Lincoln Electric IM709 User's Manual
Contents
1. gas cylinders 2467 lbs with gas cylinders 1346 2 mm 1676 4 mm 1346 2 mm 774 3 kg w o gas cylinders 1119 0 kg with gas cylinders DEMO ZONE LINCOLN P 2 INSTALLATION SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the circuit breaker or fuse box before working on this equipment 0 Do not touch electrically hot parts Always connect the Demo Zone to a power supply grounded per the National Electrical Code and any local codes This demonstration rack is intended for indoor use and display only Shelter or protect from rain moisture and condensation Do not operate electric equipment when wet CYLINDERS could explode if damaged S e Keep cylinders upright and secured to a support e Keep cylinders away from areas where they could be damaged Never allow the electrodes or torches to touch the cylinders e Keep cylinders away from live electrical circuits Maximum inlet pressures must be observed FALLING EQUIPMENT can cause injury Do not lift with gas cylinder in place Do not trailer or transport over the road ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside A 2 INPUT AND GROUNDING CONNECTIONS INPUT POWER The Demo Zone is designed to operate from 230 volt 60 Hz single phase input po2. SAFETY PRECAUTIONS Read and understand this entire section before oper ating the machine A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves Read and follow Electric Shock Warnings in the Safety section if welding must be performed under electrically hazardous conditions such as welding in wet areas or on or in the workpiece FUMES AND GASES can be dangerous Keep your head out of fumes 3 AA Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS 4 can burn Wear eye ear and body protection NW Observe additional Safety Guidelines detailed in the beginning of this manual GENERAL DESCRIPTION DEMO ZONE The Demo Zone is a compact system to display and demonstrate welding and cutting equipment The Demo Zone contains Square Wave TIG 175 Power Source Power MIG 255 Power Source Ranger 250 Power Source V350 Pro Power Source Pro Cut 55 Plasma Cutter LN 25 Wire Feeder LN 7GMA Wire Feeder Holder for 4 gas cylinders Welding table Power distribution system with circuit breaker protec tion Welding cables and torches Tool box for storage
3. duty cycle is extended from what is listed V350 PRO 200A at 28v 100 duty cycle 41A input 275A at31V 10 duty cycle 62A input Power MIG 255 machine limited 200A at 28v 60 duty cycle 37A input 250A at 30v 40 duty cycle 46 input Pro Cut 55 55A 15 duty cycle 55A input Square Wave TIG 175 150A 10 duty cycle 65A input AUXILIARY POWER OPERATION Duty cycle and maximum current may be less than rated value if the power sources are powered from the Ranger 250 Refer to Ranger 250 Operator s Manual DEMO ZONE LINCOLN e ACCESSORIES 1 FACTORY INSTALLED OPTIONS FIELD INSTALLED OPTIONS ACCESSORIES ACCESSORIES none CASTER WHEELS Caster wheels which are provided are a field installed option for the Demo Zone The 5 inch diame ter caster wheels offer high mobility for in shop use DEMO ZONE LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Turn the input power OFF at the disconnect switchs or fuse boxes before working on all equipment Do not touch electrically hot parts Have qualified personnel do all maintenance and troubleshooting work Turn engine or welders off before working inside the machines or servicing the engine Observe all safety precautions in the individual machine Operator s Manuals as well as this man ual ROUTINE MAINTENANCE Refer to individual Operator s Manuals for routine maintenance requi
4. your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded 1 0 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 DEMO ZONE LINCOLN SAFETY ELECTRIC SHOCK can kill 8 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 Welder with Reduced Voltage Control In semiautomatic o
5. 75 25 argon CO2 gas cylinder Connect a fitting to this regulator The Power MIG and LN25 is fed from the Y fitting Use hoses with inert gas fittings The short hose is used with the LN7 The oxygen fitting with 1 4 inch pipe thread is for use with the Pro Cut gas hose Use the short oxy gen hose between the Pro Cut and regulator 4 Two plasma torches are provided with the Demo Zone Use the short length plasma torch with the Demo Zone The torch with the long length is not recommended because the length is inconvenient when used with the Demo Zone Store the long plasma torch Use the long torch if the Pro Cut is removed from the Demo Zone 5 BEFORE the gas cylinders are installed run the gun for the Power MIG from the back of the rack through the bench under and then up to the Power MIG This gun will run along the back of the Square Wave TIG 175 and then to a gun holder It should be long enough to reach the worktable and this helps keep the cables from getting tangled INSTALLATION A 3 6 BEFORE the gas cylinders are installed measure the cable length needed for the spool gun it is rout ed the same way as the Power MIG gun and coil the rest wire tie it and store it underneath the bench between the Ranger and Power 7 BEFORE the gas cylinders are installed connect the battery in the Ranger 250 8 Gas cylinder covers will improve the appearance of your unit When used put the covers on before
