Lincoln Electric IM465-B Remote Starter User Manual
Contents
1. E 1 Troubleshooting epe nter eed tk HAE e Ern cerae ege E 2 Environmental Protection pp E 6 Printed Circuit Board Replacement pp E 6 Wiring Diagrams eiii e teinte En n Section F DC TIG Starter Wiring Diagram pp F 1 Connection Diagram sspears arenend ate utendo as F 2 Dimension X 3 DC TIG Starter to Invertec Assembly Illustration F 4 Parts Manual 1010100 Vi NOTES LINCOLN 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS DC TIG STARTER Standard Voltage Frequency Input Current 42 VAC 15 50 60 Hz 2 0 Amps Rated Output CURRENT LIMIT Duty Cycle 6096 Duty Cycle 10096 Duty Cycle PHYSICAL DIMENSIONS Width 10 72 in 272mm INVERTEC DC TIG STARTER LINCOLN 8 2 PRODUCT DESCRIPTION The purpose of the DC TIG Starter is to provide high frequency high voltage pulse arc starting in DC TIG welding applications It is intended to be used with the Invertec power sources which have a 5 5 amp 42 VAC auxiliary supply The DC TIG Starter s output rating matches the Invertec V300 s 300 amperes DC at a 6096 duty cycle and 250 amperes DC at a 100 duty cycle The input requirements are 42 VAC 2 0 amps The DC TIG Starter is designed for non contact start ing of DC TIG welding arcs It can select between 2 step and 4 step trigger functioning to control the Invertec s energizing of the2. lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 10 00 For value between 50 00 4 99 99 15 00 value between 100 00 4 149 00 For North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders 1 Please Invoice only if order is over 4 Invoi ly if order i 50 00 I Check or Money Order Enclosed U S Funds only Credit 1 1 1 111111111111111111 LI 1use THIS FORM TO ORDER Books OR FREE INFORMATIVE CATALOGS li incon Welding School Titles Price Code Quantity Cost ED 80 New Lessons in Arc Welding 5500 L Seminar Information Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings 5450 H Educational Video Information ImcenveManage
3. If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC DC TIG STARTER LINCOLN 8 6 TROUBLESHOOTING 6 Environmental Protection High voltage connections are covered with an RTV sealant to prevent malfunction in severe environ ments Sealant must be applied to connections which have been opened or otherwise lost their protection A noncorrosive electronic grade sealant such as Dow Corning 3140 3145 738 Columbus Adhesives 0172 or GE RTV 162 is recommended Sealant may also be purchased from Lincoln Electric order E2519 Silicone Rubber RTV Coating Printed Circuit Board Replacement 1 Handle PC boards by edges only 2 Store PC boards only in the bags that they are shipped in Some PC boards require special bags that disperse static charges 3 Inspect malfunctioning PC boards for burned con ductors or components If damage is visible inspect the machine wiring for grounds or shorts to avoid damaging a new PC board 4 If there is no visible damage to the PC board install a new PC board and see if the problem is fixed If the problem is fixed by the new board reinstall the old board and see if the problem reoccurs If the problem does not reoccur check the wiring harness and plugs for loose connections or faults INVERTEC DC TIG
4. COURSE OF ACTION Postflow Time does not vary with knob 15 Check leads and connections for the postflow adjustment poten seconds always tiometer R1 Check that there is approximately 15 VDC between leads 13 and 15 and that the voltage between leads 16 and 15 varies from 0 1 to approximately 15 VDC when the postflow knob is rotated throughout its full range Repair or replace R1 and or the associ ated leads as needed 3 Replace the control board NOTE If the postflow adjustment becomes disabled the control board will use a preset of 15 seconds for postflow timing Downslope does not vary with knob Check leads and connections for the downslope adjustment potentiometer R2 Check that there is approximately 15 VDC between leads 13 and 17 and that the voltage between leads 8 and 17 varies from 0 1 to approximately 15 VDC when the downslope knob is rated throughout its full range Repair or replace R2 and or the associ ated leads as needed Replace the control board Current Limit does not vary with knob Check leads and connections for the current limit vary adjust ment potentiometer R3 Check that there is approximately 15 VDC between leads F and 19 and that the voltage between leads A and 19 varies from 0 1 to approximately 15 VDC when the current limit knob is rotated throughout its full range Repair or replace R3 and or the associ ated leads as needed Replace the control board A CAUTION
