RPM Idle No Load 2 TP M to TP E 14 to 13 40 0 21 0 1800 RPM Idle No Load 3 TP C to TP E 3 to 13 420 0 1800 or Idle No Load 4 TP D to TP E 12 to 13 20 0 1800 or Idle No Load 5 TP A to TP E 4 to 13 415 0 1800 or Idle No Load 6 to TP E 11 to 13 15 0 1800 or Idle No Load 7 TP F to TP E 51013 4 3 1800 or Idle No Load TP G to TP E 71013 4 3 1800 or Idle No Load TP H to TP E 9 to 13 4 3 1800 or Idle No Load 8 TP J to TP E 6 to 13 18 3 1800 or Idle No Load to
2. RUN ji ae udo N li L mr INAS pe JNN NI 9 HOLIMS MS 03395 0334 gt LIM 390309 3101 1431 A Qu LT 40103 ZUM 3NON 6 Cc L vo 32s NAVYA M38WnN NOUVOO 159 TONLNOD 31039 YIYO MIO IQ NOIL23NNOO 1OMINOO 1324 Wanivn 519 wo ANTANO wenva OMAN AB MTU ANEW 3NON 100008 333 3009 HSINIJ ms jo end 56 6 si VIS 21 40018 IVNINYIL zal VIS 9 018 IWNINUIL 181 1041 HOLIMS cs 1041 HOLIMS zs 1545 5 15 HS MZ HILINOUNILOd 01u 6H 1 HOISIS3H eu Nid 9 ION3HdAY 310v1d323H er WIS 310V1d323H ONISNOH cr VIS 310V1d303H INISNOH er VIS 6 119VId3934 INISNOH ir MOTA 1SVJ OOV dWv 3SN4 83 63 GN3937 er GYVO8 Od 108109 NNN NNN Mmmm m M STATEMENT OF WARRANTY LIMITED WARRANTY Thermal Thermadyne Company warrants that its products will be free of defects workmanship or material Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc pro
3. LNGINO M3TI34 AG W3MOd 20 01 0331939 SI YOLVYINIO ONITTIM IHL JO IndinO IML 710v143238 ONY ASI OL M3 0d 5319415 IHL STY DNIADOA3N NO4 20 01 9 30 1 39Y110 2v FL SAMIM 149 1340234 19048 3000 5 SI HALDI WOLYW3N3D NOWVY3IdO 30 XOA OF 41915 SONY dris VOHINOD IGAL 015 HOLOWINOD LOAL HOLMS HILMS 3ONYM 3055344405 39403 SHY MILIKOILNILOd TOHINOD LNQMMnO 015153 140 1NNHS YILIN INDMS Y2Y80334 SEL 05 HOISISIH QYO134d S SmHO 05 SHOLSIS3H HIOBNNS 190 140 waramnv IHOHO NIINA YOYINI Mix Mid 9 TONIHANV T0V143238 W3 od Xnv Aoct ATUNO XAV stt 5M0123NN02 QNYOGS 1INDHO 3504 ONVOB IMNO 310234 1NdINO HITTI ws 30010 390nm 341234 NNI LINOVI SYO1DYAVI NOISS3HddnS 3SION JOOP Q3m SHOLIOYdYO MWigenNs 54 0 UNF V9 55 OT TITVEd 4 640 UVF r JOHINOD 310W3H 1NOHIM 004 WHINOI 40 SNOLIINNOI YSN ORO JAM JO 1331 30 3AO8V LC unja subo yim od Jo soya perso perpuder pado 0
4. 400 Amps Voltage 40 Volts Voltage open circuit max 75 Volts Duty Cycle rated 100 Current Range 20 250 M kaisa er A High Range 40 to 500 A Operating Speed See Engine Data Engine Make and model Deutz F3L 912D Types res eae Industrial diesel Displacement 172 5 cu in 2826 cm Brake horsepowet 41 BHP 9 1800 RPM Oil sump 9 1 2 quarts 9 liters Fuel tank capacity 17 gallons U S 64 4 liters Weight dry 595 pounds 270 kg Normal operating RPM 1800 RPM Dimensions and Weight See Figure 4 1 Width doors closed 28 inches 711 mm Width doors open 78 inches 1981 mm Length 61 1 2 inches 1562 mm Height top of canopy 40 inches 1016 mm Height over muffler TOS 47 1 2 inches 1207 mm Weight shipping m OON approx 1600 pounds 726 kg December 1 1997 Revised 3 1 430429 245 DESCRIPTION OF EQUIPMENT Range Selector Switch Current Control Arc Force Ampere Control 19 Amp Circuit Breakers Voltmeter Optional ER CERE Ammeter emm Control
5. 5 GSE e 140 perpe INWA NIONIS 39nv9 3UNSS3Yd R ans 710 YILINYNOH 2 140 Nona _ 5 e INVIS e qana CS GION310S 4 30435 HOLIMS 1H9n 1Hon 5 34055354 10 YOLVNYSLIV iU 3 1138 M eru cte NMOGLAHS NOILO310Md ANIONS TWNOILdO 3515535 Ayauya E TH 110A i nny Y 4815 ces HOLMS y d Le GION310S ME acis AVT34 E NMOGLNHS 5 HOLIMS 8 Oy 3OVHVIUS 8nd LS 133HS 261767 335 8 HOLIMS EELE ETTI EF E 1411 56 JAOBV REA To VUE uo TE ux d ISSN 1uvd EE C EID RUE wz 1 3015 WONJ GaMGIA SV ee 7 T dA N9 902 op P pe r 98 10 3sn4 sell KS TANI 602 i a dION310S noj 32195 us d3TVISNI ANOLIVA GALIINNOISI 1 MONIS JAUS NI ya Soc 8 SSH EM SES zc a Pi i 109 mr l o
6. 250 Volt Receptacle 115 Volt Door lt Fuel Gauge do Engine Hour Meter Contactor Control Remote awiteh Control Receptacle Figure 3 1 Supplementary Materials A copy of the instruction manual for Deutz F3L 912D Diesel Engines is included with each welding generator unit Additional copies may be obtained from the manufacturer Order from Deutz Corporation 7585 Ponce de Leon Circle Atlanta Gow 30340 U S A Engine Controls and Instruments Ignition Switch The diesel engine starting motor is actuated by this switch located in the lower right hand corner of the control panel Do NOT crank the engine for more than 30 seconds at atime as this may cause the starting motor to overheat Allow motor to cool before attempting to start the engine again Place switch in START position to start and return to RUN position after the engine Oil Pressure ight Receptacle Current Control Switch Alternator Ignition Pull Out To Light Switch Stop Control Panel has started When engine is shut down place switch in OFF position NOTE Switch must be in OFF position to avoid lighting the Alternator and Oil Pres sure light Pull To Stop Control This control shuts the diesel fuel supply off to the engine to accomplish normal shutdown Allow the spring loaded handle to return to the IN position after engine stops Oil Pressure Light Glows red when oil pres sure d
7. 2 If swallowed give large volumes of water DO NOT induce vomiting obtain medical treatment Eyewash and shower stations should be made available 3 Steps to be Taken in Case Material is Released or Spilled Dilute spill cautiously with five to six volumes of water and gradually neutralize with sodium bicarbonate soda ash or lime When exposure level is not known wear NIOSH approved positive pressure self contained breathing apparatus Reference DOT UN2796 Waste Disposal Method Neutralize and dispose in accordance with local state and federal regulations Precautions to be Taken in Handling and Storing Store away from reactive material as defined in Section V Reactivity Data Other Precautions Sodium bicarbonate soda ash sand or lime should be kept in same general area for emergency use Respiratory Protection Specific Type Acid gas respirator required when PEL is exceeded or employee witnesses respiratory irritation See Section VI Health Hazard Data Ventilation When PEL is exceeded Mechanical general Local exhaust preferred Special Other Adequate ventilation to maintain exposure concentrations below the PEL Protective Gloves acid resistant for example rubber Eye Protection Mandatory during handling and transfer of acid recommend chemical goggles Other Protective Clothing or Equipment acid resistant aprons boots protective clothing
8. This Owner s Manual usually applies to just the underlined specification or part numbers listed on the cover If none are underlined they are all cov ered by this manual Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily rec ognized as follows WARNING gives information re garding possible personal in jury Warnings will be enclosed in a box such as this CAUTION refers to possible equipment damage Cautions will be shown in bold type NOTE offers helpful information concern ing certain operating procedures Notes will be shown in italics Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be at tached to the rear panel Equipment which does not have a control panel such as gun and cable assem blies are identified only by the specification or part number printed on the shipping container Record these numbers for future reference Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immedi ately to file a claim Furnish complete information conc
9. American Welding Society 550 LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA National Fire Protection Association Batterymarch Park Quincy MA 02269 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 Asso ciation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Pro tection 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 2 4 8 V 96 430429 245 DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT Generator The Mega Arc 5040DD diesel engine driven arc welding machine is a self contained unit mounted on a welded steel frame The unit is covered by a sheet metal canopy bolted directly to the frame The control panel is at the back generator end of the unit The welding generator and auxiliary exciter gen erator revolving fields are mounted on a single heavy duty shaft supported by a ball bearing at the exciter end of the shaft and by the engine coupling at the other end The welding generator is 400 ampere 3 phase wye connected rec
10. Check oil pressure with engine running at rated RPM 1800 RPM Do not operate engine if oil pressure light stays ON Wipe accumulated water off all electrical connec tions and instruments Make sure that the alternator light is not glowing which indicates battery is being fully charged Every Week wipe accumulated dust dirt and oil off from the engine and generator Check all parts for looseness and wear If arcing has occurred at any electrical connection recondition it and se curely refasten Check engine oil level Every Month blow out generator windings with compressed air not over 25 psi 172 kPa pressure or remove with a suction type cleaner with a non metallic nozzle If windings should become slightly damp use space heaters or electric light bulbs to effectively dry out the windings If dampness is excessive apply external heat under a canvas cover well vented Heating should not exceed 194 F 90 C Pound out any dents in the canopy Sand prime or repaint any dented or rusted spots Lubrication Engine Consult Deutz Instruction Manual Exciter Auxiliary Brushes See Figure 6 1 1 Disconnect leads A from connectors on brush holder caps B CAUTION When removing the lead wires do so one at a time and replace each brush accordingly to insure that the lead wires are put back onto the proper brushes 2 Lift brush D from brushholder C for inspec tion If brushes are worn unevenly or
