Lincoln Electric RED-D-ARC E500 User's Manual
Contents
1. 217 CONNECTOR AND THESE THREE LEADS ARE NOT USED WHEN OPTIONAL POCKET AMPTROL IS PROVIDED SWITCH SHOWN IN LOCAL POSITION REMOTE CONTROL RECEPTACLE PN16688 L8184 RED D ARC E500 E 2 WIRING DIAGRAM CODE 11042 amp UP E 2 E500 WIRING DIAGRAM 230 460 575 V ELECTRICAL SYMBOLS PER E1537 LEGEND DC OUTPUT FILTER 10K OHM POT OUTPUT CONTROL 10K OHM POT ARC FORCE CONTROL 30 OHM POWER SWITCH MACHINE REMOTE SWITCH DIAL SELECTOR SWITCH SCR1 D1 SCR2 D2 SCR3 D3 D4 SCR AND DIODE RECTIFIER BRIDGE T1 MAIN TRANSFORMER T2 CONTROL TRANSFORMER 1CR INPUT STARTER COLORS AMBER GREEN WHITE YELLOW DASHED ITEMS ON WIRING DIAGRAM ARE OPTIONAL s p aa 2 4 CAVITY NUMBERING SEQUENCE COMPONENT SIDE OF BOARD 15A 32 0 HOT HOT LINE LOAD 32 I WHITE WHITE GROUNDSTUDON LINE LOAD OUTPUT PANEL 31 THERMAL FAN THERMOSTAT TO SUPPLY LINES TO GROUND PER NATIONAL ELECTRICAL CODE RECONNECT PANEL SHOWN CONNECTED FOR 230V TAPE UP SEP2. D 7 D 10 Wiring Diagrams 2 2222 ce RUN eue ee ee ee Section E Parts Lists la EL ENEE In Process P353 Series P66 J amp K Go to www lincolnelectric com for the latest Parts List information RED D ARC E500 vi 1 INSTALLATION 1 LOCATION A WARNING ER FALLING EQUIPMENT can cause injury Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Install the welder in a dry location where there is a free circulation of air in through the front louvers and out the back of the case A location which minimizes the amount of smoke and dirt drawn into the front louvers reduces the chance of dirt accumulation that can block air passages causing overheating and nuisance shut down of the machine INPUT WIRING 44 WARNING ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts Welder is rated for 230 460 575V input and is shipped from the factory connected for 460V input To change the connection see the wiring or connection diagram pasted to the inside of the access panel in the case back Be sure the voltage phase and frequency of the input power is as
3. Suonoeuuoo esoo suonoeuuoo LLZ OLZ ELZ ZIZ si aJqIssog uonoeuuoo e gissod X elqissod JUSHIUUSIU 945504 85007 eigissogd LL QZ Speal X09049 B qISSOd ADO ASGG G ADO ASS uey mq oneue paje uey 559 ADO ing ADO Dog 0 S ADO AG 0 SI ADO ASG S SI ADO 9949 3od WNL 9172119 10 ADO indino D 8 TROUBLESHOOTING PROCEDURES PROCEDURE FOR REPLACING P C BOARD The P C Board is located behind the front control panel Remove the nameplate screws to loosen the control panel When the P C Board is to be replaced follow this pro cedure Visually inspect P C Board in question Are any of the components damaged Is a conductor on the back side of the board damaged 1 If there is no damage to the P C Board insert a new one and see if this remedies the problem If the problem is remedied re insert the old P C Board and see if the problem still exists with the old P C Board a If the problem does not exist with the old board check the harness plug and P C Board plug for corrosion contamination or oversize Check leads in the harness for loose connec tions If there is damage to the P C Board refer to the Troubleshooting Guide OUTPUT VOLTAGE The open circuit voltage of the machine should be
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5. TAPE UP SEPARATELY TO PROVIDE AT LEAST 600 VOLTS INSULATION TO PRIMARY COILS FANMOTOR 233 CHOKE SECONDARY Ge CHOKE THERMOSTAT THERMOSTAT THERMOSTAT m 234 235 LEGEND D5 D POCKET AMPTROL SENSING BRIDGE L1 DC OUTPUT FILTER AUXILIARY COILS Ri 10K OHM POT OUTPUT CONTROL R2 10K OHM POT ARC FORCE CONTROL R3 40 OHM R4 4 OHM AMPTROL SENSING RESISTOR TOP PRIMARY SW1 POWER SWITCH SW2 MACHINE REMOTE SWITCH SW3 DIAL SELECTOR SWITCH SW4 OPTIONAL POLARITY SWITCH 60 Hz ONLY SCR1 D1 SCR2 D2 SCR DIODE BOTTOM PRIMARY SCR3 D3 RECTIFIER BRIDGE D4 n MAIN TRANSFORMER T2 CONTROL TRANSFORMER RECTIFIER T3 POCKET AMPTROL OPTION BRIDGE TRANSFORMER ICR INPUT STARTER THESE LEADS ARE gt PRESENT ONLY WITH A AMBER OPTIONAL METER GREEN KIT W WHITE Y YELLOW COLORS 7 1 OPTIONAL POCKET DASHED ITEMS ON WI i 2 AMPTROL P C 12345678 DIAGRAM ARE OP BOARD j i 5 d ee SNUBBER BOARD i IE ke 232 DI H 2 y 7 Io SNUBBER BOARD H 4 EE i X Late Ian i PILOT LIGHT 2 gt E CAVITY NUMBERING SEQUENCE N pic COMPONENT SIDE OF BOARD i RE Sp E Nor