5. threads INVERTEC DC TIG STARTER LINCOLN 1 1 OPERATING INSTRUCTIONS A WARNING ELECTRIC SHOCK can kill 9 Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be danger ous 3 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or gt lt explosion 3 Keep flammable material away Do not weld on closed containers ARC RAYS can burn eyes and skin Wear eye ear and body protection 22 See additional warning information at front of this operator s manual Limitations a The DC TIG Starter is not recommended for processes where procedures are not within its cur rent and or duty cycle ratings b The DC TIG Starter is not intended for use with AC welding c The DC TIG Starter is not intended for use where the input voltage will vary more than 15 from 42 VAC d The DC TIG Starter is not intended for use where the open circuit voltage of the power source is less than 35 volts or greater than 90 volts Additional Safety Precautions WARNING HIGH FREQUENCY SHOCK can cause injury or fall Keep the torch and cables in good condition Secure yourself in position to avoid a fall Do not operate machine if it is wet or sitting in water e INVERT
6. 2000 9 9 OOS FOE oz aa NO N N 8 6 A RT ei D T 2 87 LO 4 e e 10 72 Q Q 6 44 24 INVERTEC DC TIG STARTER LINCOLN F 3 DIAGRAMS INVERTEC DC TIG STARTER LINCOLN NOTES INVERTEC DC TIG STARTER LINCOLN 8 Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assemb
7. Ohren und K r perschutz Use para a vista ouvido e corpo e BH HRUBS ISUCRSREUCT ez 12 59 s ESSA READ AND UNDERSTAND THE M ANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUM ABLES 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 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 f r gute Be
8. 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 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 LINCOLN 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 V V for selecting a QUALITY product by Lincoln Electric We want you 6 hank You to take pride in operating this Lincoln Electric Company 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 purchase
9. STUD ADAPTER POWER GAS CONNECTION DC TIG STARTER POWER WATER CONNECTION 7 8 LH OR 718 RH TO 5 8 RH ADAPTER RH CONNECTION aw LE TORCH POWER LUG CONNECTION 7 8 LH TO 1 2 STUD ADAPTER POWER GAS CONNECTION 7 8 RH Dc STARTER POWER WATER CONNECTION 7 8 LH INVERTEC DC TIG STARTER LINCOLN 4 INSTALLATION A 4 Figure 2 below shows connection of water cooled torches with the required 7 8 RH to 5 8 RH adapter for the gas fitting The water coolant inlet connection for the torch should be connected directly to the 7 8 LH water coolant connection FIGURE 2 Connection Diagram for Water Cooled Torches eO 7 8 TO 5 8 RH ADAPTER POWER GAS 5 8 RH GAS CONNECTION CONNECTION L J L 7 8 STARTER POWER WATER WATER COOLED CONNECTION TORCH 7 8 LH 7 8 LH POWER WATER CONNECTION NOTE required adapters are included with the DC TIG Starter kit Torch Connection Cover Installation A torch connection cover has been provided with the DC TIG Starter The cover should be installed using the 4 screws on the case front Gas Connection The inlet gas connection is made at the back of the starter kit Water Coolant Return Connection Solenoid Controlled Water Coolant Return Connection The DC TIG Starter is sh
10. acceptable replace the HIGH FREQ FIRING BOARD If 24 VAC is not present between the Y leads with plug J7 dis connected and 115 VAC present between 418 and 215A replace the auxiliary transformer T1 If 24 VAC is present between leads 101A and 102A replace the control board 6 Replace the auxiliary transformer T1 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC DC TIG STARTER LINCOLN 8 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS COURSE OF ACTION No output fan operates Perform steps 1 and 2 under heading on previous page of No output fan does not operate Check that the Invertec s Meter Polarity Switch is in the correct position for the electrode polarity being used Check that the RED LED on the control board is not illuminated If it is illuminated replace the control board If solenoids engage when the arc start switch is closed check that the Invertec produces OCV a If OCV is not present check that the arc start switch has continuity when closed and repair or replace to correct or replace the control board if the arc start switch is correct b If OCV is present see the heading below of HF arcing OCV
11. connect the DC TIG Starter to an Invertec The cable makes the connection between the 14 pin Amphenols on the back of both the DC TIG Starter kit and the Invertec Refer to 520405 connection diagram at the back of this manual Output Connection An output cable assembly is supplied with the kit to connect the DC TIG Starter with the Invertec s nega tive or positive output quick connect terminals For electrode negative or positive connections with the Invertec mounted on top of the DC TIG Starter Refer to 520405 connection diagram at the back of this manual Torch Connection All Magnum one and two piece gas cooled or water cooled torches can be connected to the starter kit Figure 1 below shows connection of air cooled torch es with the required adapters One piece torches with 7 8 RH threads do not require an adapter while one piece torches with 3 8 RH threads require the 7 8 RH to 3 8 RH adapter The use of the 7 8 LH to 1 2 stud adapter with one piece torches is recommended to keep debris out of the water connection Two piece torches with 5 8 RH threads and a separate electrical stud connector require the 5 8 RH to 7 8 RH adapter and the 7 8 LH to 1 2 stud adapter FIGURE 1 Connection Diagram for Air Cooled Torches 0 0 7 8 RH POWER GAS CONNECTION COOLED TORCH 718 RH TO 3 8 RH ADAPTER 3 8 RH POWER 4 nene Rime AIR COOLED TORCH 7 8 LH TO 1 2
