Lincoln Electric K386 User's Manual
Contents
1. 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 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au 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 7 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 8 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 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 lev age2. Qd uil il e 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 ONRNRPAK ERUALEEE CRRBTEE LEUTESU AAS BREE Gel Aeg HAS cals 13 im Jamie gl AVISO DE PRECAUCION French ATTENTION German WARNUNG Japanese GE SIR Arabic LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR 5 MBO RHO X HA OHRBEKS BA ETIEEMUCEEU TL TRHOKREREL A AU S BBA EAN REE LHR T 55 Str o SSS SAAD HAS HUA SAE GS BEHE malt Aj gl cabelas Lgllaniut ub aded quil anal Stays agily 1 LINCOLN e World s Leader in Welding and Cutting Products e 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
3. 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 1 9 To prevent accidentally starting gasoline eng turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate from the Lincoin Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot ELECTRIC AND MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 fro
4. 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 cuffiess trousers high shoes and a cap over your hair Wear 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c CYLINDER may explode if 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 othe
5. Required Equipment AC Welding refer to procedure 1 K388 NA 4 Control 1 req d A 2 K208 B Automatic Head 1reqd A includes Automatic Flux Hopper 3 K1276 C AC 1200 Power Source 1 req d DC Welding refer to procedure 1 K210 NA 38 or K356 NA 5 Control 1 req d 2 K208 B NA 3 or K346 B 5 Automatic Head 1 req d includes Automatic Flux Hopper 3 K1288 DC 600 or K1298 DC 1000 Power Source 1 req d AC or DC Welding 4 K386 Narrow Gap Deep Groove Nozzle 1 req d 5 K215 Input Cable Assembly 1 req d 6 Work cable s As req d 7 3 32 Electrode and Flux Consumables As req d refer to procedure 8 Extra T14879 3 32 Contact Tips As req d refer to Maintenance Section V 1 extra tip included with nozzle 9 K223 Water Solenoid Assembly 1 req d 10 Cooling water tubing and fittings As req d Refer to installation Section 111 Optional Equipment K29 Vertical Head lift Adjuster 1 req d K96 Horizontal Head Adjuster 1 req d K325 S TC 3 Automatic Travel Carriage 1 req d K299 50 60 Ib Wire Reel and Mountings 1 req d M10214 Wire Straightener for LC 72 electrode 1 req d K283 Portable Digital Wire Feed Speed Meter except for NA 5 1 req d A If using an earlier K248 NA 4 Control and head with a 142 1 gear ratio 1 Order and instail a T13724 B Drive Roll and Guide Tube Kit 2 In order to obtain wire feed speeds above 150 IPM order 515013 2 motor pinion gear and 812503 helical gear to convert t
6. no kinks even when the nozzle body is pivoted between the 180 stop pins 6 Connect the electrode leads from the NA 4 to the nozzle connection tab using the bolt and nut pro vided Be sure that the cables have enough slack to permit any required pivot adjustments of the nozzle 7 Connect a flexible tube from a water supply capa ble of supplying at least 1 4 gal min to the noz zle s inlet tube furthest from flux tube and a sec ond flexible tube to the nozzle s outlet tube near est the flux tube LINCOLN 3 INSTALLATION A 3 WARNING The water tubing must be electrically non conductive since the nozzle inlet and outlet tubes will be at the same potential as the electrode while welding Also allow enough siack in the tubes to permit any required pivot adjustments of the nozzle but keep the tubes away from any hot surfaces capable of melting the tube Water Solenoid Connection The K223 water solenoid should be used with the Control to automatically turn on the water flow while welding However since the control box receptacle normally used to electrically connect the K223 is also used for the Automatic Flux Hopper the K223 must be wired directly to the terminal strip inside the control box A WARNING Be sure all power to the NA control is shut off at the power source a Remove the K223 cable bolted to the two solenoid leads b Extend the two solenoid leads to 87 and 531 at the NA co
7. BLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional 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 PERFORMED ONLY BY QUALIFIED INDIVIDUALS AN FOR ENGINE powered equipment 1 a Tum the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes a amp Lo outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and ail other moving parts when starting operating or repairing equipment