6. 9 Replace 10 Turn input power off 115V cir cuit is hot when input power is connected Check thermostats with continuity meter should read short circuit when machine is cool Replace if defective There are two thermostats one on the secondary lead and one on the choke Replace High Temperature Warning Light if defective CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed RED D ARC E500 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS RECOMMENDED SYMPTOMS Pe COURSE OF ACTION C Machine input contactor closes but has no or low output Open circuit voltage should be 67 to 71 volts FUNCTION PROBLEMS Electrode or work lead loose or broken Open transformer primary or secondary circuit Supply line fuse blown Input line grounded causing single phase input Input leads not connected to contactor Latching resistor R3 open Control circuit problems 1 Repair connections Repair Replace blown fuse check fuse size Repair input to machine Connect input lead Replace b Check leads to the resistor and repair if defective See Troubleshooting Procedures Power Silicon Controlled Rectifier D M
7. 19 59 dis due ddl y ups al yal pi e Al aan y READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaga Use ventilac o e exhaust o para remover fumo da zona respirat ria eti AmP53U tRcocuc Feu 9 fsUPBHEILTASESUCFEU EUR Ea fE
8. SH7IAE AAS AS FAAA 4 7 Qai ys Jung dul aude EAN gaal ha a A Aa qii e oe glaa us Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico e toque as partes el tricas nuas X TIA LIE ACE PARKI ETBRATY FE DF I gt e temas Aina fl NM il gS jui ae Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas ONZIRPHiI ZUUALKEEE SER HGTBI BUSUR ERE zao Sel Yala E nelle Key Gals hil ali lin Jia Y e Aale Lll dl Ayal Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO tm BIA Chinese LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE US
9. BOARD POWER RECTIFIER BRIDGE DIAGRAM 2 5 An open gate circuit will have an infinite or high resistance A good gate circuit will read a low resis tance but not zero ohms BATTERY TEST Check the batteries by shorting leads A and C then close switch SW 1 Replace batteries if voltage is less than 3 volts SCR TEST 1 Isolate SCR to be tested by disconnecting gate leads from the terminals on the P C Board Do not remove SCR from the heat sink Connect SCR into the test circuit as shown A lead to anode C lead to cathode and G lead to the gate 3 Close switch SW 1 switch SW 2 should be open voltmeter should read zero If the voltmeter reads higher than zero the SCR is shorted With switch SW 1 closed close switch SW 2 for two seconds and release The voltmeter should read 2 to 2 5 volts before and after switch SW 2 is released If the voltmeter does not read or reads only while SW 2 is depressed the SCR is open or batteries are defective repeat Battery Test Procedure Open switch SW 1 disconnect the gate lead G and reverse the A and C leads on the SCR Close switch SW 1 The voltmeter should read zero If the voltage is higher than zero the SCR is shorted RED D ARC E500 E 1 WIRING DIAGRAM CODE 10649 ONLY E 1 E500 WIRING DIAGRAM 230 460 575 V TO SUPPLY LINES RECONNECT PANEL SHOWN TO GROUND CONNECTED FOR 230V PER NATIONAL ELECTRICAL CODE
10. GFCI is designed to do RED D ARC E500 TROUBLESHOOTING D 1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibili ties that may contribute to the machine symptom Step 3 RECOMMENDED COUHSE OF ACTION This column provides a course of action for the Possible Cause If you do not understand or are unable to perform the Recommended Course of Action safely contact you local Authorized Field Service Facility 44 WARNING Sc 0 ELECTRIC SHOCK can kill Do not touch electrically hot parts e Have an electrician install and service this equip ment Turn the input power of
11. M meter on the X10 scale connect the positive lead to the lead removed Touch the nega tive lead to the shunt The indicating needle on the meter will move quickly to the right low resistance value and then slowly return to the left high resis tance value This indicates that the capacitor in the snubber circuit is taking a charge If the needle stays to the right the capacitor is shorted and the assembly is defective If the needle does not move the capacitor or resis tor on the snubber assembly is open and the assembly is defective CHECKING CURRENT CONTROL RHEOSTAT ON MACHINE Turn the machine off Remove the control panel screws and open the front cover Turn the current control switch to remote Disconnect the harness plug from the control board Put current range switch to B range With an ohmmeter on X1K connect it to lead 210 and 211 on SW 2 Rotate the current control rheostat The resistance reading should be from around zero to 10K ohms OX RED D ARC E500 D 9 Check the resistance reading between 75 on the ter minal strip and 211 on SW 2 The reading must be 10K ohms No reading will indicate an open rheostat and a low reading will indicate a shorted or partially shorted rheostat in either case replace TOGGLE SWITCH CHECK 1 Turn off the machine power input SW 1 has 115 volts across it when the input power is connected Isolate the switch to be tested by removing all con necti