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13. procedures or are unable to perform the necessary tests repairs safely contact your local authorized field service facility before you proceed INVERTEC DC TIG STARTER LINCOLN 5 E 1 2 TROUBLESHOOTING 2 Observe all Safety Guidelines detailed throughout this manual No output fan does not operate 1 Check that the input cable assembly is tightly connected 2 Check the wiring at the 14 pin and 6 pin Amphenols All connec tions should be insulated and free of debris Check that there is 42 VAC present between cavities I and leads 42 and 41 of the 14 pin Amphenol If 42 VAC is present between these cavities at the Invertec but not at the DC TIG Starter replace or repair the input cable assembly If 42 VAC is not present at the Invertec s cavities see the Instruction Manual for the Invertec Check that 115 is present between leads 418 and 215A If it is present replace the fan and check that the outputs of the auxiliary transformer are within 15 of nominal values 380 VAC between the U leads and 24 VAC between the Y leads Check that the GREEN LED on the control board is illuminated If it is not illuminated perform the following Check that 24 VAC is present between leads 101A and 102A and between leads Y and Y If 24 VAC is present between the Y leads and not between leads 101A and 1024 check that all con nections on these wires are tight and have continuity If all con nections are
14. torch The DC TIG Starter has a water solenoid to control the on off flow of coolant and a gas solenoid to control a preset preflow and allow a variable postflow Maximum current limit can be adjusted for amptrol or arc start switch use The DC TIG Starter comes with a preset upslope and an adjustable downslope An Amphenol and control switch are provided for simultaneous wire feeder con nection to Invertec power sources RECOMMENDED PROCESSES AND EQUIPMENT The DC TIG Starter is to be used with DC TIG welding processes A work cable TIG torch gas supply and an arc start switch are required An optional amptrol may be used A water supply is required if using water cooled torches For best results use of Thoriated Tungsten electrodes is recommended COMPATIBLE LINCOLN ELECTRIC EQUIPMENT V300 s with 5 5 amp 42 VAC auxiliary supply V200 s with 5 5 amp 42 VAC auxiliary supply Field installed options and accessories See ACCESSORIES section Compatible with all Magnum one and two piece water cooled torches with 7 8 left hand threads and gas cooled torches with 3 8 5 8 and 7 8 right hand threads Compatible with Magnum water coolers The sole noid controlled coolant flow will help yield longer Magnum cooler life INSTALLATION A 2 INSTALLATION A WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box before wo
15. 3 b Keep the work and torch leads as short as possible and as close together as possible Lengths should not exceed 25 ft 7 6m Tape the leads together when practical c Be sure the torch and work cable rubber coverings are free of cuts and cracks that allow high frequen cy leakage d Keep the torch in good repair and all connections tight to reduce high frequency leakage NOTE The DC TIG Starter s frame is grounded to the Invertec s frame by the input cable assembly The input cable assembly must be kept in good repair and all connections kept tight The Invertec frame must be grounded per the Invertec s instruction manual e When the machine is enclosed in a metal building several good earth driven electrical grounds around the periphery of the building are recommended f When the machine is in operation keep all covers securely fastened in place to minimize interference radiation Failure to observe these recommended installation procedures may cause radio or TV interference prob lems and may result in unsatisfactory performance Securing to Invertec To secure the DC TIG Starter kit to the bottom of the Invertec refer to page F 4 at the back of this manual a Remove the bottom 4 wraparound screws from the Invertec b Place the Invertec on top of and inside the starter kits case c Align holes and reinsert the 4 screws Input Connection An input cable assembly is supplied with the kit to
