AUTO ARC 255 Owner`s manual

Model Advantage® HF
High Frequency Arc Starter
For the Following Specs:
• 7027
• 7027A
115 V, 60 Hz
115 V, 60 Hz
OWNER’S MANUAL Number 430429-255
Revised December 1, 1997
IMPORTANT: Read these instructions before installing, operating, or servicing this system.
THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.
Advantage HF is a registered trademark of Thermal Arc Inc., Troy, Ohio
430429-255
Table of Contents
INTRODUCTION
1
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Receipt Of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SAFETY INSTRUCTIONS AND WARNINGS
2
DESCRIPTION OF EQUIPMENT
3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Controls, Instruments, Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
INSTALLATION
Location . . . . . . . . . . . . . . . . .
Direct Radiation From Welding Machine
Direct Radiation From Welding Leads .
Radiation From Power Lines . . . . . .
Wiring In The Welding Area . . . . . . .
Re-Radiation . . . . . . . . . . . . . .
Wiring Changes . . . . . . . . . . . . .
Use In Metal Buildings . . . . . . . . .
Welding Leads . . . . . . . . . . . . .
Remote Control Cables . . . . . . . . .
Certification Notice . . . . . . . . . . .
Individual Installation Certification . . .
Responsibility For Interference . . . . .
Grounding . . . . . . . . . . . . . . . .
Connection To Line Voltage . . . . . .
External Power/Control/Hose Installation
Welding Adjustments . . . . . . . . . .
OPERATION
4
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4-1
4-1
4-1
4-1
4-1
4-1
4-2
4-2
4-2
4-2
4-2
4-2
4-2
4-2
4-4
4-4
4-4
5
TIG Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Welding Currents For The TIG Process . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Regulation Of Inert Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
MAINTENANCE
6
High Frequency Arc Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Inspection And Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
TROUBLESHOOTING
7
PARTS LIST
8
Equipment Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
How To Use This Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
CERTIFICATION NOTICE
DIAGRAMS
December 1, 1997 Revised
430429-255
INTRODUCTION
INTRODUCTION
How To Use This Manual
This Owner’s Manual usually applies to just the
underlined specification or part numbers listed on
the cover. If none are underlined, they are all covered by this manual.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these
headings. These special annotations are easily recognized as follows:
WARNING gives information regarding possible personal injury. Warnings will be enclosed
in a box such as this.
CAUTION refers to possible equipment
damage. Cautions will be shown in bold
type.
NOTE offers helpful information concerning certain operating procedures. Notes will
be shown in italics.
Equipment Identification
The unit’s identification number (specification or
part number), model, and serial number usually
December 1, 1997 Revised
appear on a nameplate attached to the control
panel. In some cases, the nameplate may be attached to the rear panel. Equipment which does not
have a control panel such as gun and cable assemblies is identified only by the specification or part
number printed on the shipping container. Record
these numbers for future reference.
Receipt Of Equipment
When you receive the equipment, check it against
the invoice to make sure it is complete and inspect
the equipment for possible damage due to shipping.
If there is any damage, notify the carrier immediately to file a claim. Furnish complete information
concerning damage claims or shipping errors to
Thermal Arc, Order Department, 2200 Corporate
Drive, Troy, Ohio 45373-1085. Include all equipment identification numbers as described above
along with a full description of the parts in error.
Move the equipment to the installation site before
uncrating the unit. Use care to avoid damaging the
equipment when using bars, hammers, etc., to uncrate the unit.
Additional copies of this manual may be purchased by contacting Thermal Arc at the address
given above. Include the Owner’s Manual number
and equipment identification numbers.
1-1
430429-255
INTRODUCTION
This page intentionally left blank.
1-2
December 1, 1997 Revised
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does
not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
training before using this equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld. Certain
of the practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
Safe practices are outlined in the American National Standard Z49.1 entitled: SAFETY IN WELDING AND CUTTING. This publication and
other guides to what you should learn before operating this equipment are listed at the end of these safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating mats
or covers.
4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open,
or remove line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
hearing.
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water
to cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly spliced cables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment. Repair or replace damaged
parts at once.
13. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A6.2-73.
