RETURN TO MAIN MENU INVERTEC DC TIG STARTER ® IM465-B October, 1999 This manual for use with DC TIG Starter Codes 9926, 9990 & 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 thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii 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.
iii iii SAFETY WELDING SPARKS can 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. 6.b.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want 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 purchaser upon receipt by the carrier.
vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Product Description ...............................................................................................A-2 Recommended Processes and Equipment ...........................................................
NOTES
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – DC TIG STARTER INPUT Standard Voltage/Frequency 42 VAC ±15% / 50/60 Hz. Input Current 2.0 Amps - Rated Output CURRENT LIMIT Duty Cycle 60% Duty Cycle 100% Duty Cycle Amps 300 250 PHYSICAL DIMENSIONS Height 6.44 in 164 mm Width 10.72 in 272 mm Depth 21.01 in 523 mm INVERTEC DC TIG STARTER Weight 23 Ibs 10.
A-2 A-2 INSTALLATION PRODUCT DESCRIPTION INSTALLATION The purpose of the DC TIG Starter is to provide a high frequency, high voltage pulse for 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 60% duty cycle and 250 amperes DC at a 100% duty cycle). The input requirements are 42 VAC, 2.0 amps.
A-3 A-3 INSTALLATION 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 frequency 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.
A-4 INSTALLATION 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. A-4 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 removing 4 connecting fasteners.
B-1 B-1 OPERATION Limitations OPERATING INSTRUCTIONS 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. -----------------------------------------------------------------------FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone.
B-2 B-2 OPERATION Power Source and Starter Kit Operation Duty Cycle Mode: This switch on the Invertec should be set to the GTAW position for both scratch start and non-contact, high frequency starting use. 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.
B-3 B-3 OPERATION DC TIG Starter Front Panel 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.
B-4 B-4 OPERATION FIGURE 3 Operation with an Amptrol 2-Step Trigger Control Using Arc Start Switch For best use of the DC TIG Starter with an optional hand or foot amptrol, the Trigger Function Switch should be placed in the 2-step position and the downslope control should be placed in the FAST (or OFF) position.
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 (K85270): Attaches to welding cable to provide quick disconnect 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 the kit beneath the Invertec.
D-1 MAINTENANCE MAINTENANCE WARNING 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.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING 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.
E-2 TROUBLESHOOTING E-2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) No output; fan does not operate. RECOMMENDED COURSE OF ACTION 1. Check that the input cable assembly is tightly connected. 2. Check the wiring at the 14-pin and 6-pin Amphenols. All connections should be insulated and free of debris. 3. Check that there is 42 VAC present between cavities “I” and “K”, (leads 42 and 41), of the 14-pin Amphenol.
E-3 TROUBLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) No output; fan operates. RECOMMENDED COURSE OF ACTION 1. Perform steps 1 and 2 under heading on previous page of “No output; fan does not operate”. 2. Check that the Invertec’s Meter Polarity Switch is in the correct position for the electrode polarity being used. 3. Check that the RED LED on the control board is not illuminated. If it is illuminated, replace the control board. 4.
E-4 TROUBLESHOOTING E-4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION No HF arcing; OCV not present. 1. Check that the Invertec’s Meter Polarity Switch is in the position for the electrode connection being used. 2. Check that the RED LED on the control board is not illuminated. If it is illuminated, replace the control board. 3.
E-5 TROUBLESHOOTING E-5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION Postflow Time does not vary with knob; 15 seconds always. 1. Check leads and connections for the postflow adjustment potentiometer, R1. 2. 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.
E-6 TROUBLESHOOTING Environmental Protection High voltage connections are covered with an RTV sealant to prevent malfunction in severe environments. 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.
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F-4 DIAGRAMS INVERTEC DC TIG STARTER F-4
NOTES INVERTEC DC TIG STARTER
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● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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