16. EC DC TIG STARTER LINCOLN 8 2 2 Source Starter Operation The DC TIG Starter kit is rated to match the V300 Invertec s duty cycle of 300 amps 60 duty cycle and 250 amps 100 duty cycle Invertec Control Function Operation Power Switch Placing the Invertec s power switch in the ON position will energize the Invertec and the DC TIG Starter kit When the power is on the digital meter in the Invertec will activate and the fans in the Invertec and the DC TIG Starter kit will operate Output Control The welding current level is set by adjusting this knob on the Invertec if the Local Remote Control Switch is set to the Local position If the Local Remote Control Switch is set to the REMOTE position output current is set by use of optional remote controls and or current limit control OUTPUT 2 2 4 38 18 2 49 9 1 10 NOTE The digital meter in the Invertec will indicate the current limit level when no current is flowing When current is flowing the digital meter will display the output current level Mode This switch on the Invertec should be set to the GTAW position for both scratch start and non contact high frequency starting use SMAW at CRISP SMAW 215 SOFT Output Terminals Switch To allow the DC TIG Starter kit to control the Invertec s power to the welding termi nals set this sw
17. IM465 B INVERTEC DC TIG STARTER This manual for use with DC TIG Starter Codes 9926 9990 amp 10368 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 CU LINCOLN 8 World s Leader 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 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 R
18. NNOO 104110 3H OLIMS ONISU3A3H A8 180 SI ONIGTAM 3ALLISOd OG ONIGTAM DIL SAILVOAN OG 803 SI NMOHS 135 NOISH3ANOO 5530084 OL 23181915 911 90 AHL OLNI 049914 38 NYO 830333 3UIM NOILVOlTddV 40 19AO ALNG 1IN ddT1O UOJ 9371 38 LSNW 31479 ON YOM OL HOLIMS 18915 7187 1004 0 8 O dH3MOd cy GG 308105 d3MOd O3183 NI QT3M VN 83181915 911 90 5 2 JON3HdWV yl 401 dNVH 2967 DIAGRAMS F 2 SHO103NNOO 5830333 3HIM 3IViHdOHddV __ 903 IYnNVA NOILONYLSNI 93183ANI LINSNOO 830333 JON3HdIAV IWOLLOS 14 3018135 JO esn pjnous suosiod AJUO e Jeue1S BIL 9g 1 SIM Ionduv 991 10 Jemod ou 01 151215 eui ou 12 UO1IAWS 109UUOOSID eoJnoS 991 01 Jemod lndul WN e NOILO3NNOO 2312915 SIL TID NYO JId19 1 Y INVERTEC DC TIG STARTER LINCOLN E 3 DIAGRAMS 11 11 1 2 5 fc at Lr N
19. ROUBLESHOOTING GUIDE AND GENERAL INFORMATION ON TROUBLE SHOOTING WARNING This Troubleshooting Guide is designed to be used by the machine Owner Operator 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 please observe all safety notes and precautions detailed in the Safety Section of this manual to avoid electrical shock or danger while troubleshooting this equipment This Troubleshooting Guide is provided to help you locate and repair possible machine misadjustments Simply follow the procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that your machine may exhibit Find the listing that best describes the symptom that your machine is exhibiting Step 2 PERFORM RECOMMENDED PROCEDURES The second column labeled RECOMMENDED COURSE OF ACTION lists the possibilities that may contribute to the machine symptom Perform these tests checks in the order listed Step 3 CONSULT LOCAL AUTHORIZED FIELD SERVICE FACILITY If you have exhausted all of the recommended tests in step 2 consult your local Authorized Field Service Facility Visual Inspection Clean interior of machine with a low pres sure airstream Make a thorough inspection of all components Look for signs of over heating broken leads or other obvio
20. STARTER LINCOLN 8 b Jequunu 3812 e 104 31310013120130 3218136 sjeued 31750121013 y Jo euo uo y LL paysed si 104 6 Jenueuu saulu2eui Joj 332117232 jou 3 AIUO 32101313131 10 SI SIUL 3 LON 09061 18613 H3d SIO8NAS TVOIH10 00601 3AO8V YAEWNN 3009 V S3NIHOVA NI IN3S3dd SI IN3NOdAOO 3018 n aN 8 alu SNId ISN 9NIdInD3d 5830333 3HI 8N 40 3015 IJN3NOdNOO WOH 39N3N03S ALIAYO HOLOANNOO NOT dgNnN 3009 NONNOO V ONIAVH SIN3NOdNOO JOYX3 3HL MOHS LON AVN VHBVI SIHL 08908 313 121100 V 40 ALHIISY3ONVHOH3INI JHL Se 389 9 SNIL9 HHV LNOHLIM 39NVHO AVN 081908 V 40 AHLINOHIO SIN3NOdANOO 3ONIS VN 6 yOV 23258288 22585262 oo S 1ON 3000 40109 9VA9L 5 6 MM H 1 gt 8303333018801 519193954 104110 0 OVAO8E n 1 802 HOLIMS 108INO9 10W H N 4 11111141 eR a Y SES oy 3 Lis 912 16 HHWHOSNVHL SL 81 49 HOHINOO r 35 9 9 92
21. alve 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 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 Mar 95 PR CAUTIONS DE S RET zones l on pique le laitier Pour votre propre protection lire et observer toutes les instructions 6 Eloigner les mat riaux inflammables ou les recouvrir afin de 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 Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les par
22. anneaux 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 N o opere com os paineis abertos ou guardas removidas E Ro erol Yel HAE ye WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese LEIAE COMPREENDA AS INSTRUC ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR CL TRHORERE HS MS HAS Aix PAS EFSA HEHE LINCOLN B World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distrib