12. lead connector J4 on control P C Board AC leads X1 X2 and X3 from the anodes of the SCRs and cathodes of the diodes The 200 221 222 and 223 leads from the Snubber P C Board Lead 220 that connects to the latching resistor R3 The cathode of each diode 4 total POWER DIODE TEST 1 Establish the polarity of the ohmmeter leads and set to the X10 scale Connect the ohmmeter positive led to anode and negative lead to the cathode Reverse the leads of the ohmmeter from Step 2 A shorted diode will indicate zero or an equally low resistance in both directions An open diode will have an infinite or high resistance in both directions and a good diode will have a low resistance in Step 2 and a much higher resis tance in Step 3 POWER SILICON CONTROLLED RECTIFIER TEST The SCR must be mounted in the heat sink when mak ing this test 1 Connect the ohmmeter set to the X10 scale leads to the anode and cathode Reverse the leads of the ohmmeter from Step 1 A shorted SCR will indicate zero or an equally low resistance in one or both directions Establish the polarity of the ohmmeter Connect the positive lead to the gate and the negative lead to the cathode Ox RED D ARC E500 D 10 Su Batteries La ele 4 557 3 volts TROUBLESHOOTING SW 1 WEI a Cathode 4 L_ Batteries SE Stud or Heat Sink Anode 5 2 Watt D 10 GATELEADS TO CONTROL P C
13. option electrode and to work Tighten the holding nuts with a wrench Cable Sizes for Combined Length of Electrode and Work Cable Copper at 6095 Duty Cycle Extreme care must be observed when installing or extending the wiring of a remote control Machine Up to 100 ft 100 to 150 ft 150 to 200 ft 200 to 250 ft Size 30 m 30 46 m 46 61 m 61 76 m E500 2 0 68 mm 3 0 86 mm 3 0 86 mm 4 0 108 mm TIG WELDING The E500 is shipped with proper R F By pass circuitry installed to protect the control circuit when TIG welding with a TIG Module unit CAUTION To provide protection the welder frame grounding stud must be connected to ground RED D ARC E500 B 1 OPERATION B 1 WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet cloth ing Insulate yourself from work and ground Always wear dry insulating gloves 2 FUMES AND GASES can be danger a D Use ventilation or exhaust to remove fumes from breathing zone ous Keep your head out of fumes A WELDING SPARKS can cause fire or Tw c explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn 4 Wear eye ear and body protection NS NOTE The P C Board is protected by a moisture resistant coating When the welder is operated this coating will bake off of certain p
14. specified on the welder nameplate Have a qualified electrician remove the access panel in the case back and connect the three phase AC power to terminals L4 Lo L4 of the input contactor in accor dance with the U S National Electrical Code all local codes and the wiring diagram located inside the machine The welder frame must be grounded A stud marked with the symbol located on the floor of the input box is provided for this purpose See the U S National Electrical Code for details on proper grounding meth ods Recommended Input Wire Ground Wire and Fuse Sizes Based on U S National Electrical Code For 60 hertz 3 phase Welders at 60 Duty Cycle Copper Wire Size Type 75 in Conduit 3 Input Wires Wire 1 Ground Super Lag Fuse Size in Amps This welder is rated for 500 Amps 60 duty cycle Duty cycle is based on a ten minute period Therefore the welder can be operated at nameplate rated output for 6 minutes of every 10 minute period without overheat ing An amber high temperature warning light provides a visual indication of an over temperature condition OUTPUT CONNECTIONS OUTPUT STUDS With the machine off run electrode and work cables of the appropriate sizes see the following table up through the rectangular holes in the machine base located below the output studs Connect the cable lugs to the output terminals marked and or if the welder comes equipped with the polarity switch