11. See Deutz Instruction Manual for F3L 912 engine Detailed Troubleshooting Instructions The Mega Arc 5040DD machines are solid state welding machines The method of troubleshooting is different but it is not more difficult than trou bleshooting a conventional unit Do not overlook the obvious As in the case of all electrical equipment loose connections are the primary cause of mal function both internal and external to the power source Do not overlook bad grounds shorted con trol cables wrong settings blown fuses miscon nections from auxiliary equipment misapplications etc The only equipment needed to properly detect a problem on this power source is a simple vol tohmmeter although an oscilloscope is the best method to quickly see the problem Voltages Refer to proper connection diagram See Diagram chapter included in this manual The following voltages should be read at 1800 RPM engine speed 1 Welding Generator phase to phase on all three phases 60 V AC 10 2 Phase to Neutral of Welding Generator 35 V AC 10 3 Check for blown fuses F3 F8 Refer to Diagram 492107 included in the Diagrams chapter Between wires 13 7 brown 14 8 orange 15 9 grey 16 10 black 17 11 yellow and 18 12 blue on fuse block 60 10 NOTE The 10 value indicates the pos sibility of having a high or low engine RPM Malfunction In SCRs Or Diodes The following conditions will probably
12. unburned fuel that accumulates in the exhaust pipe due to extremely low exhaust temperatures The following procedure will apply a load to the engine assuring the hot exhaust at least 450 F 232 C which will aid in preventing wet stacking 1 Open the fuel shut off valve at fuel tank 2 Start the engine see instructions under Engine Controls and Instruments included in Description of Equipment chapter and let it turn for a few minutes to warm up lubricating oil and coolant and then shut the engine off NOTE Idling RPM is approximately 1300 3 Check engine for low oil pressure leaks or malfunctioning parts If oil pressure does not show a sufficient steady pressure within 5 seconds shut engine down and determine cause 4 Start engine again Operate unit with canopy doors closed 5 Apply load to the welding generator This can be accomplished by attaching a proper resistance load across the welding terminals and setting the current control The load should be equal to at least one half of the normal full load output of the unit rated 400 amps 40 volts 6 Operate the engine generator unit for approxi mately one hour under the above loading condi tions NOTE This procedure can be followed at any time that wet stacking becomes a prob lem in order to burn out the unburned hydrocarbons that accumulate in the ex haust stack Prewelding Instructions To adjust weld current and arc character
13. unit is shipped with SAE 10W30 oil installed 8 After engine has been properly prepared for use start the engine and allow it to idle for 30 minutes or so Carefully check again for any leaks or loose connections during this period 9 Determine which welding polarity willbe suitable for the welding job to be done a For STRAIGHT polarity DCEN attach ELEC TRODE lead leading to electrode holder to the NEGATIVE terminal on the Terminal and Re ceptacle Panel Attach the WORK lead with clamp on end to POSITIVE terminal b For REVERSE polarity DCEP attach ELEC TRODE lead leading to electrode holder to the POSITIVE terminal Attach the WORK lead with clamp on end to the NEGATIVE terminal CAUTION Do not change welding leads while generator is running as open cir cuit voltage 80 volts is furnished to the terminals Shut engine down to change leads 10 Make sure that no loose bars tools parts etc are in or on any part of engine as they could cause serious damage to or wreckage of engine or gener ator or personal injury to anyone standing nearby 11 Carefully read and follow Operating Instruc tions in your engine operator s manual 4 2 December 1 1997 Revised 430429 245 INSTALLATION Welding Leads Table 4 1 shows welding lead sizes recommended for various lengths of leads The footage shown includes complete welding circuit both electrode and w
14. For portable use the machine may be located within 12 inches 305 mm of a truck cab panel or whatever if it is to be operated in the open air The engine of the welding machine must be placed at the tongue end of the portable mounting for December 1 1997 Revised 4 1 430429 245 INSTALLATION proper balance If leads etc are to be stored on the unit they must be forward of the axle to maintain proper balance of loading on the tongue end of the unit NOTE The unit should be operated in as near a normal horizontal position as possi ble and never at a tilt greater than 15 from horizontal Initial Preparation For Use 1 Open canopy doors on sides of engine CAUTION The canopy doors may fall to aclosed position during operation of the unit if it is resting on an inclined surface or for other reasons Tie the doors to each other to lifting eye or fuel filler cap Failure to do so may result in injury to operating personnel 2 Inspect unit thoroughly to be sure it is in proper working order Check all fuel and wire connections to be certain they are secure Tighten any loose screws nuts or bolts Check closely for any dam age which may have occurred in transit 3 Remove all special tags from the machine read carefully and follow any special directions they may carry Keep tags with manual for future reference 4 Make certain that all cooling air passages and cooling fins are free from foreign matt
15. 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 grave ment L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimenta tion et les circuits internes de l quipement sont aussi sous tension d s la mise en marche En soudage automatique ou semi automatique avec EN A fil ce dernier le rouleau ou la bobine de fil le N utilisez pas de c bles lectriques us s endommag s mal logement des galets d entrainement et toutes les piss s ou de section trop petite pi ces m talliques en contact avec le fil de soudage N enroulez pas de c bles lectriques autour de votre corps sont sous tension Un quipement inad quatement N utilisez qu une bonne prise de masse pour la mise la terre install ou inad quatement mis la terre est dangereux de la souder Ne touchez pas des pi ces sous tension Ne touchez pas l lectrode lorsqu en contact avec le circuit de Portez des gants et des v tements isolants secs et non trou s soudage terre Isolez vous de la pi ce souder et de la mise la terre au moyen N utilisez que des quipements en b
16. S Government Printing Office Washington D C 20402 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 Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances Ameri can Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safe Practices for Occupation and Educational Eye and Face Pro tection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 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 This page intentionally left blank 2 4 May 8 1996 PRECAUTIONS SECURITE EN SOUDAGE L ARC Instruction 830002 PRECAUTIONS DE SECURITE SOUDAGE AL 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 NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTION
17. and face shield Protective Gloves acid resistant for example rubber Work Hygienic Practices Good personal hygiene and work practices are mandatory 430429 245 DIAGRAMS DIAGRAMS e Note the model and specification number shown on the equipment nameplate e Locate these numbers in the model and specification number columns below e Use only those diagrams and instructions that are applicable CONTROL MODEL SPECIFICATION CONNECTION BOX ENGINE NUMBER NUMBER DIAGRAM DIAGRAM DIAGRAM 6436A 1 494157 494699 494157 Mega Arc 5040DD 6436B 1 494157 494699 494157 December 1 1997 Revised 90 6 sr x mum 15161969 118 91 01 c KANA ee wu 3000 ismi 9 10934 6 a 9t ugdnnr Ssvug 330 v3u8 E ea M lt N TN 02 12 O 140 Cido in cn TE eee D am m he ja PES po 5 1 4 334039 134 XH 3nssv s3univi34dm3p IY 3ONYISISSM YO ZION raura CRE 30058 341234 INdLNO SUIS JO INYU TIONY SI INJUHAI 3 ALMMOVIS 5 1 0182
18. are shorter than 7 16 inch 11 mm replace them 3 Inspect slip rings whenever brushes are re moved for servicing brushes or brushholders Note surface condition of rings Surface should appear smooth and clean Scoring or roughness of slip rings may be caused by grit or abrasive substance in brushes or by oil on the rings Moderately rough slip rings can be smoothed by holding grade 00 flint paper against their surface while the rings are re volving slowly If the rings are badly scored the unit must be sent to an overhaul facility for repair After cleaning slip rings blow dirt and grit out of the unit with compressed air Do not use over 25 psi 172 kPa air pressure to blow dirt out 4 Slip new brushes into brushholder guides and place caps on top and screw them into the guides to a bottomed position The spring attached to the brush will determine the pressure at which the brush contacts the slip rings Figure 6 1 Exciter Auxiliary Brushes December 1 1997 Revised 6 1 430429 245 5 To fit new brushes to the slip rings lay a strip of No 00 sandpaper smooth side down on slip ring surface and draw the sandpaper in the direction of rotation of the slip rings lifting the brush on the return stroke Continue until the brushes have the same curvature as the slip rings Blow all carbon dust out of the machine using not over 25 psi 172 kPa air pressure Failure To Build Up
19. asso ciated equipment and CGA publication P 1 listed in Safety Standards ENGINES can be hazardous 1 2 Use equipment outside in open well ventilated areas If used in a closed area vent engine exhaust outside and away from any building air intakes 2 2 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 fingers and hands and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit Do not add 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 Do not spill fuel If fuel is spilled clean up before starting engine Have only qualified people remove guards or covers for mainte nance and troubleshooting as necessary To prevent accidental starting during servicing disconnect nega tive battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before starting eng