23. ble to the area being welded 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 LINCOLN SAFETY 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 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 cabl
24. 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 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 2 d 1 Route the electrode and work cables together Secure them with tape when possible 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 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 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 Connect the work cable to the workpiece as close as possi
25. d Releasing the trigger initiates the downslope crater fill sequence and then starts the postflow timing Reclosing the trigger during the downslope crater fill sequence begins the upslope sequence starting at the current level reached in the downslope sequence Reclosing the trigger during postflow skips the preflow stage and immediately restrikes the arc If the arc is lost during welding the starting circuit will resume operation for up to two min utes to re establish the arc If the arc is not re estab lished the DC TIG Starter kit will shut off the starting circuit shut off the Invertec s trigger begin postflow timing and await the release of the arc start switch See FIGURE 3 INVERTEC DC TIG STARTER LINCOLN 4 B 4 FIGURE 3 2 Step Trigger Control Using Arc Start Switch START SWITCH CLOSED URRENT LIMIT CL START TRIGGER SWITCH CLOSED 11814 340 34019NMOQ SS PREFLOW POSTFLOW 4 TRIGGER PULLED WITHOUT GAS FLOWING 9 TRIGGER PULLED DURING POSTFLOW TRIGGER RELEASED TO INITIATE FINISHING SEQUENCE 4 STEP In this mode closing the trigger or arc start Switch will start the welding process with a 0 5 second gas preflow The Invertec s welding terminals will ener gize and the solid state starting circuit will operate until the trigger is opened regardless if the arc has been established or not When the welding arc is initiated and the trigger is re
26. e kit beneath the Invertec Remote Control K963 Hand Amptrol or K870 Foot Amptrol can be used with the DC TIG Starter kit for full range remote current control and arc starting stopping control K814 Arc Start Switch can be used with the DC TIG Starter kit for arc starting stopping control INVERTEC DC TIG STARTER LINCOLN 8 1 MAINTENANCE MAINTENANCE A WARNING N e ELECTRIC SHOCK can kill Only qualified persons should install use or service this equipment Turn off the input power to the Welding Power Source using the disconnect switch at the fuse box before connecting the DC Tig Starter to the power source or the Remote Control Amptrol or adapter to the DC Tig Starter Welding cable must be sized for current and duty cycle of application Routine Maintenance 1 Every 6 months or so the machine should be cleaned with a low pressure airstream Keeping the machine clean will result in cooler operation and higher reliability 2 Examine the sheet metal case for dents or break age Repair the case as required Keep the case in good condition to ensure that high voltage parts are protected and correct spacings are maintained All external sheet metal screws must be in place to ensure case strength and electrical ground continu ity Periodic Maintenance No scheduled periodic maintenance is required for the DC Tig Starter Kit INVERTEC DC TIG STARTER LINCOLN 8 1 TROUBLESHOOTING HOW TO USE T
27. e 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 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 Z87 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 rays or to hot spatter or metal 23 FUMES AND GASES 4 can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases Wh
28. e partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra ecran 84 Hq e 2x9 amp Keepflammable materials Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos AI uie 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
29. ead 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 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 powered equipment 1 3 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC 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 flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current
30. en 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 5 b 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 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 5 e Also see item 1 b Mar 95 LINCOLN WELDING SPARKS ca