15. 67 to 71 volts and should not vary when the rheostat is varied If any other condition exists refer to the Troubleshooting Guide OVERLOAD PROTECTION E500 s have built in protective thermostats If the recti fier or transformer reaches the maximum safe operat ing temperature because of frequent overload or high room temperature plus overload the line contactor drops out stopping the welder The thermostats auto matically reset and the line contactor pulls in when the temperature reaches a safe operating level The power rectifier bridge is also protected against short term high current overloads generally caused by poor operating techniques For example if an arc RED TROUBLESHOOTING D 8 gouging carbon or the electrode is allowed to touch or almost touch the work for a couple of seconds more the overload protection P C Board automatical ly reduces the output to minimum and keeps it there until the overload is removed or the machine is turned off CHECKING SNUBBER CIRCUIT In case of an SCR malfunction or failure the snubber assembly should be checked Turn the machine off and disconnect one lead of the snubber assembly Either 221 222 or 223 depending on the SCR in question See wiring diagram The sides of the machine have to be removed to do this See parts list for the exact location 1 Visually inspect the snubber assembly for overheat ed components Using a V O
16. ARATELY TO PROVIDE AT LEAST 600 VOLTS INSULATION TO PRIMARY COILS HIGH TEMP LIGHT 232 235 AAN SECONDARY THERMOSTAT CHOKE THERMOSTAT 234 235 31A 14 201 en 13 fe AUXILIARY COILS 4l 66 oy 7 TOP PRIMARY BOTTOM PRIMARY M 11 17 66V 5 5 RECTIFIER BRIDGE 12345678 J5 SNUBBER BOARD 232 CONTROL P C 235 rs PILOT LIGHT 235 Se BOARD c B A REMOTE CONTROL RECEPTACLE SW2 SWITCH SHOWN IN LOCAL POSITION RED D ARC E500 L11467 E 3 DIAGRAMS E 3 22 84 GAS SUPPOR 12244 7 7 1 18 RED D ARC E500 NOTES P E500 NOTES RED D ARC E500 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO it is BIR Chinese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo
17. IM656 A RED D ARC e E500 For use with machines having Code Numbers 10649 11042 er N VOW RED D ARC Welderentals OPERATOR S MANUAL Red D Arc Spec Built Welding Equipment This RED D ARC welder is built to RED D ARC Extreme Duty design specifications by Lincoln Electric Safety Depends on You This welder is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful 1 800 245 3660 North America s Largest Fleet of Welding Equipment SAFETY AA WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additio
18. O E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR WIREHPEHNI H DETER ICH A ETHBRLTF SL ZLTAHDREHELEITF LN E D o eo ZARJA Apia AR Oka FAS ESA BHE gl Catia aiig d AA giall lala ay LINCOLN 5 World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
19. a softer arc A setting that is too low may cause the electrode to stick in the pud dle Higher settings will provide a higher short circuit current a more forceful arc and possibly more spatter For most welding the dial should be set at approximately mid range 5 6 Adjustment up or down can then be made depending on the electrode procedures and operator preference For most TIG welding appli cations adjust this control to minimum for best operating characteristics 115 VAC Duplex Receptacle Code 10649 only The duplex receptacle is located near the output studs and is protected by a 15 amp circuit breaker 115 VAC GFCI Receptacle Codes 11042 and above The GFCI receptacle is located near the output studs and is protected by a 15 amp circuit breaker OPTIONAL EQUIPMENT 1 Undercarriage K817 K817R includes a spring loaded handle for hand towing and a choice of wheels 2 Remote Control Supplied by Red D Arc RED D ARC E500 1 C 1 44 WARNING e ELECTRIC SHOCK can kill Have an electrician install and ser vice this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts GENERAL MAINTENANCE 1 The fan motor has sealed bearings which require no service 2 In extremely dusty locations dirt may clog the air channels causing the welder to run hot Blow out the welder at regular intervals The side
20. achine has maximum output but no control Possible defective power SCR Possible defective control board Remove all gate leads G1 G2 and G3 at PC board If welder has any open circuit voltage power SCR is defective Check per Troubleshooting Procedures Replace See Troubleshooting Procedures Replacing PC Boards Connector J4 on latest control board CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed RED D ARC E500 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS RECOMMENDED SYMPTOMS COURSE OF ACTION E Machine does not have maximum output 67 to 71 volts FUNCTION PROBLEMS Input fuse blown Machine is single phased One phase of main transformer windings open Defective power bridge Replace fuse or repair input line Check reason for fault Repair Check bridge See Troubleshooting Procedures Checking Snubber Circuit and Power Rectifier Bridge Assembly F Machine comes on but soon trips off while under load and High Temperature Warning Light glows Choke or Secondary thermostat tripped Improper ventilation Loaded beyond rating Fan inoperative Shorted diode or SCR in power