20. contine Hazardous Components Specific Chemical Identity Other Limits Common Name s OSHA PEL ACGIH TLV Lead and Lead Components 0 050 mg m 0 15 mg m Appearance and Odor N A Solubility in Water N A Boiling Point N A Specific Gravity H 0 1 N A Evaporation Rate Butyl Acetate 1 Vapor Density AIR 1 N A Melting Point N A Vapor Pressure mm Hg Flash Point Method Used N A Flammable Limits N A LEL Extinguishing Media Dry chemical carbon dioxide water spray or foam 5 ecial Fire Fighti Stability Stable Conditions to Avoid N A Incompatibility Material to Avoid N A Hazardous Decomposition of By Products N A Hazardous Polymerization will not occur Page 1 of 2 MSDS Battery Electric Storage Dry page 2 of 2 Route s of Entry No applicable under normal use Health Hazards acute and chronic Internal components contain lead Repeated or prolonged exposure to lead can result in lead poisoning Lead accumulates in the bone and body organs and is eliminated from the body slowly Ref 29 CFR 1910 1025 Carcinogenicity N A IARC Monographs Group 2B carcinogen OSHA Regulated 29CFR1910 1025 Medical Conditions Generally Aggravated by Exposure Pregnant women and children must be protected from lead ex Signs and Symptoms of Exposure Short term Skin and eye irritation headache nausea vomiting abdominal spasms fatigue weight loss anemia pain in legs arms and joints Long term CNS damage k
21. 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 mou vement 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 c bles d accumulateur N utilisez que des outils anti tincelles pour travailler sur un accumulateur N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment un v hicule Utilisez la polarit correcte et de l accumulateur 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 Z49 1 American Welding Society 550 N W LeJeune Rd Miami FL 33128 Safety and Health Standards 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 norme AWS 4 1
22. example rubber Eye Protection preferred Other Protective Clothing or Equipment acid resistant aprons boots and protective clothing Work Hygienic Practices Good personal hygiene and work practices are mandatory EAST PENN manufacturing co inc Material Safety Data Sheet BATTERY FLUID ACID 8 UN2796 Manufacturer s Name Date Prepared Revised April 1994 East Penn Manufacturing Co Inc Deka Road Lyon Station PA 19536 Telephone Number for Information 610 682 6361 Emergency Telephone Number CHEMTREC 1 800 424 9300 In Washington D C or outside continental U Hazardous Components Specific Chemical Identity Other Limits Common Name s Recommended Percent 30 Appearance and Odor clear odorless colorless Solubility in Water completely Boiling Point approximately 235 F Specific Gravity H0 1 1 220 1 325 Evaporation Rate Butyl Acetate 1 less than 1 0 Vapor Density AIR 1 N A Melting Point N A Vapor Pressure mm Hg 13 Flash Point Method Used non flammable Flammable Limits N A Extinguishing Media N A LEL UEL Special Fire Fighting Procedures Sulfuric acid will not burn but is capable of igniting finely combustible material on contact Combustibles may be smothered by dry chemical extinguishing media Unusual Fire and Explosion Hazards Stability Stable Condition to Avoid Contact with metal may release explosive hydrogen gas Incompatibility Materials to Avoid Strong alka
23. 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 par cours 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 con tact 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 TIONS BRULANTES PEUVENT CAUSER DES BLESSURES LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font nor malement 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
24. located on the Control Panel see Figure 3 1 furnish 3 kVA 115 volt and 230 volt 60 Hz power NOTE The output voltage will drop below the rated volts when engine is in the idling mode Low voltage may damage electrical equipment connected to the generator through this receptacle Welding Terminals Figure 3 2 Weld Output Panel December 1 1997 Revised 3 3 430429 245 DESCRIPTION OF EQUIPMENT DC VOLTS OUTPUT 100 200 300 400 500 600 700 800 DC AMPS OUTPUT Volt Ampere Curve Low Range Voltage MEGA ARC 504000 HIGH RANGE DC VOLTS OUTPUT DC AMPS OUTPUT Volt Ampere Curve High Range Voltage 3 4 December 1 1997 Revised 430429 245 INSTALLATION INSTALLATION General Engine Driven Welder Installation The frame of an engine driven welder is intended to be a base to held the welder components to gether This frame is not intended to be the primary structure of a trailer or wagon This welder is in tended to be installed on a rigid flat surface This surface must allow the weight of the welder to be distributed evenly along the length of the welder frame Never install any vibration isolation material shock mounts etc beneath the welder frame This could defeat the engine generator shock mounts and cause abnormal vibration throughout the welder and produce vibration related problems Before choosing an installation location make note of where the service it
25. state and local codes Keep all panels and covers securely in place 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 ARC RAYS can burn eyes and skin Wear a welding helmet fitted with a proper shade of filter see NOISE can damage hearing ANSI 249 1 listed in Safety Standards to protect your face and eyes when welding or watching Wear approved safety glasses Side shields recommended Arc rays from the welding process produce intense Use protective screens or barriers to protect others from flash heat and strong ultraviolet rays that can burn eyes and glare warn others not to watch the arc de KII Noise from some processes can damage Wear protective clothing made from durable flame resistant 9 material 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 Electrode Size i Electrode Size Welding or Cutting Metal Thickness Welding or Cutting Metal Thickness Operation or Welding Current Operation or Welding Current Torch soldering Gas metal arc welding MIG Torch brazing Non ferrous base metal All Oxygen cutting Ferrous base metal All Light Under 1 in 25 mm Gas tungsten arc welding TIG All Medium 1 to 6 in 25 150 mm Atomic hydrogen welding All Heavy Over 6 in 150 mm Carbon arc welding All Gas weldi
26. 8 Housing Exciter Assembly 1 All 491464 Brushholder Assembly 1 All 3 491463 Bracket Brushholder 1 All 4 402531 Cap Brushholder 2 All 5 402788 Brush 2 All 6 402530 Guide Brushholder 2 All 7 492021 Armature 1 All 8 356773 43 Housing Gen Assembly 1 All 9 31 Key Coupling 1 All 10 491658 2 Fan amp Coupling Assembly 1 All 11 492183 1 Cover Exc Housing 1 A 492183 2 Cover Exc Housing 1 B 12 402037 9 Grommet Exc Cover 1 All 13 491813 Cover Gen Housing 1 A 491813 1 Cover Gen Housing 1 B 14 351683 Grommet Lead Hole 1 All 15 No Number Flywheel Supplied W Engine 1 All 16 492111 1 Housing Flywheel Assembly 1 All 17 491758 1 Cover Hole 1 A 491758 3 Cover Hole 1 B December 1 1997 Revised 8 5 430429 245 PARTS LIST Figure 8 3 Frame Group 8 6 December 1 1997 Revised 430429 245 PARTS LIST Parts List for Figure 8 3 Description Qty Application No Number per Code Assy 1 492054 1 Top Canopy 1 A 492054 2 Top Canopy 1 B 2 409158 Label Danger 1 All 3 494130 Shield Safety 1 All 4 494133 Cap Fuel Tank 1 All 5 405089 Label Fuel 1 All 6 406000 Label Warning Fuel 1 All 7 494445 Label Precautionary 1 All 8 406650 1 Hood Air Cleaner 1 All 9 406652 Muffler 1 All 10 359699 Brace Canopy 2 A 359699 1 Brace Canopy 2 B 11 406651 Air Cleaner 1 All 12 W 10869 5 Clamp Air Hose 1 All 13 406672 Tub
27. 81013 18 3 1800 or Idle No Load TP L to TP E 10 to 13 18 3 1800 or Idle No Load Table 7 2 7 4 December 1 1997 Revised 430429 245 PARTS LIST PARTS LIST Equipment Identification All identification numbers as described in the In troduction chapter must be furnished when ordering 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 numbers How To Use This Parts List The Parts List is a combination of an illustration Figure Number and 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 commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded SPEC NUMBER 6436A 1 6436B 1 to another part The part descriptions may be indented to show part relationships To determine the part number description quan tity 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 inthe Part
28. 9234 338 Cable Output Term to Rectifier 1 All W 9234 339 Cable Output Term to Reactor 1 All 491229 Pivot Fuel Shutoff 1 All 160 34 Bushing Shutoff Rod 1 All 492187 Rod Speed Control 1 All 90 494383 Bracket Mtg Alt 1 All 405548 Label Ground 1 All 494541 Clamp Throttle 1 All Not Illustrated December 1 1997 Revised 8 11 430429 245 PARTS LIST Figure 8 4 Fuel Lines and Speed Control 8 12 December 1 1997 Revised 430429 245 PARTS LIST Parts List for Figure 8 4 Description Qty Application No Number per Code Assy 492118 1 Lines Fuel amp Return Assembly 1 All 1 491889 3 Hose Rubber 3 16 1 All 2 405814 1 Insert Hose 1 All 3 W 10869 14 Clamp Hose 4 All 4 491667 2 Hose Low Pressure 3 8 1 All 5 402927 1 Nut Inverted Flare 1 All 6 400504 Filter 1 All 7 W 10750 2 Nipple Pipe 1 8 1 All 8 12CW 2125 Elbow Street 45 1 All December 1 1997 Revised 8 13 430429 245 PARTS LIST This page intentionally left blank 8 14 December 1 1997 Revised EAST PENN manufacturing co ine Material Safety Data Sheet BATTERY ELECTRIC STORAGE DRY Manufacturer s Name Date Prepared Revised April 1994 East Penn Manufacturing Co Inc Deka Road Lyon Station PA 19536 Telephone Number for Information 610 682 6361 Emergency Telephone Number CHEMTREC 1 800 424 9300 In Washington D C or outside
29. ALL OTHER CIRCUITS AND COMPONENTS INCLUDING 1 YEAR 1 YEAR 1 YEAR BUT NOT LIMITED TO CONTACTORS RELAYS SOLENOID PUMPS POWER SWITCHING SEMI CONDUCTORS ENGINES ENGINES ARE NOT WARRANTED BY THERMAL ARC ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS CONSOLES CONTROL EQUIPMENT HEAT 1 YEAR 1 YEAR 1 YEAR EXCHANGES AND ACCESSORY EQUIPMENT TORCH AND LEADS 180 DAYS 180 DAYS 180 DAYS REPAIR REPLACEMENT PARTS 90 DAYS 90 DAYS 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 repair 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 customer All returned goods shall be at the customer s risk and expense This warranty supersedes all previous Thermal Arc warranties Thermal Arc is a Registered Trademark of Thermadyne Industries Inc Thermal Arc Inc Effective January 4 1999 Troy Ohio 45373 830538
30. DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs LE CARBURANT PEUR CAUSER UN IN CENDIE 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 concus 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 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 Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent Ne faites pas le plein en fumant