31. f CL This switch should be placed in the fast downs lope off position when the DC TIG Starter is used with an amptrol DOWNSLOPE ES 1 3 8 0 Remote Current Limit This feature limits the maxi mum current obtainable when the DC TIG Starter is used with a remote amptrol or sets the welding current when the DC TIG Starter is used with an arc start switch Current limit can be controlled by adjusting this knob on the front panel REMOTE CURRENT LIMIT L a X 3 J 8 2 a 2 9 1 M Trigger Function Switch This switch selects a 2 step or 4 step trigger function when used with an arc start switch This switch should be placed in the 2 step position when the DC TIG Starter is used with an amptrol For best utility the output terminals switch on the Invertec should be placed in the REMOTE posi tion pari 4 STEP pain 2 STEP Operation with an Arc Start Switch 2 5 In this mode closing the trigger or arc start switch will start the welding process with a 0 5 sec ond gas preflow The Invertec s welding terminals will energize and the solid state starting circuit is enabled The starting circuit will continue operation until the arc has been established or 2 minutes elapse Once the welding arc is established an optimized upslope takes the welding current up to the desired current limit and the arc will be maintained as long as the trigger is close
32. h open and 3 VAC with the arc start switch closed a 24 VAC not present with arc start switch open check conti nuity of input cable assembly and consult the Invertec s Instruction Manual b Voltage is not 3 VAC with arc start switch closed replace control board If solenoids do not engage when the arc start switch is closed a Check that the arc start switch has continuity when closed b Check that there is 28 40 VDC between leads D and E If voltage is not present between D and E replace the con trol board With the kit timing postflow check that 115 VAC is present between leads B and B to the gas and water solenoids Replace the control board if voltage is not present Replace the sole noid s if voltage present Arc does not start consistently HF present Use Thoriated tungsten electrodes Pure tungsten electrodes may exhibit starting difficulty Check continuity of work lead torch and HF transformer sec ondary T2 Check for tight clean connections between all out put connectors CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC DC TIG STARTER LINCOLN 8 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS
33. igh Frequency Interference Protection 2 Securing to IrniVerteo e e a A 3 Input Corin ectlon ttt ee A 3 00 000008 3 Torch Gonnectlon eerie ioo ee Ra A 3 Torch Connection Cover Installation A 4 Gas Gonnectlom ree A 4 Water Coolant Return Connection A 4 Water Solenoid A 4 Coolant Feed Through Connector A 4 Operation shine Section B Safety Pr cautions iiredas iai ena ed vr eap aba Dei gua ae B 1 Ed de reete dae dide dede B 1 Power Source and Starter Kit Operation pp B 2 Invertec Control 8 2 DC TIG Starter Control Function Operation pp B 2 Operation with an Arc Start Switch B 3 Operation with an Amptrol is B 4 Remote Control Switch B 4 ACCeSSOFIeS e de Te de ee T Section C Accessories 1 1 121 i tege e ee ae vade C 1 Maintenance 1 2 2 1 1 121212 Ea i aaa Section D Safety Precaultloris ode ice E E Aetas d dtes CORR Ts D 1 Routine and Periodic Maintenance D 1 Troubleshooting re Section Safety Precautloris ned tte e rd S le une ere eda E 1 How To Use Troubleshooting Guide and General Information
34. ipped with a solenoid in the coolant path for fluid control The water coolant inlet connection is made at the 5 8 LH connector at the back of the DC TIG Starter Non Solenoid Controlled Water Coolant Return Connection Use of water coolers which need non interrupted fluid flow require the replacement of the DC TIG Starter s water solenoid with the fluid connector supplied with the kit Water Solenoid Removal a Turn power off to the V300 b Disconnect all items connected to the DC TIG Starter from the V300 input cable V300 output cable torch connection and gas and coolant lines c Uncouple Invertec from DC TIG Starter by remov ing 4 connecting fasteners d Detach DC TIG Starter s wraparound by removing 6 fasteners e Loosen clamp on coolant line then remove line from solenoid f Remove exterior 5 8 LH connector from solenoid g Disconnect 4 pin mini molex P4 from J4 on con trol board and cut any tie wraps to free the water solenoid input leads h Detach water solenoid from center panel by remov ing 2 fastening screws Coolant Feed Through Connector Installation a Insert fitting through vacated hole in case back and secure with supplied lock washer and hex nut Slight clearing of the center panel and case back may be necessary b Slide coolant hose over fitting and secure with hose clamp c Secure any loose wires by replacing removed tie wraps NOTE water coolant threads are left hand