21. cept when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P I Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations RED D ARC E500 SAFETY iv PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides
22. e vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place RED D ARC E500 V V for selecting this QUALITY product We want you to take pride in hank You operating this product ses as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportati
23. ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c GET NA CYLINDER may explode KI damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight ex
24. f at the fuse box before working on equipment 44 CAUTION Iffor any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed RED D ARC E500 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS RECOMMENDED SYMPTOMS Pe COURSE OF ACTION A Input contactor chatters FUNCTION PROBLEMS 1 Faulty input contactor 2 Low line voltage 1 Repair or replace 2 Check with Power Company B Machine input contactor does not operate 1 Supply line fuse blown 2 Power circuit dead 3 Broken or loose power lead 4 Wrong voltage 5 Thermostats tripped High Temperature Warning Light should be lit Welder overheated 6 Input contactor coil open 7 Open winding on 115V pilot transformer 8 Power ON OFF switch not closing 9 Lead broken or loose connec tion in 115V starter circuit 10 Thermostats defective High Temperature Warning Light should be lit 1 Replace look for reason for blown fuse first 2 Check voltage 3 Repair 4 Check voltage against instructions 5 a Make sure the fan is operating and that there are no obstruc tions to free flow of air b Operate at normal current and duty cycle c Replace High Temperature Warning Light if defective 6 Replace 7 Replace 8 Replace
25. lds may interfere with some pacemakers and welders having a pacemaker should consult their physician Keep all equipment safety guards covers before welding and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 e In some cases it may be necessary to remove safety 2 d 1 Route the electrode and Work cables together Secure guards to perform required maintenance Remove them with tape when possible guards only when necessary and replace them when the maintenance requiring their removal is complete 2 4 2 Never coil the electrode lead around your body Always use the greatest care when working near moving parts 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right Do not put your hands near the engine fan Do not attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turni
26. nal safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE n 4 1 h dare scalding do eet the powered equipment De iu or pressure cap when the engine is 1 the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 2 cm 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld S may be dangerous ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current flowing through any conductor causes ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fie
27. ng leads Check to make sure the switch is making connec tions with a V O M meter The meter should read zero resistance Put the ohmmeter on X1K scale and measure the resistance between the terminal and the case of the machine touch a self tapping screw Reading should be infinite If either step 3 or step 4 fails replace the switch REMOTE CONTROL CHECK Disconnect the remote field control and connect an ohmmeter across 75 and 76 and rotate the rheostat in the remote control The resistance reading should go from zero to 10K ohms Repeat with ohmmeter across 77 and 76 with same results Connect ohmmeter across 75 and 77 The reading should be 10K ohms A lower reading will indicate a shorted or partially short ed rheostat A very high reading will indicate an open rheostat In either of the last two cases replace the rheostat Check for any physical damage CHECKING POWER RECTIFIER BRIDGE CAUTION ASSEMBLY Precise evaluation of diodes or SCRs require laboratory equipment If a bridge problem still exists after test please call a Lincoln Field Service Shop Equipment Needed 1 V O M or ohmmeter for diodes 2 Circuit Diagram 1 for 5 5 TROUBLESHOOTING D 9 DEVICE ISOLATION See the instruction manual parts list for the exact location Disconnect the following leads from the bridge shown in Diagram 2 1 Wiring harness gate leads G1 G2 G3 from gate