6. ED 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 Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases 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 Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventila o exhaust o para remover fumo da zona respirat ria eti ADP5oUtRE 9 fsPBHEILTABSSUCFEU Fat in ER c EUR Bit MEM SH7IAE else MASH 918 27127471 ARSHAIS os Land duly an bacs L A
7. IM709 Demo Zone Sege For use with equipment having Number K1854 1 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 E OPERATOR S MANUAL Copyright 2001 Lincoln Global Inc LINCOLN ELECTRIC 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 SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some 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 BEF
8. ORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase copy of Safety Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 Free copy of Arc Welding Safety booklet 205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 9 1 avoid scalding do remove the radiator pressure cap when the engine is hot 1 6 engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 FIELDS may be dangerous 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 2 a Electric current f
9. SDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Mar 95 DEMO ZONE LINCOLN SAFETY Wee WELDING SPARKS 2 75 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 see address abo
10. ST FEU E HN RA BA EL ECTS E ECKE Azo SIAD HAYA Sei ETS BE VT Aal d d AAL Gail Ca L LINCOLN ELECTRIC 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
11. Zone must be sheltered from rain and water ENGINE EXHAUST CAUTION Provide an exhaust capability for the Ranger 250 machine Flexible metal exhaust hose available from automobile parts stores should be used to exhaust gasses to the outdoors The exhaust pipe on the Ranger 250 is 1 5 diameter nominal Use a clamp at the muffler to ensure a good seal The exhaust pipe and flexible metal exhaust hose is hot Do not touch when hot Keep flammable material away from the exhaust hose Place a Hot Do not touch sign near the hose to warn of the hazard Ensure that there is sufficient fresh air and venti lation available during operation of the Ranger 250 WELDING SMOKE AND FUME Provide an exhaust for welding smoke and fume STACKING The Demo Zone is not designed for stacking INSTALLATION HANDLING A pallet jack or forklift truck can be used to move the Demo Zone and to install the caster kit The place ment of the pallet jack or forks must balance the Demo Zone load to prevent tipping A WARNING FALLING EQUIPMENT can cause nir Do not lift the Demo Zone by over head crane Do not lift the Demo Zone with gas cylinder in place e Lift from front of Demo Zone only Do not lift from left right or rear sides The Demo Zone is too heavy for one person to move by hand on an inclined surface Avoid situa tions that may injure yourself or others DEMO ZONE LINCOLN P B 1 OPERATION B 1
12. er 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 except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL 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 PR CAUTIONS SURETE 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 6 zones o l on pique le laitier Eloigner les mat riaux i
13. er to the Demo Zone is controlled by a 40 amp circuit breaker located on the rear of the Demo Zone REGULATORY REQUIREMENTS The power source and wire feed equipment included with the Demo Zone are individually listed or certified to CSA or UL agencies OPERATING INSTRUCTIONS Read and understand the Operator s Manuals for all of the equipment contained in the Demo Zone The operating instructions for each equipment type are not repeated here in the Demo Zone man ual Plug the Demo Zone into a 230 volt 40 amp recepta cle Locate the circuit breaker at the rear of the Demo Zone and switch it on Plug the lighting system into a 120 volt receptacle Switch the power for individual machines on as required for demonstration purposes ADDITIONAL SAFETY PRECAUTIONS WELDING AND CUTTING AREA WARNING Welding and Cutting must take place only on the welding table provided with the Demo Zone Do not weld or cut on objects away from the Demo Zone welding table Do not weld on the frame of the Demo Zone Direct sparks away from welding machines especially the fuel fill area of the Ranger 250 WARNING CYLINDERS could explode if damaged Keep cylinders upright and secured to a support Keep cylinders away from areas where they could be damaged Never allow the electrodes or torches to touch the cylinders Keep cylinders away from live electrical circuits Maximum inlet pressures must be observed D