35. itch on the Invertec to the position Set this switch to the ON position for a con tinuously energized torch oN OUTPUT TERMINALS REMOTE Meter Polarity Switch Located at the rear of the Invertec this switch must be placed in the negative position for electrode negative welding and in the positive for electrode positive welding T13086 84 Arc Force Inductance This control on the Invertec is disabled in the GTAW mode O Uz Has no effect when DC TIG Starter is used INVERTEC DC TIG STARTER LINCOLN 3 DC TIG Starter Front B 3 REMOTE CURRENT ENDO 4 8 DC TIG STARTER Q pudo CODE SERIAL NO 60 DUTY CYCLE 300A 100 DUTY CYCLE 250A DOWNSLOPE TIME XY POSTFLOW TIME 17 te REMOTE OOF DC TIG Starter Control Function Operation Postflow Time An infinite range of postflow times between 5 and 55 seconds can be set by adjusting this knob on the front panel POSTFLOW Sue TIME 15 13 ka 20 XN 425 9 1 5 7 5 5 Downslope Current downslope fade out ulated from fast 0 seconds to slow 30 seconds by adjusting this knob on the front panel The current downslope starts at the level set by the current limit CL knob and reduces to a crater fill level of 25 o
36. leased the optimized upslope will ramp the current up to the desired current limit Closing the trigger the second time initiates the selected downslope which ramps the current down to 2596 of current limit Releasing the trigger stops the crater fill current level and starts postflow Reclosing the trigger during postflow skips the preflow stage and immediately restrikes the arc If the arc is lost during welding the solid state start ing circuit will resume operation for up to two seconds to re establish the arc If the arc is not re established the DC TIG Starter kit will shut off the high frequency shut off the Invertec s trigger and begin postflow timing See FIGURE 4 FIGURE 4 4 Step Trigger Control Using Arc Start Switch START SWITCH SWITCH OPENED CLOSED spar r CURRENT LIMIT C YT START TRIGGER SWITCH SWITCH CLOSED 1 1 1973 330 34018 00 q INED NE PREFLOW POSTFLOW TRIGGER PULLED WITHOUT GAS FLOWING TRIGGER PULLED DURING POSTFLOW TRIGGER RELEASED TO START WELDING PROCEDURE IF ARC HAD STARTED POSTFLOW STARTS IF ARC DID NOT START TRIGGER PULLED TO INITIATE FINISHING SEQUENCE 0 TRIGGER RELEASED TO STOP CURRENT TRIGGER RELEASED DURING DOWNSLOPE STOPS CURRENT AND STARTS POSTFLOW Operation with an Amptrol For best use of the DC TIG Starter with an optional hand or foot amptrol the Trigger Function Switch should be
37. ly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00
38. met 3590 M 5099 New Approach to Industral Economics 5500 NA Lames F Lincoln Arc Welding ______ The American Century of John C Lincoln 500 AC Foundation Book Information Welding PrsheatCalcutor 300 wee FLF 515 Pipe Welding Charis 9 50 ED Shipping Costs any OA Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Name Address Telephone Signature as it appears on Charge Card eleme WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese Korean Do nottouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Notoque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo 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 Ber hren Sie keine stromfuhrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toqu
39. n gt 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 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 garmen
40. ne 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 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 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 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 donc REDRESSEUR a Utiliser un bon 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
41. placed in the 2 step position and the downslope control should be placed in the FAST or OFF position Remote Control Switch Located at the rear of the DC TIG Starter this switch gives output control of the Invertec to the DC TIG Starter or to a wire feeder Use of this switch and con necting a wire feeder to the lower 14 pin Amphenol or the back of the DC TIG Starter allows for simultaneous connection of the DC TIG Starter and a wire feeder to the Invertec Changing between GTAW and GMAW processes or vise versa then requires changing the Invertec s switches as needed changing the DC TIG Starter s remote control switch to the WIRE FEEDER position and changing connections to the Invertec s output terminals as needed FIGURE 5 Remote Control Switch CONTROL AT CONNECT TO TOP DCTIG INVERTEC SN STARTER 2529 CONTROL 1 CONTROL OO WIRE WIRE XL FEEDER FEEDER sorrow INVERTEC DC TIG STARTER LINCOLN C 1 ACCESSORIES There are no factory installed options The DC TIG Starter comes complete with cables torch adapters and hardware for installation Field Installed Options Accessories Cable Plugs Cable Plug Kit for 1 0 2 0 cable K852 70 Attaches to welding cable to provide quick dis connect from machine NOTE A 17 1 0 cable with two K852 70 plugs installed is included with the DC TIG Starter kit for use in installing th