28. ng the engine or welding generator during maintenance 2 d 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropriate RED D ARC E500 3 b SAFETY e ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be a
29. on company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life 44 CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment RED D ARC E500 vi TABLE OF CONTENTS Page Installation Rn RR eee Made de eee Section A LOCATION EE A 1 Input Wiring cesses Rm eyes neo A 1 Output Connections A 1 Operating Instructions Section B Maintenance ae e ERES Gk kx ee NIE Section C Troubleshooting ee NNN ENNEN a EN EE annee ae aaa Section D Troubleshooting Procedures
30. ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au
31. ower resistors that normally operate at high temperatures emitting some smoke and odor for a short time These resistors and the P C Board beneath them may become blackened This is a normal occurrence and does not damage the component or affect the machine performance NOTE The cooling fan on this unit is controlled by a thermostat to operate only when it is needed 1 To Start the Welder move the Power switch to On This starts the welder and lights the white pilot light on the machine control panel This light indi cates that the line contactor is energized 2 Setting Welding Current a The Current Control dials on the front of the machine indicates the output current at the NEMA arc voltage The A range controls the current over about 1 2 of the range of the B range A toggle switch on the control panel allows selection of the desired range The output control can be adjusted while welding b Provisions for remote control are standard A current control switch on the machine control panel labeled Current Control at E500 or Current Control Remote is provided for select ing the desired mode of operation either at the machine or remote Be certain the machine remote switch is in the machine position unless a remote control is connected c The Arc Force Control located on the right side of the front control panel is calibrated from one to ten Lower settings will provide less short cir cuit current and
32. panels can be removed even when the machines are stacked POWER RECTIFIER REPLACEMENT Refer to the troubleshooting section Power Rectifier Bridge Assembly Checking Procedure if a rectifier fail ure is suspected NOTE Since proper material and correct assembly procedures are critical field disassembly of the power rectifier bridge sections can do more harm than good Return a defective rectifier bridge section or the entire bridge to the factory for repairs TESTING THE GFCI RECEPTACLE Turn the welder ON Press the reset button fully Plug a lamp or radio into the GFCI and leave it plugged in to verify that power is ON If there is no power go to the TROUBLESHOOTING section Press the TEST button in order to trip the GFCI device This should stop the flow of electricity making the lamp or radio shut OFF Note that the RESET button will pop out If the power stays on go to the TROU BLESHOOTING section If the power goes OFF the GFCI is working properly To restore power press the RESET button Press the TEST button then RESET button every month to assure proper operation NOTE The GFCI receptacle is in a 115V circuit where the neutral is floating with respect to ground Consequently if a GFCI tester is plugged into the GFCI receptacle the tester will show that there is an open ground This indication of an open ground is normal and the GFCI will function properly in the event of a ground fault current as the
33. re load on receptacle or GFCI does not exceed 15 rating of circuit breaker See General Maintenance Section for testing GFCI Replace Check all wiring going to recepta cle or GFCI and circuit breaker for possible broken connection N Fan runs continuously Defective Thermal Fan Thermostat Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed RED D ARC E500 TROUBLESHOOTING D 7 D 7 T pieoq 9 QISSOJ H9S Jamod 1901109 jou SI a eyon pue pea ajeb T ejgissod HO Jousydwe T joueuduue eoejdeJ JO T HIP 10 LH PUB ZMS e qissod YO S a9Ue sIsal dis 18819 Jou lu IN9 9Z WNWIUIW QN9 SZ Se 1snui eoueijsiseu punojf duis SI uo jo eoueisisaJ HOOUTD seule indino spee yoayo osje pue spee pue 40 quiesse ousydwe euiuexe