8. 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 as 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 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock j Also see Items and 8 4 b 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 5 b screening and or warn them not to watch the arc nor expose the
9. LVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la de respiraci n e Mantenga ta caheza 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 aspirateur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria ts LPSMEBTEIILT Feu 9 fSUCHRICTHOBEEUCTFSV e mana M m e E e FII e Y22374 BH7IAE Wels S XACOBPBEE S7I R x21817 As TAMH ESIE Qual aye sui jud bid ja gl ill AI AM ge oia S Turn power off before servicing Desconectar el cable de alimentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servi o Nao toque as partes el tricas nuas AVLFF YA Y EAZLRUP PRE TER Fe BEM DT FEV e EU SIDE era AHS HAS lus Ajo
10. Nozzle Adjustments Nozzle Body Pivot By loosening the upper hand wheel clamp the entire nozzle assembly can be rotated 180 between two stop pins and clamped in the desired position This adjustment is designed to permit 180 travel direction reversal and can only be adjusted when the nozzle body is out of the deep groove joint The noz zle s flux tube most always lead the nozzle in the welding direction of travel Welding Angle Pivot By loosening the lower hand wheel clamp the noz zle s wire guide tube and contact tip can be pivoted up to 30 either side of center using the insulated pivot handles The hand wheel can then be tightened to clamp the nozzle in the desired position This adjustment is designed to set the required weld ing angle to joint procedure requirement and can be adjusted even while welding Flux Tube Height By loosening the wing nut of the insulated clamp the height of the flux tube can be adjusted then clamped This adjustment is designed to obtain the proper weld ing flux depth and can be adjusted while welding Proper flux depth is usually obtained when the end of the flux tube is 1 8 to 1 4 inch below the nozzle s insu lation jacket LINCOLN 8 C 1 MAINTENANCE Maintenance See the parts list section following for replacement parts and assembly Contact Tip Replacement The 14879 3 32 contact tip should be replaced by the time the maximum inside dimension of the elec trode exit hol
11. RETURN TO MAIN MENU IM335 K386 October 2005 NARROW GAP DEEP GROOVE NOZZLE Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful 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 OPERATOR S MANUAL 180 9001 mm GN 227 LINCOLN Copyright 2005 Lincoln Global Inc 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 Designed Quality ABS Quality Eval to ISO 9001 Re CERTIFICATE NUMBER 30273 i SAFETY i A 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 POSSI
12. Y product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee 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 transportation 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 Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration R
13. 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 9 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 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou ies 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 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles 4 Garder tous les couvercies et dispositifs de s ret leur place Mar 93 LINCOLN 5 V V for selecting a QUALIT
14. d Screw 1 4 20x1 25 1 Plain Washer 9262 23 1 Wing Nut T9968 1 1 22 Flux Tube 1 23 Pivot Housing Arm M14717 1 lodwaser Epeki4 Hex Head Screw 5 16 18x1 50 3 24 Mounting Clamp Asbly 517550 1 25 Roli Pin T9967 43 1 26 Plain Washer 59262 104 2 27 Roll Pin T9967 29 1 29 Hex Head Screw 1 2 13x1 25 1 31 Nozzle Tube Strap T14974 1 Round Head Screw 8 32 75 1 Lockwasher T9695 3 1 Hex Nut 18 32 1 5 17 96 LINCOLN NOTES LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese m SR 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 mojada e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v tements mouill s entrer en contact avec des pi ces 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 N o toque partes el tricas electrodos com a pele ou roupa mothada 1501 da e terra e BE POBMBA MSIE PRON ERCMNEWIE ORL APSREMEBA HTVSRIELTFSU e DEMME BHR CRRA CRAMER era SHEE RE 2H Se su ASA nis e AAG HSA Juil gab Goss uii el a Qual