31. MEGA ARC 5040DD 400 Amp Constant Current Diesel Engine Driven Welding Generator For the Following Specs 6436 1 6436B 1 THERMAL A THERMADYNE Company OWNER S MANUAL Number 430429 245 Revised December 1 1997 THERMAL ARC INC TROY OHIO 45373 1085 U S A 430429 245 Table of Contents CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm INTRODUCTION 1 How To Use This Manual 1 1 Equipment Identification 1 1 Receipt Of Equipment 5 1 1 SAFETY INSTRUCTIONS AND WARNINGS 2 DESCRIPTION OF EQUIPMENT 3 Generator 2 21 2 oa 8 e aoa he de ele GEE ea ee 0 t 3 1 Engine 52 Acus Due dd tud i du ot sd 3 1 Identification a oe Set ae ee ae ee a 3 1 Tabulated Bata 2 st Qt Gk Bs ee ee 3 1 Supplementary Materials 3 2 Engine Controls and Instruments 3 2 Generator Controls 3 3 INSTALLATION 4 General Engine Driven Welder Installation 4 1 uu aree fe he Reese eh a Ede de SP de 4 1 SUID EA rp a eet Ae Bathe ee Sud did tide Reed 4 1 Indo
32. OTING TROUBLESHOOTING The following chart contains information which can be used to diagnose and correct unsatisfactory opera tion or failure of the various components of the welding generator Each symptom of trouble is followed by a list of probable causes and the procedure necessary to correct the problem Troubleshooting Guide Auxiliary Power Generator Exciter and Welding Generator No output at Auxiliary Power Receptacles or Welding Terminals Unit won t build up voltage Loose connections Check connections completely Open circuit in exciter revolving field Replace armature see detail instructions at end of chart Brush and slip rings dirty Check brushes and clean slip rings Broken wiring Repair Shorted diode in field rectifier bridge Replace bridge No output at welding terminals auxiliary power receptacles output OK Open circuit in welding generator revolving field coils Replace armature Shorted power diode SCR or flyback diode in output rectifier assembly Replace defective device Fuses to control P C Board blown Replace fuses Control P C Board failure Replace P C Board Output voltage too high Engine overspeeding Check engine RPM should read 1825 1840 no load December 1 1997 Revised 7 1 430429 245 TROUBLESHOOTING Output voltage too low Engine running underspeed Check engine RPM One or more revolving field coils shorted Replace defective coils Engine
33. OUT as far as it will come until engine completely stops and then release it 3 Turn engine starting switch to OFF 4 Allow engine to cool sufficiently then check crankcase oil level If engine oil is to be changed it can be done most effectively while engine is still warm 5 After engine has cooled completely fill the fuel tank See Safety Warnings chapter included in this manual for precautions that should be taken when filling the fuel tank Storage Nightly After operation the following steps should be taken before storing the welding machine for short periods of time 1 Clean up around working area Put all tools parts and supplies in their proper places 2 Disconnect welding leads from machine Coil them and stow away in their place 3 If unitis to be stored outdoors itis wise to cover it with a tarpaulin Extensive Storage Time If unit is to be laid up for some time please referto Engine Preservation in Deutz Engine Instruction Manual which is sup plied with each unit Adverse Weather Precautions Cold Weather Operation Operation of engine driven welding units at sub zero temperatures re quires special precautions and extra servicing from both operation and maintenance personnel if poor performance or total functional failure is to be avoided Consult Deutz Engine Manual and recom mendations below a Fuel System Keep system clean and free from water which may collect in a l
34. S 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 entrainement avant d utiliser l equipement Toute personne n ayant pas suivi un entrainement intensif en soudage et 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 Z49 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre 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
35. Terminal 6 Station 1 All 13 404915 1 Spacer P C Board 6 All 14 491238 Board P C Control 1 All 15 367579 Insulator Fuse Block 1 All 16 405129 1 Block Fuse 6 Station 1 All 17 W 11166 9 Fuse 1 Amp Fast Blow 6 All IE 405157 Label Fusdil 492008 Door Control Box Assembly 1 A 492008 1 Door Control Box Assembly 1 B 18 492009 Door 1 A 492009 1 Door 1 B 19 406040 Boot Toggle Switch 3 All 20 367703 1 Resistor 1 2 Watt 1 All 21 405365 1 Switch Toggle 1 All 22 406926 1 Potentiometer 2 Watt 5 2 All 23 402663 Nut Pot Lock 2 All 24 492576 Board Mtg Pot 1 All 25 406806 1 Knob Control 1 A 406806 3 Knob Control 1 B 26 491773 1 Knob Control 1 A 491773 3 Knob Control 1 B 27 8BW 106A Spacer 1 All 28 402682 Switch Toggle 2 All 29 400758 Receptacle 6 Pin Amphenol 1 All 30 404875 8 Chain Assembly 1 All 31 494122 Panel Control Lower 1 A 4941 22 1 Panel Control Lower 1 B 32 HF 1458 Rod Shutoff 1 All Not Illustrated December 1 1997 Revised 8 3 430429 245 PARTS LIST Figure 8 2 Generator Group December 1 1997 Revised 8 4 430429 245 PARTS LIST Parts List for Figure 8 2 Description Qty Application No Number per Code Assy 491461 3 Generator AC Assembly 1 A 491461 7 Generator AC Assembly 1 B 1 5J 260 0 Cap Bearing 1 A 5J 260 3 Cap Bearing 1 B 2 356773 3
36. Voltage Refer to Connection Diagram in Diagrams chapter included in this manual One common problem with engine driven gener ators is failure to build up voltage from loss of residual magnetism in the fields Check all wiring from the exciter stator T1 T2 to rectifier CR1 and to slip rings SR Also check CR1 diode bridge for a shorted diode which would not allow unit to build up If this check does not solve problem check the revolving fields for continuity as explained below See Figure 6 2 To check for revolving field coil problems it is necessary to understand that there are two field circuits permanently paralleled at the slip ring con nections A good armature will show 6 ohms resis tance measured at the slip rings with brushes lifted from rings If the resistance measured at the rings is 8 ohms then the exciter revolving fields 23 ohm coils have an open circuit If the measured resis tance at the slip rings is 23 ohms then the exciter fields 8 ohms have an open circuit A resistance measurement of much less than 6 ohms at the slip rings indicates that there is a short circuit some where in the revolving field windings Parallel Field Resistance 6 Ohms Slip Slip Ring Ring Exciter Revolving Welding Generator Bearing Fields Revolving Fields 1 23 Ohms 2 8 Ohms 15 4 Figure 6 2 Slip Ring Continuity 6 2 December 1 1997 Revised 430429 245 TROUBLESHO
37. a lower level This will be the SCR which should be changed Printed Circuit Board Testing The next step is to check the Printed Circuit Board inside the unit See Figure 7 1 and Table 7 2 for location of test points and voltage values at the test points The following conditions indicate the possibility of a defective P C Board 1 Loss of welding arc completely 2 Rough sputtering arc very noticeable 3 Loss of welding arc control 4 Difficulty in starting arc If any voltage measurement does not agree with Table 7 2 voltage values the P C Board is probably defective NOTE Do not attempt to repair or recali brate these voltages as they are factory set December 1 1997 Revised 7 3 430429 245 TROUBLESHOOTING
38. and wire connections to be certain they are secure Tighten any loose screws nuts or bolts 3 Wipe off the entire unit and clean the air pas sages control box and hard to reach places with compressed air not over 25 psi 172 kPa 4 Make sure that no loose bars tools parts etc are in or on any part of the engine as they could cause serious damage to the engine generator or personal injury to anyone standing nearby 5 If the unit is operated indoors make sure that an exhaust line is properly connected to the engine exhaust system and discharges out of doors Avoid short bends or reduction in line size in exhaust pipes and locate the unit so as to necessitate the shortest possible exhaust line to insure the least amount of back pressure on the engine Back pres sure can cause engine damage and loss of power 6 Check welding leads Attach welding leads as described under Initial Preparation For Use located in Installation chapter Observe Table 4 1 and de termine that welding leads are proper size for am perage being used for welding Break in Procedures A proper break in procedure for a new diesel en gine driven welding generator is extremely impor tant to avoid future problems Long periods of operation at idle or light load condition may result in cylinder wall glazing and resultant poor seating of piston rings so that oil consumption will be exces sive Also it may result in wet stacking which is
39. ate Rect Right 1 All 40 492200 1 Plate Rect Left 1 All 41 W 10931 3 Rectifier Silicon Controlled 4 All 42 405140 1 Clamp Mtg 3 All 43 492197 Heat Sink SCR 3 All 44 405826 Rectifier Silicon Controlled 3 All 16DA 954 12 Pin Spring 3 All 45 406436 Washer Rocker Arm 8 All 46 492029 Bushing Insulator 4 All 47 491905 Spacer Rect 2 All 48 6FW 3167 Spacer Rect 2 All 49 490040 Hinge 6 All 50 490174 Plate Hinge 12 All 51 492090 1 Door Side Left 1 A 492090 2 Door Side Left 1 B 52 492244 Handle Door Latch 4 All 53 493457 Spacer Door Latch 4 All 54 490234 Latch Door 4 All 55 494129 Panel Side Left 1 A 494129 1 Panel Side Left 1 B 56 492033 1 Frame Mtg 1 A 492033 2 Frame Mtg 1 B 57 491683 1 Bar Mtg Gen 1 A 491683 2 Bar Mtg Gen 1 B 58 406254 2 Mount Shock 4 All 59 491799 Washer Shock Mount 8 A 491799 1 Washer Shock Mount 8 B Not Illustrated 8 8 December 1 1997 Revised 430429 245 PARTS LIST Parts List for Figure 8 3 Description Qty Application No Number per Code Assy 60 494295 Rod Battery 1set 61 491122 Angle Mtg Front Panel 2 A 491122 1 Angle Mtg Front Panel 2 B 62 491962 1 Clamp Battery 1 A 62 491962 2 Clamp Battery 1 B 63 402086 5 Battery 1 All 493797 2 Protector Battery Term 1 All 64 492132 1 Cable Batt Negative 1 All 65 492133 1 Cable Batt Positive 1 All 66 W 9360 229 Bonding 1 Al