14. erre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPOR Trant 6 ATUBS ELTFEL KEE 945 MAIER d TH e Siss Xe snp nisle e Su AXE ole Ju Gu Gi ll el all Arca das 39 SONT gh la ell All fl Jai P dua ule Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos e naodoe6008 cosiTEX THEW EA e i 9 E Vi ML LS Aal uie s ALD a pis 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 prote o para a vista ouvido e corpo e BH HRUBS ISUCRSREUCT RRR ez 12 Sal HSE s ESSA dis due ule 481 gulag gua e A daag READ AND UNDERSTAND THE 5 INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO US
15. feuda e B 2 Welder Operation SEENEN en e i Ue nent B 3 Duty Cycles ete eO Rt ANE RSEN EE AIR PRU est HR 3 Auxiliary Power Operation EE B 3 50 ini ne Section Factory Installed Options Accessories C 1 Field Installed Options Acceseories C 1 Gaster Wheels edere Eb dae i e ERU Ad C 1 Maintenance me Section D Safety Pr CAUTIONS dir bte mi d oe ag D 1 Routine Maintenance D 1 Periodic D 1 Troubleshooting E Section E Diagrams EE Section WINING Dia TEE 1 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS Demo Zone 1854 1 ELECTRICAL INPUT REQUIREMENTS Voltage Specification Input Connection Specification 230 VAC single phase 40 amps Type 6 50P plug RATED OUTPUT The Demo Zone is intended for display and demonstration use It is intended for light duty operation The Demo Zone operator must observe the 40 amp input current limitation Because of the input power limitation power sources except Ranger 250 when used at maximum output must be operated at low duty cycles Refer to Welder Operation Duty Cycle section of this manual PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 53 00 in 66 00 in 53 00 in 1707 lbs
16. installing the cylinder c Place the cylinders in the Demo Zone The cylin ders can be installed by using the rear or side openings or a combination of both When using the rear frame opening move the upper and lower support bars out of way Install the cylin ders and replace the support bars to the closed position When using side frame opening lift brace and swing out of the way Install the cylinders and swing brace back into position push brace down through locking tube to secure Place the air cylinder directly in back of the Pro Cut Place the argon cylinder next to the air cylinder 10 Install the optional casters This is easily done after placing cylinders in Demo Zone as the height of the Demo Zone is higher with the wheels installed 11 Set up the two TIG torches provided The TIG torch that comes with the SW175 is used on both AC and DC A recommendation is to use a point at one end of the tungsten and a ball at the other end 12 The welding table must exposed before demon strating Pull the table to the open position when in use The table can be pushed back in out of the way when the table is not in use Since the table has a bolted work lead permanently attached no work clamp is necessary for welding or cutting operations DEMO ZONE LINCOLN 4 GENERAL INSTALLATION REQUIREMENTS LOCATION Locate the Demo Zone on a flat surface The Demo Zone is intended for indoor use only The Demo
17. lowing 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 1 d 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 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 1 e In some cases it may be necessary to remove safety Se d minimize exposure to EMF fields from the welding circuit 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 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 1 f 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 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on
18. masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 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 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 DEMO ZONE LINCOLN V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Com
19. mitations 1 2 Electrode and Work Cable Connections A 2 Installation of Field Installed ss A 3 Caster Wee hotel gis pp a E Ee A fey A 3 Installation of Equipment Required for Recommended Processes A 3 General Installation Requirements 4 Beie E 4 Engine Exhaust cte ete Eeer 4 Welding Smoke and Fume sise A 4 STACKING EEN 4 ef ale Tele GEET 4 ont m P Safety Pr cautions isa sun items ect EE Eech teat hd fedt e a B 1 General Description EE en ee a aoe he de ge B 1 D mMO ZONE ete e CRI tei ue d dee tp P ANE EEN B 1 Recommended Processes and Equipment B 1 Recommended Processes in bte ec edes e Reit Eee d B 1 Process Limitations icy etat ee ee RL n ee eec ttes B 1 Recommended Equipment Interface B 2 Equipment Blut EE 2 Design a B 2 Platform Gommaonialities tr ation Gives eater eg B 2 Operational Controls and Features of the Demo Zone B 2 Circ it Breaker tasted ete Rte We heme B 2 Reg latory Requ lremeris Sete ben A SRM E eo B 2 Operating Irstr ctions iit B 2 Additional Safety Precautions ii B 2 Welding and Cutting Area AA B 2 Gas C le ue e ee ede B 2 Powet SOUfGeS et ona ee tete