15. e wears to 130 inch When using non coppered electrode such as LC 72 the tip wear should be monitored when feed deposition exceeds about 200 pounds Unscrew the contact tip with a pair of pliers Insulation Jacket Replacement The 517545 insulation jacket should be reversed top to bottom or replaced if the jacket erodes so as to expose the brass cooling bar or the wire guide tube to possible arcing to work LINCOLN PARTS K386 NARROW GAP DEEP GROOVE NOZZLE GENERAL ASSEMBLY L Ld LE a SY 2 29 Nu PEN ATEN AC 18 1 22 IKE TA Pn nee 2297 CZ G1653 7 15 88G CRE CES LINCOLN PARTS K386 NARROW GAP DEEP GROOVE NOZZLE GENERAL ASSEMBLY Item Description No Req d Nozzle Tip T14879 3 32 2 1 i 1 1 2 1 1 7 Insulation Jacket 517545 Round Head Screw 8 32x 75 Plain Washer 9262 3 Hex Nut 8 32 2 Retain 4 i 2 1 Snap Ring S9776 46 1 1 Pivot Asbly T14883 1 15 Nozzie Insulator Asbly 10493 1 1 16 Socket Head Screw T10570 1 17 Nozzle Insert Asbly 15106 1 1 18 Pressure Belt 1 19 Pressure Arm Asbly T14890 1 Socket Head Screw T9447 56 1 20 Flux Tube Clamp 817542 1 Button Head Socket Screw T11551 6 2 21 Hex Hea
16. ead 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury damage to this equipment TABLE OF CONTENTS Page Installation 1e eee eere Section A IB I Te 4Te o ARR A 1 Recommended Welding Equipment A 1 Required Equipment ss A 1 Optional Equipment ss A 1 Installation ss A 2 Automatic Flux Hopper Mounting ss A 2 Nozzle Mounting iii A 2 Water Solenoid Connection ses A 3 NA 4 Control Modification ss A 3 Operation M Section B Loading the Nozzle B 1 Nozzle Adjustment scies B 1 Nozzle Body 1 Welding Angle 1 Flux Tube Heights 1 Maintenance QE Section Contact Tip Replacement ses C 1 Insulation Jacket Replacement sis C 1 Parts List G1653 11 cele eee LL Lee
17. he 142 1 gear ratio to 95 1 per the instructions given in Section L6 2 1 of the NA 4 IM278 Manual See NA 4 Control Modification section for user modification of NA 4 Contro to extend wire speed range LINCOLN A 2 INSTALLATION 2 Installation The following instructions pertain to the installation and operation of the K386 Narrow Gap Nozzle The installation and operation of the required and optional equipment see previous Section used with the K386 nozzle is covered in the 1M278 NA 3 4 manual the IM305 NA 5 manual or in the literature included with the equipment used Automatic Flux Hopper Mounting 1 Mount the wire feed head so the drive roll axis of rotation is perpendicular to the direction of travel 2 To obtain smooth symmetrical flux hose routing from the flux hopper to the nozzle flux tube for either direction of travel it is recommended that the faceplate of the head be rotated 180 about the drive roll axis Incoming Guide Tube and straightener Travel Direction Outgoing Guide Tube As Recommended As Shipped This rotation requires the following additional changes be made during initial set up a Exchange the outgoing guide tube and nozzle mountings with the incoming guide tube straight ener and its mounts A WARNING Be sure all power to the NA control box is shut off at the power source b Interchange the motor field lead connections at the terminal strip i
18. i ye St pagel slay ay BST ol il AU Jan Ji dus Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez a l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guardados SMRAVTUBDOMTORERIM eclss AIX Jia e Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo e ERUOBISUCREREUCF aus HESHSERIERR 719 20 555 8 di die uie Xl cil ysl Mau 9 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES 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 HERSTELLERS DIE UNFAL
19. 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 b Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique 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 c Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et 5 tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour ie refroidir e Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines f Si on utilise 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
20. m the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables if the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source Mar 95 LINCOLN 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 3 b 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
21. mselves to the arc rays or to hot spatter or metal 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 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 5 c 5 e LINCOLN 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 empl