40. d SCR do NOT turn the unit ON Disconnect the leads from the generator to the rectifier assembly 7 2 December 1 1997 Revised 430429 245 TROUBLESHOOTING and check with a VOM for shorted SCRs and di odes An open gate or an open SCR cannot be checked with a VOM If an SCR is not firing the open circuit voltage will shift down Check the following table for typical values for a Mega Arc 5040DD unit All Three SCRs One Not Two Not Firing Firing Firing Firing Max 75VDC 50VDC 25VDC OVDC Table 7 1 NOTE The above values in Table 7 1 were recorded at normal engine RPM 1800 Isolating Malfunctioning SCR This can be done best by trial and error method Use proper diagram as reference while inspecting the unit On the output rectifier heat sink there are three SCRs each having small lead The lead a white one is connected to a wire harness providing the gate signal to the SCRs Turn the Current Control to maximum position fully clockwise and begin disconnecting the white leads from the harness one at a time As the first lead is disconnected observe the open circuit volt age of the machine If the OCV drops to a lower value it will indicate that this particular SCR is working properly Reconnect this lead and proceed to do the same with the remaining two leads until you discover which disconnection does not cause the OCV to drop to
41. ducts as stated below Thermal Arc shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal Arc s specifications instructions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal Arc s sole option 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 PARTICULAR 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 Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect 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 strike tort or under any warranty or otherwise shall not except as expressly provided herein e
42. e Air Cleaner 1 All 14 W 10869 6 Clamp Air Hose 1 All 15 406768 1 Indicator Restriction 1 All 16 406538 Bracket Mtg 2 All 17 491763 1 Door Side Rt 1 A 491763 3 Door Side Rt 1 B 18 491414 Reactor Stability Assembly 1 All 19 494135 1 Sender Fuel Gauge 1 All 20 494127 Tank Fuel 1 All 21 494145 Support Fuel Tank 1 A 494145 1 Support Fuel Tank 1 B 22 406358 2 Resistor Preload 1 All 23 402191 Panel Heat Shield 1 A 402191 1 Panel Heat Shield 1 B 24 491820 Support Heat Shield 1 A 491820 1 Support Heat Shield 1 B 25 492195 Cover Heat Shield 1 All 492533 5 Panel Terminal Assembly 1 A 492533 7 Panel Terminal Assembly 1 B 26 492532 1 Panel Output 1 A 492532 2 Panel Output 1 B 27 5CW 974 Bar Bus 2 All 28 No Number Nut 1 2 13 HWH ST 2 All 29 5CW 975 Bushing 2 All December 1 1997 Revised 8 7 430429 245 PARTS LIST Parts List for Figure 8 3 Description Qty Application No Number per Code Assy 30 5CW 976A Washer Bakelite 4 All 31 No Number Washer 1 2 FL ST 2 All 32 No Number Washer 1 2 LK ST 5 All 33 368705 7 Capacitor Assembly 2 All 34 No Number Screw 6 32 x 3 16 MH ST 2 All 35 492317 Shunt 1 All 36 No Number Screw 1 2 13 x 1 1 2 ST 1 All 37 494456 Yoke Lifting Assembly 1 A 494456 1 Yoke Lifting Assembly 1 B 38 402037 11 Grommet Lifting Yoke 1 All 492201 1 Rectifier Assembly 1 All 39 492199 1 Pl
43. ecessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded 5 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 prevent 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 contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Wear approved face shield or safety goggles Side shields rec ommended Wear proper body protection to protect skin Keep cylinders away 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
44. ems are located on the welder oil change fill battery air filter fuel fill etc Install the welder for best access to the important service items Allow sufficient room for cooling air intake and exhaust If you are unsure about any installation consult the factory Trailer Installation Do not use the frame assem bly of this welder as the frame of a trailer do not attach axles or tongues directly to this frame When a trailer is required use only trailers with its own support frame that has a gross weight rated to carry the weight of the welder and any other components mounted on the trailer Be sure the trailer tires are for use with trailers The soft sidewall design used in radial tires can cause vibration related problems Be sure welder frame and trailer frame are electri cally bonded together Truck Bed Installation When installing this welder on the bed of a truck allow the welder to sit flat on the bed or a surface which completely con tacts the bottom of the welder frame Do not modify the welder frame by cutting or otherwise damaging it or the warranty may be voided Bolt the welder frame directly to the bed to secure it Do not install any vibration absorption device shock mounts etc between the welder and the truck bed Be sure welder frame and truck frame are electrically bonded together Ground Installation The welder will operate per fectly fine just sitting on the ground with or without the shipp
45. er Use clean dry compressed air to blow dirt and dust out of cooling passages and control cabinet 25 psi 172 kPa maximum pressure 5 Attach battery cables to poles of battery as indicated on wiring diagram The negative pole should be grounded to the frame of the unit in a secure manner WARNING Connect proper bat tery cable clamp to the positive battery post first then the other cable clamp to the nega tive post CAUTION A short circuit to rectifier is created if a battery is installed with po larity reversed Current can flow from positive terminal of battery through negative and positive rectifiers and into heat sink From heat sink a completed circuit exists back to negative battery terminal Full battery voltage will be im pressed on rectifiers in the alternator The resulting high current will damage rectifiers and or wiring harness 6 Fill fuel tank with grade of fuel recommended by engine manufacturer Consult engine instruction manual Be sure fuel is free of WATER and other foreign matter Make sure air vent to fuel tank is open See Safety Warnings chapter included in this manual for precautions necessary when filling the tank 7 Pull the dipstick and check the oil level in crankcase If it is necessary to add oil fill to dipstick mark with correct seasonal grade of quality deter gent oil See engine operator s manual for recom mended viscosity and temperature chart
46. erning damage claims or shipping errors to Thermal Arc Order Department 2200 Corporate Drive Troy Ohio 45373 1085 Include all equip ment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before uncrating the unit A lifting eye extends through the top of the cabinet on most equipment to facilitate handling with a hoist or crane Use care to avoid damaging the equipment when using bars ham mers etc to uncrate the unit WARNING Falling machine due to lifting eye failure may cause death or serious injury e Lifting device may fail when overloaded e This lifting device is designed to lift the power source ONLY If the machine is equipped with a trailer or accessories over 100 pounds DO NOT LIFT by lifting eyes e Avoid sudden jerks drops or swinging e Check lifting device components visually for looseness and signs of metal fatigue e Before changing any hardware check grade and size of bolts and replace with bolts of equal or higher size and grade Additional copies of this manual may be pur chased by contacting Thermal Arc at the address given above Include the Owner s Manual number and equipment identification numbers December 1 1997 Revised 1 1 430429 245 INTRODUCTION This page intentionally left blank 1 2 December 1 1997 Revised ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruct
47. exist One SCR does not turn on either itis open or gate signal is not being received by the SCR gate circuit and a very small change will occur at the welding arc and will be difficult to detect by the average welding operator Generally when this hap pens it will be necessary to adjust the current control on the front of the power source see Figure 3 1 increasing the current to obtain the same welding current that was being produced before the SCR defect occurred Open Circuit Voltage Test If the power source is suspected a very simple test can tell you a great deal about the power source Observe the open circuit voltage of the machine by placing a voltmeter across the output terminals The voltage reading should be approxi mately 75 V DC If the voltage is not equal or close to 75 V DC there is something wrong with the power source welding machine Note that this voltage was observed at normal engine speed 1800 RPM It will vary ac cording to the engine speed If the 75 V DC is observed there is a very good chance that the power source is operating properly NOTE It is important to note that in the LOW range 15 to 200 amperes at mini mum setting of the Current Control the open circuit voltage will drop to a lower value and vary slightly with the current con trol This is not a malfunction but a normal situation Power Diode And SCR Testing In case of a severe malfunction such as a shorte
48. g can easily go through small cracks and openings to adjacent areas 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 Protect compressed gas cylinders from excessive heat mechani cal shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent 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 Work in a confined space only if it is well ventilated or while wearing 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 cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if n
49. idney disfunctions and potential reproductive hazard Symptoms of lead exposure can be confirmed by the presence of elevated levels of lead in blood Emergency and First Aid Procedures Not applicable under normal use If lead exposure is suspected seek medical attention Steps to be Taken in Case Material is Released or Spilled Avoid contact with internal components See Section VI Health Hazards Lead Waste Disposal Method Lead acid batteries are completely recycable For information on returning batteries to East Penn for recycle call 610 682 6361 Precautions to be Taken in Handling and Storing Other P N A Respiratory Protection Specific Type For specific information see 29CFR 1910 1025 Lead Exposure Ventilation Local exhaust Mechanical general Special Other Protective Gloves N A Eye Protection N A Other Protective Clothing or Equipment N A Work Hygienic Practices Always practice good personal hygiene habits and safe work practices Shipping Name Battery dry Identification Number N A non assigned Hazard Class N A This article is not applicable to 49CFR 172 101 Hazardous Materials and not subject to Parts 170 189 of this sub chapter U S Postal Service Regulations unrestricted EAST PENN manufacturing co inc Material Safety Data Sheet BATTERY WET FILLED WITH ACID 8 UN2794 PGIII Manufacturer s Name Date Prepared Revised April 1994 East Penn Manufacturing Co Inc Deka Road L