34. rectifier bridge Defective thermal fan thermostat Make sure all case openings are free for proper circulation of air Operate at rated current and duty cycle Check leads choke and sec ondary thermostat and motor bearings Fan can be tested on 115 volt line Check thermal fan thermostat Refer to Power Hybrid Bridge Checking Procedure See Troubleshooting Procedures Checking Snubber Circuit and Power Rectifier Bridge Assembly Replace G Machine comes on but reduces to low output under load and remains there until the load is broken and arc re started See Fault Protection Operation Section Excessive load causing the over load protection on control board to operate Machine output shorted causing overload protection on control board to operate Control circuit defective Reduce load Turn machine off and remove short Replace per PC board replace ment See Troubleshooting Procedures Replacing PC Boards CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed RED D ARC E500 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS RECOMMENDED SYMPTOMS COURSE OF ACTION H Machine trips off when under no load or make
35. rol Rheostat Repair or connect See Troubleshooting Procedure Power Silicon Controlled Rectifier CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed RED D ARC E500 TROUBLESHOOTING Observe all Safety Guidelines detailed througout this manual PROBLEMS RECOMMENDED SYMPTOMS Pe COURSE OF ACTION L Optional remote current control not functioning See Troubleshooting Procedures before connecting FUNCTION PROBLEMS Current control switch in the wrong position Leads 75 76 and 77 not con nected to correct numbers on models with terminal strip Remove control leads broken Remote control potentiometer open Lead or connection in current control circuit open Control PC board plug discon nected or loose Control circuit problems Place switch in posi tion Correct connection Repair broken leads See Troubleshooting Procedures Connecting Remote Control Connect or repair Connect plug See Troubleshooting Procedures Power Silicon Controlled Rectifier M 115 VAC Receptacle or GFCI not working Circuit Breaker Tripped Defective Circuit Breaker Broken connection in wiring Reset circuit breaker Make su
36. s close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 GET NA L ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 3 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at
37. s excessive noise like it is loaded FUNCTION PROBLEMS Power bridge rectifier may have a shorted diode or SCR Short in the transformer Fan hitting vertical baffle 1 Refer to Power Hybrid Bridge Checking Procedure See Troubleshooting Procedures Checking Snubber Circuit and Power Rectifier Bridge Assembly Repair Clear the fan Variable or sluggish welding arc Poor work or electrode cable connection Current too low Welding leads too small Open SCR or diode in power rectifier bridge Control circuit problems Check and clean cable connec tions Check recommended currents for rod type and size See Troubleshooting Procedures Fault Protection Operation Check per Power Hybrid Bridge Procedures See Troubleshooting Procedures Checking Snubber Circuit See Troubleshooting Procedures J Welder will not shut off Input contactor contacts frozen Replace input contactor K Current control on machine not functioning Current control switch in wrong position Current control switch defective Current control potentiometer defective Lead or connection in control circuit open Defective control or circuit boards Place switch in machine posi tion See Troubleshooting Procedures Toggle Switch Check See Troubleshooting Procedures Checking Current Cont
38. sible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear
39. soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence d
40. the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b RED D ARC E500 SAFETY 3 7 WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not pos
41. y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pieces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da terra XIuiiHMIU IRANRACRENANCE E n O amp 5B C EXEAT PETER Saiss ze uc iss AU ne e Hz B Sal ole Au e M quali Y 0 el ai gl o zial DS dan wae Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e RAPTUSOOM BENLULTERNERA ein OSTEN LS AS Aal Am Aal Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo A HAUSHERMRELTTF alt RRR HRARGHRBAR ex
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