22. nside the NA control box to re estab lish proper wire feed direction 626 lead to terminal 627 627 lead to terminal 626 3 Using the flux hopper Extension Mounting Brackets and Pins included with the nozzle mount the flux hopper above the faceplate as shown Extension Mounting Bracket Left Side of A Faceplate 14 gt Mounting Pin NOTE Both Extension Brackets must be against the side of the faceplate so as not to electrically contact the bin of the flux hopper Nozzle Mounting 1 Make sure the nozzle s incoming guide insert is in place then snugly mount the nozzle over the head s outgoing guide tube using the nozzle mounting clips provided with the head 2 Loosen the nozzle s body pivot clamp top hand wheel and rotate the nozzle body clockwise looking down the nozzle to its stop pin limit then re tighten the body pivot clamp 3 Re loosen the nozzle mounting clips and position the entire nozzle so the nozzle s side is parallel to the direction of travel with its flux tube on the left side of the nozzle Then securely tighten the nozzle mounting clips 4 Loosen the nozzie s flux tube clamp wing nut then adjust and re clamp the flux tube height so the bot tom end of the tube is 1 8 to 1 4 below the bottom edge of the nozzle s insulation jacket 5 Attach the 10 50 inch Flux Hose included with the nozzle between the flux hopper and the nozzle s flux tube Adjust for a smooth routing with
23. ntrol box terminal strip c Connect a wire from the K223 grounding screw to the NA control box grounding screw NA 4 Control Modification The wire feed speed procedures for narrow gap weld ing approach or exceed the range of speed control provided by the NA 4 Control as shipped from the fac tory This range can be extended to adequately pro vide the procedure speed requirements in the follow ing manner A WARNING Be sure all power to the NA 4 is shut off at the power source 1 Open the NA 4 Control box door and subpanel then locate the Logic P C board on the rear of the NA 4 subpanel 2 Locate the 9 cavity plug on the bottom center of the Logic board 3 Locate lead 641 routed to the center cavity of the plug 4 Cut Lead 641 and insulate both cut ends with tape LOGIC BOARD 5 Close the NA 4 subpanel and door LINCOLN B 1 OPERATION B 1 Nozzie Operation Loading the Nozzle 1 Check that the nozzle contact tip is screwed in tight against the tip block with a pair of pliers 2 The end of the electrode should be cut off clean with minimal burrs or flattening and straightened for about the first 8 inches 3 Push the electrode down through the straightener to the drive rolls then inch down and out of the nozzle s contact tip 4 While feeding adjust the straightener as required to obtain a consistent location of the wire for at least 2 inches beyond the end of the contact tip
24. oyers safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Mar 95 WELDING SPARKS can M cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible 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
25. r source of heat sparks or flame Never allow the electrode electrode holder or any other electrically 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 except when the cylinder is in use or connected for use 7 4 Read and foliow the instructions on compressed gas cylinders associated equipment and CGA publication P l Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington V 22202 FOR ELECTRICALLY powered equipment 8 a off input power using the disconnect switch at the fuse box before working on the equipment 8 b Install equipment in accordance with the U S National Electrica 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 Mar 95 LINCOLN SAFETY _ 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 manuei 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
26. s eere eene eene etas e sense etn essa annos assesses rne anna Appendix vi A 1 INSTALLATION A 1 Description The 750 amp water cooled automatic nozzle is designed for narrow gap deep groove submerged arc welding procedures using a single 3 32 diameter LC 72 or solid electrode fed by a standard NA Automatic head Features 1 A rigid water cooled nozzle body fully insulated with a replaceable insulation jacket capable of welding in a 5 8 inch minimum joint gap of up to 10 inches deep 2 A built in 7 tip drag angle provides consistent pos itive electrode contact at the replaceable contact tip Two contact tips are included with each nozzle 3 A pivoting wire guide tube with hand wheel clamp permits welding angle to joint adjustment of up to 30 to the left and 30 to the right sides of the joint even while welding 4 The entire nozzle body can be rotated 180 and is clamped by a second hand wheel to permit rapid direction of travel reversals when the nozzle body is out of the joint 5 A flux feed tube is mounted on the nozzle with a wing nut clamp which permits easy flux height con trol and adjustment even while welding 6 Included with the nozzle are extension mounting brackets and pins for the K219 Automatic Flux Hopper included with the K208 B or K346 B Automatic head and a flexible flux hose for proper dispensing of welding flux to the nozzle Recommended Equipment For Use With The K386 Nozzle
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