50. ine SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin 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 Observe correct polarity and on batteries Batteries contain acid and generate explosive gases STEAM AND PRESSURIZED HOT Do not remove radiator cap when engine is hot Allow engine to COOLANT can burn face eyes and cool skin Wear gloves and put a rag over cap area when removing cap The coolant in the radiator can be very hot and under Allow pressure to escape before completely removing cap pressure 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 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 ba
51. ing agents such as hot nitric acid etc Hazardous Decomposition of By Products Combustion can produce carbon dioxide CO and carbon monoxide CO Hazardous Polymerization will not occur Conditions to Avoid not applicable Page 1 of 2 MSDS Battery Wet Filled with Acid 8 UN2794 page 2 of 2 Route s of Entry Inhalation skin contact and ingestion Health Hazards Acute and Chronic Short term exposure Sulfuric acid may cause irritation of eyes nose and throat Prolonged contact may cause severe burns Long term exposure Repeated contact causes irritation and skin burns Repeated exposure to mist may cause errosion of teeth chronic eye irritation and or chronic inflammation of the nose throat and bronchial tubes TARGET ORGAN respiratory system eyes skin amp teeth Carcinogenicity N A Signs and Symptoms of Exposure Acid contact may cause irritation of eyes nose and throat Breathing of mist may produce respiratory difficulty Contact with eyes and skin causes irritation and skin burns Sulfuric acid is a CORROSIVE chemical Medical Conditions Generally Aggravated by Exposure Pulmonary edema bronchitis emphysema dental errosion and traceobronchitis Emergency and First Aid Procedures 1 Flush contacted area with large amounts of water for at least 15 minutes Remove contaminated clothing and obtain medical attention 2 If swallowed give large volumes of water DO NOT induce vomiting obtai
52. ing skid No special precautions are re quired Location For best operating characteristics and longest unit life take care in selecting an installation site Avoid locations exposed to high humidity dust high am bient temperature or corrosive fumes Moisture can condense on electrical components causing corro sion or shorting of circuits Dirt on components helps retain this moisture and also increases wear on moving parts Safety Refer to additional installation instructions under the Safety Warnings chapter included in this man ual Indoor Installation Adequate air circulation is needed at all times in order to assure proper operation Provide at least 24 inches 610 mm of space at radiator end of unit Make sure that ventilation openings are not ob structed Allow ample space to open canopy doors on sides of the unit see Tabulated Data in Descrip tion of Equipment chapter for dimensions for serv icing and space at the control panel end of unit for operation If unit is to be operated inside a building make certain there is adequate ventilation to carry off escaping exhaust fumes and to provide an ample supply of oxygen Place unit so that exhaust fumes are carried out of the building using the shortest exhaust pipe possi ble and one with the fewest possible number of bends Exhaust back pressure can seriously affect engine efficiency All exhaust connections must be gastight Portable Installation
53. ion 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 training before using this 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 249 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 Turn off all equipment when use Disconnect power to equipment if it will be left unattended or out of service Use fully insulated elec
54. istics while welding the High Low Range Switch Current Control and Arc Force Control can all be adjusted under load without damaging the welding machine However caution should be used in switching from low to high range on the Range Selector Switch as this would cause the welding current to be immedi ately doubled This might be more than the elec trode in use could stand This would cause immediate problems with the welding arc Note that on the Current Control dial the low range is just one half of the high range values For exam ple leaving the Current Control setting constant the high range would deliver 200 amperes and the low December 1 1997 Revised 5 1 430429 245 range 100 amperes This relation holds consistent through the entire range of the welding machine giving two widely overlapping current ranges The low range is 20 to 250 amperes and the high range is 40 to 500 amperes The entire usable range of the machine for stick electrode SMAW welding can be obtained in the single high range Adjustable Arc Force control for the welding proc ess gives the operator great flexibility in selecting the arc characteristics needed for a particular job Refer to Volt Amp Curves in Installation chapter Setting the Arc Force Control at 4 to 6 or in the FORCEFUL range will adjust the welding charac teristics of the Mega Arc 5040DD machine to be normal and similar to many of the conventi
55. jo m vu CLES OO Au jo 34 pus uox vegeuueja go uus MUODON MO100 HIBNNN FLUE JO ON3 Jen MOD mu 06 1 arr EUR N38NnN NOULV2O1 LUV pe eid N ILVNV 14X3 WVUSVIG 3005 40105 NOHIINNOI NVYOVIG 9 10 Wruv 68 25 01 SM UVO 1074 100008 834 3002 HSINIJ TeV urexso wus mur AN3LLVB ow Emm end v pest KIRT ze az 9 GION310S MilNvis dION310S 1303 osz 8 pezs e NMOGLNHS 5 553 HOLIMS L 138 ds HOLIMS H NOILINO 9 ird 10 25 92 UNo 667 439435 39nv9 13 LIM 3NION3 IVNOILdO iu t EE LHON aab diy xp 01 Les 52 6 YILINYNOH p we MIT ce x8 3c do EST dit ol ANS ZE M NI BE 8 NO St NOLLNB 1515 aee IS EC E 0 El xg 752 40 13915 JIHLVIM 09109 133H ON oma 0126 7183 21139 93as 03 1439 3 144 0736 SIINVUJTOL SN3DMITIR S3HOMI SNOISNMN 031319395 5 SSIINA
56. l 67 492053 1 Panel Front 1 A 492053 2 Panel Front 1 B 68 491689 1 Plate Front End 1 A 491689 2 Plate Front End 1 B 69 492142 1 Guards Belt 2 A 492142 2 Guards Belt 2 B 70 406001 Label Danger 2 All 71 492109 1 Support Engine 1 A 492109 2 Support Engine 1 B 72 492143 1 Bracket Alt Adj 1 A 492143 2 Bracket Alt Adj 1 B 408261 3 Belt Alternator 1 All 73 494181 Alternator 1 All 494184 Pulley Alt 1 All 494183 1 Spacer Pulley 1 All 74 492140 5 Spacer Adj Alt 1 All 75 Deleted 76 492140 7 Spacer Mtg Alt 2 All 77 406602 Engine Deutz Diesel 1 All 78 492115 2 Pipe Exhaust 1 All 79 492186 1 Duct Intake Assembly 1 A 492186 2 Duct Intake Assembly 1 B 80 494174 Bracket Mtg Sender 1 A 494174 1 Bracket Mtg Sender 1 B 81 494172 1 Hose Oil Line 1 All 82 W 10909 1 Tee Pipe 1 8 1 All 83 409159 Switch Oil Pressure 1 All 84 402130 Switch Oil Pressure 1 All Not Illustrated December 1 1997 Revised 8 9 430429 245 PARTS LIST This page intentionally left blank 8 10 December 1 1997 Revised 430429 245 PARTS LIST Parts List for Figure 8 3 Description Qty Application No Number per Code Assy 85 494128 Panel Side Right 1 A 494128 1 Panel Side Right 1 B 86 409554 1 Rectifier 1 All 86A 202258 5 Suppressor W Lugs 1 All 87 367634A 5 Suppressor Surge Assembly 1 All 88 492049 Bracket Mtg Bus 1 All 89 492047 Bar Bus 1 All W
57. li materials carbides chlorates nitrates and pierates organic acid acetates anhydrites Hazardous Decomposition of By Products Thermal decomposition or combustion may produce a sulfur trioxide and or sulfur dioxide Hazardous Polymerization will not occur Page 1 of 2 MSDS Battery Fluid Acid 8 UN2796 PGII page 2 of 2 Route s of Entry Inhalation skin contact and ingestion Carcinogenicity N A Signs and Symptoms of Exposure Acid contact may cause irritation of eyes nose and throat Breathing of mist may produce respiratory difficulty Contact with eyes and skin causes irritation and skin burns Sulfuric acid is a CORROSIVE chemical Medical Conditions Generally Aggravated by Exposure Pulmonary edema bronchitis emphysema dental errosion and traceobronchitis Health Hazards Acute and Chronic Short term exposure Sulfuric acid may cause irritation of eyes nose and throat Prolonged contact may cause severe burns Long term exposure Repeated contact causes irritation and skin burns Repeated exposure to mist may cause errosion of teeth chronic eye irritation and or chronic inflammation of the nose throat and bronchial tubes TARGET ORGAN System eyes skin amp teeth Emergency and First Aid Procedures 1 Flush contacted area with large amounts of water for at least 15 minutes Remove contaminated clothing and obtain medical attention
58. 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 LES VAPEURS ET LES FUMEES SONT 5 Ne travaillez dans un espace confin que s il est bien ventil DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer 1 Eloignez la t te des fum es pour viter de les respirer l int rieur assurez vous que l aire de soudage est bien ven til e ou que les fum es et les vapeurs sont aspir es l arc Sila ventilation est inadequate portez un respirateur adduc tion d air approuv Lisez les fiches signal tiques et les consignes du fabricant relatives aux m taux aux produits consummables aux rev te ments et aux produits nettoyants sinon portez un respirateur adduction d air Les gaz protec teurs de soudage peuvent d placer l oxyg ne 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