42. present No HF arcing OCV present Ifa welding arc can be started using the scratch start method a Check leads 107 and 108 for proper connections and conti nuity b Replace the HIGH FREQ FIRING BOARD c Replace the CONTROL BOARD d Replace the HIGH FREQ TRANSFORMER T2 welding arc cannot be started using the scratch start method check continuity of the work lead and torch and repair or replace as needed Check the continuity between both of the DC TIG Starter s torch connectors and the Invertec s negative output terminal repair or replace the input cable assembly the HF transformer lead connections or the HF transformer T2 as needed A CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed INVERTEC DC TIG STARTER LINCOLN 5 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual HF arcing not present Check that the Invertec s Meter Polarity Switch is in the position for the electrode connection being used Check that the RED LED on the control board is not illuminated If it is illuminated replace the control board If solenoids engage when the arc start switch is closed check that 24 VAC is present between leads 2 and 4 with the arc start switc
43. r 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 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 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 5 Installation 1 1 1 1 1 SE a Section Technical Specifications ae enne 1 Product Descriptio eel ee ur 2 Recommended Processes and Equipment RN A 2 Compatible Lincoln Equipment A 2 Location xL 2 H
44. rking on equipment Do not touch electrically hot parts Location The DC TIG Starter kit has been designed with many features to protect it from harsh environments Even so it is important that simple preventative measures are followed in order to assure long life and reliable operation a The machine must be located where there is free circulation of clean air such that air movement in the back and out the bottom will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum b Keep machine dry Shelter from rain and snow Do not place on wet ground or in puddles High Frequency Interference Protection The DC TIG Starter employs a solid state non contact torch starting circuit which drastically reduces high fre quency emissions from the machine as compared with spark gap type high frequency generators Radiated interference can develop however in the following four ways a Direct interference radiated from the machine b Direct interference radiated from the welding leads c Direct interference radiated from feedback into the power lines or d Interference from reradiation or pickup by ungrounded metallic objects Keeping these contributing factors in mind installing equipment per the following instructions should mini mize problems a Keep the machine power supply lines as short as possible INVERTEC DC TIG STARTER LINCOLN 3 INSTALLATION A
45. ties 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 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 PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie dico LES MACHINES SOUDER TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince u
46. ts 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 Also see item 1 c LINCOLN CYLINDER may explode 1228 s 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 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 v
47. und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria e FR EE HA A RHE RA BERE o e daze SH7IAE S XACE E 25 AAS AH 71 97471 5 44 Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico Nao toque as partes el tricas nuas e e HERES BEER e Meg xp AIR e Do not operate with panel open guards off No operar con panel abierto o guardas quitadas N op rez pas avec les p
48. us prob lems Inspect all wiring lugs and connec tions to ensure that electrical connections are tight and free of debris All connectors should make complete contact with their mating components leads and lugs should be fully inserted into their respective connector cavities Many problems can be uncovered with a good visual inspection Open Circuit Voltage The DC TIG Starter does not alter the open circuit voltage of the Invertec Consult the Invertec s manual for applicable open circuit voltages With the Invertec s Output Terminals Switch in the position the open circuit voltage should appear between the Invertec s positive output terminal and both of the torch connection terminals of the DC TIG Starter for electrode negative con nections Test Conditions Perform all powered tests with an isolated 42 VAC input supply such as from an Invertec V300 Make ohmmeter checks only after power has been disconnected from machine Certain high voltage connections have been insulated with RTV sealant It is necessary to break through the sealant with a sharp probe in order to make voltage or resistance checks on these connections After the com pletion of all measurements and repair work all RTV punctures should be resealed with RTV Refer to the DC TIG Starter s wiring diagram at the back of this manual for lead and con nector references listed A CAUTION If for any reason you do not understand the test
49. utors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
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