20. n Authorized Field Service Facility for technical troubleshooting assistance before you proceed DEMO ZONE LINCOLN F 1 8086717 0004 01 MS WHO 00 32unos OL du udddOD H3MOT DIAGRAMS MS WHO 00 7 TIVNIIAHLL HHOM J318Vl _ ADYNOS YAMOd OL SONID TAM OL uva 34 uaddn LINDHID JAHOM 34020 21419313 1VNOILVN 34 OL 1 170A OEZ er 009 139151593 110 SVD NMH L NHHL DMV 8 N3349 OL SALON M 39vV19 40109 419V143934 dv OS 1419vV143934 dv OS 10 14404 dv OS LAdNI 9NI HIM INOZ ON 419V143934 dv OS DEMO ZONE LINCOLN 8 NOTES DEMO ZONE LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese BIR Korean Do not touch electrically live parts electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la t
21. nflammables ou les recouvrir afin de pr venir tout risque d incendie d 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 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 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 Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement 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 souder 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 pi
22. o not lift Demo Zone with gas cylinders in place Do not strike an arc on any gas cylinders Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Gas cylinders must be securely fastened to the Demo Zone frame Chains are supplied and are attached to the frame When caster wheels are installed block the Demo Zone from movement when removing or installing gas clinders POWER SOURCES The Demo Zone is a flexible system capable of demonstrating many varied processes The set up of equipment may require polarity changes torch changes or electrode changes Turn off the welding power source or plasma cutter when changing or con necting output cables torches or electrodes DEMO ZONE LINCOLN 3 WELDER OPERATION DUTY CYCLE Full output and duty cycle may not be obtained from all power sources The output and duty cycle may be limited by the 40 amp input power limitation of the Demo Zone The duty cycle of the power source must be adjusted to be within the capability of the 40 amp input supply Duty cycle is based upon a ten minute period A 10 duty cycle represents 1 minute of welding and 9 min utes of idling a ten minute period Some examples of allowable duty cycles of the Demo Zone are given If the duty cycle or input currents exceed the capability of the 40 amp circuit breaker the breaker will trip off For lower output currents the
23. of tools welding accessories and welding plates Illuminated lower area by neon and florescent lamps Prominent promotional sign Caster wheels allow easy movement All equipment on the Demo Zone is connected and ready to weld The Demo Zone obtains its power from a 230V 40A receptacle RECOMMENDED PROCESSES AND EQUIPMENT RECOMMENDED PROCESSES The Demo Zone is capable of demonstrating MIG TIG SMAW CAC and plasma cutting PROCESS LIMITATIONS determined by individual equipment DEMO ZONE LINCOLN B 2 OPERATION B 2 RECOMMENDED EQUIPMENT INTERFACE EQUIPMENT LIMITATIONS The Demo Zone is intended for indoor display and demonstration use The Demo Zone is intended for light duty operation Because of the input power limita tion power sources except Ranger 250 may only be used at maximum output with low duty cycles Refer to Welder Operation Duty Cycle section of this manu al The Demo zone is not intended for road transportation or to be hauled on a trailer The Demo zone must not be lifted with gas cylinders in place DESIGN FEATURES PLATFORM COMMONALTIES The Demo Zone utilizes standard power source and wire feeder configurations Output cables and torches are modified in length for use with the Demo Zone OPERATIONAL CONTROLS AND FEATURES OF THE DEMO ZONE Refer to the individual Operator s Manuals for equip ment included in the Demo Zone CIRCUIT BREAKER The 230V input pow
24. p gaal sag uc Turn power off before servicing Desconectar el cable de ali de poder de la maquina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue corrente antes de fazer servico e toque as partes el tricas nuas o FIYR Y 908 PSB ETEREATSTE e HFS AHS 4h NM pil gS ae Do not operate with panel open or guards off No operar con panel abierto 0 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 Mantenha se afastado das partes moventes com 05 paineis abertos ou guardas removidas CHIMIE LEUTFEL Ro egado wel ze L t cus 13 D Aale Al ll Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG J apanese it ie BIR LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR SRM OBUOX H OHBRBEE lt K HA EL TCHHORKREREK H
25. pany product 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 refer to Individual machine Operators Manuals for Parts Order information Read this Operators Manual and any others included with this equipment 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 or damage to this equipment TABLE 5 VT Section A Technical Specificatiors 1 Safety Precautions er Ree me ee A e 2 Input and Grounding Connections 2 Input POWOL reo eei eng ef ct EE A 2 GO NdING EE 2 Output Cables Connections Li