59. n medical treatment Eyewash and shower stations should be made available Steps to be Taken in Case Material is Released or Spilled SULFURIC ACID Dilute spill cautiously with five to six volumes of water and gradually neutralize with sodium bicarbonate soda ash or lime When exposure level is not known wear NIOSH approved positive pressure self contained breathing apparatus Reference DOT UN2796 Waste Disposal Method Lead acid batteries are completely recyclable For information on returning batteries to East Penn for recycling call 610 682 6361 Precautions to be Taken in Handling and Storing Store away from reactive material as defined in Section V Reactivity Data Other Precautions Sodium bicarbonate soda ash sand or lime should be kept in same general area for emergency use See Section IV on generation of hydrogen gas If battery case is broken avoid direct contact with internal components Respiratory Protection Specific Type Acid gas respirator required when PEL is exceeded or employee witnesses respiratory irritation See Section VI Health Hazard Data Ventilation Must be provided when charging in an enclosed area 29CFR1910 178 g and 305 3 7 Mechanical general acceptable at 1 to 4 air exchanges hour or to maintain air concentrations below the PEL Local exhaust preferred Special Other local building fire codes may require explosion proof fans and equipment Protective Gloves acid resistant for
60. ng Plasma arc welding All Light Under 1 8 Carbon arc air gouging Medium 1 8 to 1 2 in 3 12 mm Light Heavy Over 1 2 in 12 mm Heavy Shielded metal arc welding Under 5 32 in 4 Plasma arc cutting stick electrodes 5 32 to 1 4 in 4 to 6 4 mm Light Under 300 Amp Over 1 4 in 6 4 mm Medium 300 to 400 Amp Heavy Over 400 Amp May 8 1996 2 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 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 remove 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 work piece 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 Be alert that welding sparks and hot materials from weldin
61. nopy closed when not in use It is advisable to keep the unit covered with a tarpaulin if available while not in operation Salt water should be wiped from the engine and all terminals and connections in the electrical system wiped dry Keep all linkage oiled c Brushes The brushes of the welding gen erator and exciter should be inspected regularly to make certain that they are free in the holders Lift the brushes in the brushholders about every two days to insure their freedom to slide within the holder Wipe dry all the parts that can be reached and use compressed air if available to dry the parts of the generator that cannot otherwise be reached See Maintenance chapter for brush and commuta tor care d Field Coils The fields should be dried as thoroughly as possible If they have become damp proceed with recommended procedure in Mainte nance chapter e Battery Terminals Thoroughly clean the battery terminals and connections Coat terminals and connections with petroleum jelly to retard cor rosion December 1 1997 Revised 5 3 430429 245 This page intentionally left blank 5 4 December 1 1997 Revised 430429 245 MAINTENANCE MAINTENANCE Engine And Related Components NOTE Check diesel engine instruction manual for all engine related maintenance Inspection And Cleaning Every Day check for oil or fuel leaks Also check for loose electrical connections
62. on tat R parez ou rem de tapis isolants ou autres placez aussit t les pi ces endommag es D connectez la prise d alimentation de l quipement ou arr tez Dans des espaces confin s ou mouill s n utilisez pas de source le moteur avant de l installer ou d en faire l entretien Bloquez le de courant alternatif moins qu il soit muni d un r ducteur de commutateur en circuit ouvert ou enlevez les fusibles de l alimen tension Utilisez plut t une source de courant continu tation afin d viter une mise en marche accidentelle Portez un harnais de s curit si vous travaillez en hauteur Veuillez installer cet quipement et le mettre la terre selon Fermez solidement tous les panneaux et les capots 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 Portez des lunettes de s curit approuv es Des crans lat raux LE RAYONNEMENT DE L ARC PEUT BRULER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER L OUIE s bap Entourez de soudage de rideaux de cloisons pour de soudage produit une chaleur et des prot ger les autres des coups d arc ou de l blouissement rayons ultraviolets intenses susceptibles de avertissez les observateurs de ne pas regarder briler les yeux et la peau Le bruit caus par Portez des v tements en ma
63. onally controlled engine driven stick electrode welding machines However turning down the Arc Force Control to the 2 to 4 or SMOOTH range gives a softer less spatter type of welding arc Setting the Arc Force Control to DIGGING 6 to 10 range gives a very forceful driving arc which makes sticking the electrode nearly impossible Note on the Volt Amp Curves that this adjustment of arc characteristics is accomplished by changing the short circuit to welding current ratios as indi cated by the dotted lines for arc force settings of O 2 5 and 10 on the dial Welding After all Prestarting and Break In Procedures have been carried out the controls for using the gener ator for welding may be set and welding accom plished Follow this procedure 1 Start engine per instructions under Engine Con trols and Instruments Operate unit with canopy doors closed 2 Set Range Selector Switch on desired range and adjust current control for desired current Turn ing the current control clockwise increases the weld ing current and open circuit voltage while turning it counterclockwise decreases the welding current 3 Strike an arc and begin welding If a change in welding current is desired increase by turning knob clockwise until desired current is obtained See Prewelding Instructions above for details on current range current level and arc force control Stopping The Engine 1 Stop welding 2 Pullthe control handle
64. or Installation 4 1 Portable Installation 4 1 Initial Preparation For Use 4 2 Welding Leads 3 5 sites SR m eee gun UE ae ee tons 4 3 OPERATION 5 Prestarting Instructions 204 04 fb ee Sa ube wae Wo do 5 1 Procedures 5 1 Prewelding Instructions 5 1 Welding Scere diede ee Te ter a 5 2 Stopping The Engine 5 2 le ee hee A Mae RY a 5 2 Adverse Weather Precautions 5 2 MAINTENANCE 6 Engine And Related Components 6 1 Inspection And Cleaning 6 1 EubricatiOlr ae Bo Ro wee NUM eed Ned Andes 6 1 December 1 1997 Revised Page 1 430429 245 Table of Contents Exciter Auxiliary Brushes 6 1 Failure Build Up Voltage 6 2 TROUBLESHOOTING 7 PARTS LIST 8 Equipment Identification 8 1 How To Use This Parts List 8 1 MATERIAL SAFETY DATA SHEET DIAGRAMS Page 2 December 1 1997 Revised 430429 245 INTRODUCTION INTRODUCTION How To Use This Manual
65. ork leads TOTAL LENGTH OF LEAD CIRCUIT IN FEET AND METERS Welding ELECTRODE LEAD PLUS WORK LEAD 50 Feet 100 Feet 150 Feet 200 Feet 250 Feet mperes 15 2 M 30 5 M 45 7 M 61 0 M 76 2 M 100 4 4 2 1 1 150 2 2 1 1 0 2 0 200 1 1 1 0 2 0 3 0 250 1 0 1 0 2 0 3 0 4 0 300 2 0 2 0 3 0 4 0 2 2 0 350 3 0 3 0 3 0 2 2 0 2 3 0 400 4 0 4 0 4 0 2 2 0 2 3 0 NOTE Cable size shown is for 90 194 F cable insulation 30 C 86 F ambient and not over 4 5 volts cable drop Table 4 1 Suggested Copper Welding Lead Size Guide 40 1016 mm 45 1143 mm Log 61 1 2 1562 m Figure 4 1 Dimensions 28 711 mm December 1 1997 Revised 4 3 430429 245 INSTALLATION This page intentionally left blank 4 4 December 1 1997 Revised 430429 245 OPERATION OPERATION Prestarting Instructions In all probability the welding unit will be moved from one location to another many times during its lifetime of service Therefore reference to Initial Preparation For Use located in Installation chapter is suggested each time the unit is moved prior to using it 1 Check the supply of fuel and crankcase oil See Deutz F3L 912D Instruction Manual for specifica tions 2 Inspect the unit thoroughly to be sure it is in proper working order Check all fuel line
66. 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 2 3 PRECAUTIONS SECURITE EN SOUDAGE L ARC Instruction 830002 DES PIECES EN MOUVEMENT PEU VENT 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 Avant d installer ou de connecter un syst me arr tez le moteur DES ETINCELLES PEUVENT FAIRE EX PLOSER 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 RE FROIDISSEMENT 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 protec teurs ou des capots pour faire l entretien ou le d pannage n cessaire Pour emp cher un
67. ow spot in the fuel line and freeze plugging the line Fuel tanks should be kept FULL to prevent water condensation from the air above the fuel Check the filter bowl daily for presence of water b Fuel Keep fuel storage tanks or drums as full as possible to avoid condensation of moisture from the air above the fuel After filling or moving fuel containers allow fuel to settle before using Never draw fuel from the extreme bottom of the container Strain all fuel to remove any foreign matter When operating outdoors take steps to prevent the entry of snow water and ice into the fuel containers c Lubrication Drain the crankcase prefer ably when warm after running and fill with a lighter 5 2 December 1 1997 Revised 430429 245 OPERATION grade of oil See Engine Oil Recommendations chart in the Maintenance and Operator s Manual for recommended viscosity oil for various atmospheric temperatures In cold weather drain oil more fre quently Water condenses and collects quickly mixes with the oil and increases deposits to form a sludge Check oil frequently for this condition Water in crankcase or oil lines may freeze and cause serious damage to the oil pump or shut off the oil supply d Battery Battery efficiency decreases sharply with lower temperatures Maintain the spe cific gravity of the battery between 1 275 and 1 300 fully charged condition Make sure of full charge before attempting to star
68. que si les zones souder ont t gratt es fond que si l 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 moment du soudage 2 2 8 V 96 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC Instruction 830002 LE SOUDAGE PEUT CAUSER UN IN CENDIE 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 des particules volantes ou des projections peuvent atteindre des mat riaux 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
69. rops to 3 5 psi for any reason Alternator Light Glows when engine alternator circuit is not charging the battery at sufficient level Fuel Gauge Indicates level of fuel in fuel tank Hour Meter Indicates run time on engine 3 2 December 1 1997 Revised 430429 245 DESCRIPTION OF EQUIPMENT Generator Controls Range Selector Switch This toggle switch is used to select either the low or high welding range as indicated on the Current Control Current Control The welding current control is located in the center of the control box door panel Turning knob clockwise will increase welding cur rent counterclockwise will decrease current Voltmeter Optional Indicates open circuit and welding arc voltage when supplied Ammeter Optional Indicates welding current being used to weld when supplied Arc Force Ampere Control Varies the short cir cuit welding arc current and produces an increase of amperage when arc length is shortened Turning this control clockwise increases arc force counter clockwise decreases arc force See Operation chapter for details Welding Terminals See Figure 3 2 The two welding terminals are located on the Welding Output Panel which is located on the left hand side of the unit facing the control panel See instructions in Initial Preparation for Use located in the Installation chapter Auxiliary Power Receptacles Duplex recepta cles
70. s List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appro priate 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 APPLICATION NUMBER December 1 1997 Revised 8 1 430429 245 PARTS LIST 31 7 EL Figure 8 1 Control Panel Parts List for Figure 8 1 Part Description Qty Application Number per Code Assy 494120 2 Panel Control Assembly 1 A 494120 3 Panel Control Assembly 1 B 409527 3 Circuit Breaker Thermal 3 All 404089 Receptacle Duplex 3 Wire 230 V 1 All 494121 Panel Control 1 A 494121 1 Panel Control 1 B 8 2 December 1 1997 Revised 430429 245 PARTS LIST Parts List for Figure 8 1 Description Qty Application No Number per Code Assy 4 404856 Switch Toggle 1 All 5 406004 1 Light Snap Mt Red 2 All 6 79C 1149 1 Meter Hour 1 All 7 494134 1 Gauge Fuel Electric 1 All 8 405982 1 Cover Meter Hole 2 All 9 402670 Receptacle Duplex 3 Wire 115 V 1 All 492010 1 Box Control Assembly 1 A 492010 7 Box Control Assembly 1 B 10 492036 Box Control 1 A 492036 1 Box Control 1 B 11 406003 2 Strip Terminal 12 Station 1 All 12 406003 1 Strip
71. sed on experiments at the cellular level and from studies with animals and people 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 coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science 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 Do not coil or drape cables around the 2 Arrange cables to one side and away from the operator 4 Keep welding power source and cables as far away from body as practical About Pacemakers The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 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 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U
72. t riaux ignifuges et durables laine certains proc d s peut endommager et cuir et des chaussures de s curit 1 Portez une casque de soudeur avec filtre oculaire de nuance Portez un casque antibruit ou des bouchons d oreille approuv s appropri e consultez la norme ANSI Z49 indiqu e ci apr s lorsque le niveau de bruit est lev 8 V 96 2 1 PRECAUTIONS SECURITE EN SOUDAGE L ARC Instruction 830002 SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE Op ration de Coupage ou soudage Brasage tendre au chalumeau Brasage fort au chalumeau Oxycoupage mince moyen pais Soudage aux gaz mince moyen pais Soudage 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 Soudage l hydrog ne atomique AHW Soudage avec lectrode de carbone CAW Soudage Plasma PAW Gougeage Air Arc avec lectrode de carbone mince pais Coupage a Plasma PAC mince moyen pais selon AWS 8 2 73 Dimension d lectrode ou Epaisseur de m tal ou Intensit de courant toutes conditions toutes conditions moins de 1 po 25 mm de 1 po 25 150 mm plus de 6 po 150 mm moins de 1 8 po 3 mm de 1 8 1 2 po 12 mm plus de 1 2 po 12 mm
73. t engine in sub zero condi tions Operation In Hot And Humid Conditions Battery The specific gravity and proper level of the battery electrolyte should be maintained Observe recommendations in the Maintenance and Operator s Engine Manual for proper care of the battery Operation In Extremely Dusty Conditions If unit is to be operated under dusty out of door con ditions place in a sheltered area Take advantage of any natural barriers which may offer protection from blowing dust If the installation is more than temporary erect a protection shield a Fuel System Drain the fuel water trap sediment bowl frequently and keep all fuel contain ers covered and protected against dust entry b Oil Filter and Air Cleaner These both need more frequent attention under dusty conditions Check air Restrictor Indicator daily Clean oil filter cartridge as needed Change or clean element in the air cleaner as required Crankcase The crankcase oil level will bear close attention Dusty conditions tend to load crankcase oil with dirt Watch for dirty and gritty oil conditions and change oil more frequently as re quired Operation In Salt Water Areas a Canopy Wash canopy regularly to remove salt film Repaint any damaged places and oil the side panel hinges regularly b Covering To protect the engine and gen erator as much as possible from salt water atmos phere keep the side panels on the ca
74. tified to DC power by the output rectifier and stabilized by the stability reactor The auxiliary generator is self excited The AC voltage output furnishes 115 volt power to a diode bridge rectifier which provides DC voltage for exci tation of the auxiliary generator fields and welding generator fields It provides 115 volt and 230 volt AC power to the receptacles on the Control Panel for operation of small tools lights etc See Tabu lated Data for rated auxiliary power of your unit Engine The engine used in this unit is a Deutz Model F3L 912D diesel engine It is directly coupled to the welding generator shaft by a flexible coupling Identification The welding generator unit has an identification plate attached to the control panel on the left hand side The unit is identified as to SPEC number by the dash number which follows it The engine identification number is stamped on right hand side of the cylinder block When ordering spare parts or communicating about this machine be sure to specify the engine serial number engine type unit specification and serial numbers Left and right hand sides of the unit are determined when facing the control panel See Supplementary Mate rials for address for communicating or ordering en gine parts Tabulated Data Generator Output Auxiliary Power 115 230V AC Output Welding 16 kW Amperes rated
75. trode holders Never dip holder in water to cool it or lay it down on the ground or the work surface Do not power circuit and machine internal circuits are also ee ao live when power is semiautomatic or automatic 4 peop wire welding the wire wire reel drive roll housing Do not use worn damaged undersized or poorly spliced cables and all metal parts touching the welding wire are Do not wrap cables around your body electrically live Incorrectly installed or improperly Ground the workpiece to a good electrical earth ground grounded equipment is a hazard Do not touch electrode while in contact with the work ground Do not touch live electrical parts circuit Wear dry hole free insulating gloves and body protection Use only well maintained equipment Repair or replace damaged Insulate yourself from work and ground using dry insulating mats parts at once or covers In confined spaces or damp locations do not use a welder with Disconnect input power or stop engine before installing or serv AC output unless it is equipped with a voltage reducer Use icing this equipment Lock input power disconnect switch open equipment with DC output or remove line fuses so power cannot be turned on accidentally Wear a safety harness to prevent falling if working above floor Properly install and ground this equipment according to its level Owner s Manual and national
76. xceed 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 JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT PURCHASER S RIGHTS 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 authorized 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 ALL OTHER P WEE PRO LITE POWER SUPPLIES POWER SUPPLIES PRO PLUS PRO WAVE LABOR MAIN POWER MAGNETICS STATIC amp ROTATING 3 YEARS 2 YEARS 1 YEAR ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS 1 YEAR CONTROL PC BOARD 3 YEARS 2 YEARS 1 YEAR
77. yon Station PA 19536 Telephone Number for Information 610 682 6361 Emergency Telephone Number CHEMTREC 1 800 424 9300 In Washington D C or outside continental U S call 1 202 483 7616 Hazardous Components Specific Chemical Identity Other Limits Common Name s OSHA PEL ACGIH TLV Recommended Percent Lead CAS 7439921 0 05 mg m 0 15 mg m 43 70 Sulfuric Acid CAS 7664939 1 00 mg m 1 00 mg m 20 44 Antimony CAS 7440360 0 50 mg m 0 50 mg m Appearance and Odor clear odorless colorless Solubility in Water completely Boiling Point approximately 235 F Specific Gravity 0 1 1 220 1 325 Evaporation Rate Butyl Acetate 1 less than 1 0 Vapor Density AIR 1 N A Melting Point N A Vapor Pressure mm Hg 13 Flash Point Method Used non flammable Flammable Limits hydrogen gas Extinguishing Media Class ABC extinguisher CO and or Halon LEL 4 UEL 745 Special Fire Fighting Procedures Cool exterior of battery if exposed to fire to prevent rupture The acid mist and vapors in a fire situation are corrosive Wear special respiratory protection SCBA and clothing Unusual Fire and Explosion Hazards Hydrogen gas which may explode if ignited is produced by this battery especially when charging Use adequate ventilation avoid open flames sparks or other sources of ignition Stability Stable Condition to Avoid Cases decompose at 160 410 C 322 770 F Incompatibility Materials to Avoid Strong oxidiz

MEGA-ARC 5040DD 400 Amp Constant Current Diesel Engine

Contents

Download Pdf Manuals

Related Search

Related Contents