26. r 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 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 ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 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 4 b 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 ray
27. rements Perform the following daily routine Check that no combustible materials are in the weld ing or cutting area or around the machine Remove any debris dust dirt or materials that could block the air flow to the machines for cooling PERIODIC MAINTENANCE Refer to individual Operator s Manuals for periodic maintenance requirements Perform the following periodically Inspect the welding cables torches and electrode holders for any slits or punctures in the cable jacket or any condition that would affect the proper opera tion Inspect gas hoses and regulators Inspect gas cylinder chains and fasteners The weld table is insulated from the Demo Zone frame Inspect the weld table mechanism to ensure that the insulation system is intact DEMO ZONE LINCOLN 1 TROUBLESHOOTING 1 WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this and individual machine Operator s Manuals Consult individual machine Operator s Manuals for detailed troubleshooting of specific machines CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincol
28. s or to hot spatter or metal FUMES AND GASES can be dangerous 5 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 prod ucts 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 M
29. stolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger 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 lev age 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 de 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 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 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie du corps LES MACHINES SOUDER TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel donc REDRESSEUR a Utiliser un bon
30. ve 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 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 6 h Also see item 1 c DEMO ZONE LINCOLN CYLINDER may explode El x 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 Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any oth
31. wer with 40 amp capacity A 6 50R type receptacle must be provided by the user The receptacle must be installed by a qualified person and must be in accordance with applicable local and national electrical codes The lighting system requires 120 volt 60 Hz power Plug the line cord into a conventional 120 volt recepta cle for lighting operation The lighting system is for display and convenience purposes The Input Plugs for the Demo Zone are connected at the factory GROUNDING CAUTION When the Demo Zone is connected to a conventional power distribution system the frame of the Demo Zone must be grounded The input cable provided with the Demo Zone contains a grounding conductor Additionally another ground lead must be connected Connect the frame of the Demo Zone to a good elec trical ground using the 1 AWG lead included with the Demo Zone The purpose of this additional ground is to minimize disturbance of the high frequency unit and to provide a path for stray welding currents Some applications may not use conventional input power and instead utilize the generating capability of the Ranger 250 for power In this case the ground lead is required only if the high frequency unit of the Square Wave TIG 175 is used OUTPUT CABLES AND CONNECTIONS ELECTRODE AND WORK CABLE CON NECTIONS The Demo Zone is supplied with the output cables connected at the power sources for positive electrode polarity To change the polarit
32. y of a power source switch the cables at the output terminals of the power source or change the power source polarity switch as applicable A bolted work lead runs from the work buss connec tion of the Demo Zone to the work table The work table connection must be firm and secure DEMO ZONE LINCOLN 3 INSTALLATION FIELD INSTALLED OPTIONS CASTER WHEELS PART OF K1848 1 Caster wheels which are provided can be installed by lifting the Demo Zone approximately eight inches above ground level Use the mounting hardware sup plied to fasten the caster wheel to the mounting plate Tighten all fasteners INSTALLATION OF EQUIPMENT REQUIRED FOR RECOMMENDED PROCESSES 1 As shipped from the factory two diagonal braces are bolted to either side of the Demo Zone The braces are approximately 62 in length Remove the brace on the tool box side of the Demo Zone Do not remove the brace located on the Ranger 250 side of the Demo Zone 2 The Demo Zone is made for ease of set up Drive rolls are installed and liners are in the guns 3 A Harris Kit containing gas components is includ ed with the Demo Zone Some details about the kit The double flow meter regulator is for the argon gas cylinder A Y fitting is also used on one of the flow meter outlets The argon is fed to the Spool Gun The Square Wave TIG 175 and the two piece TIG torch attached to the Ranger 250 The other regulator is provided for the
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