Filter
Electrode Size
Shade
Welding or Cutting
Metal Thickness
No.
Operation
or Welding Current
2
Torch soldering
—
3 or 4
Torch brazing
—
Oxygen cutting
3 or 4
Light
Under 1 in., 25 mm
4 or 5
Medium
1 to 6 in., 25-150 mm
5 or 6
Heavy
Over 6 in., 150 mm
Gas welding
4 or 5
Light
Under 1/8 in., 3 mm
5 or 6
Medium
1/8 to 1/2 in., 3-12 mm
6 or 8
Heavy
Over 1/2 in., 12 mm
10
Shielded metal-arc welding
Under 5/32 in., 4 mm
12
(stick) electrodes
5/32 to 1/4 in., 4 to 6.4 mm
14
Over 1/4 in., 6.4 mm
May 8, 1996
Welding or Cutting
Operation
Gas metal-arc welding (MIG)
Non-ferrous base metal
Ferrous base metal
Gas tungsten arc welding (TIG)
Atomic hydrogen welding
Carbon arc welding
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light
Medium
Heavy
Electrode Size
Metal Thickness
or Welding Current
Filter
Shade
No.
All
All
All
All
All
All
11
12
12
12
12
12
12
14
Under 300 Amp
300 to 400 Amp
Over 400 Amp
9
12
14
2-1
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
WELDING can cause fire or explosion.
5. Watch for fire, and keep a fire extinguisher nearby.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or fire.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process,
be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
them to a stationary support or equipment cylinder rack to prevent
falling or tipping.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
1. Wear approved face shield or safety goggles. Side shields recommended.
2. Wear proper body protection to protect skin.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety
Standards.
ENGINES can be hazardous.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
2-2
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
May 8, 1996
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely
in place.
2. Stop engine before installing or connecting unit.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteries contain acid and generate explosive gases.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and under
pressure.
2. Do not add fuel while smoking or if unit is near any sparks or open
flames.
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
1.
2.
3.
4.
5.
Always wear a face shield when working on a battery.
Stop engine before disconnecting or connecting battery cables.
Do not allow tools to cause sparks when working on a battery.
Do not use welder to charge batteries or jump start vehicles.
Observe correct polarity (+ and –) on batteries.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Sec. 25249.5 et seq.)
NOTE: Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects
of Power Frequency Electric & Magnetic Fields — Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): “... there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of
this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to
offer clear science-based advice on strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following procedures:
1. Keep cables close together by twisting or taping them.
3. Do not coil or drape cables around the body.
2. Arrange cables to one side and away from the operator.
4. Keep welding power source and cables as far away from body as
practical.
About Pacemakers:
The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
May 8, 1996
2-3
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
This page intentionally left blank.
2-4
May 8, 1996
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
PRECAUTIONS DE SECURITE EN SOUDAGE A L′ARC
LE SOUDAGE A L′ARC EST DANGEREUX
PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES
ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN).
CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU
ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel
et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises
par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage
ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres
s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à
suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces
instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET
D’ESSAI.
L’E LE C T R OC UTION P E UT ETRE
MORTELLE.
Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous
tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont
aussi sous tension dès la mise en marche. En
soudage automatique ou semi-automatique avec
fil, ce dernier, le rouleau ou la bobine de fil, le
logement des galets d’entrainement et toutes les
pièces métalliques en contact avec le fil de soudage
sont sous tension. Un équipement inadéquatement
installé ou inadéquatement mis à la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
3. Isolez-vous de la pièce à souder et de la mise à la terre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez
le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le
commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon
le manuel d’utilisation et les codes nationaux, provinciaux et
locaux applicables.
LE RAYONNEMENT DE L′ARC PEUT
BRÛLER LES YEUX ET LA PEAU; LE
BRUIT PEUT ENDOMMAGER L′OUIE.
L’arc de soudage produit une chaleur et des
rayons ultraviolets intenses, susceptibles de
brûler les yeux et la peau. Le bruit causé par
certains procédés peut endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquée ci-après)
8-V-96
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant
en même temps. Ne jamais toucher quelqu’un d’autre avec
l’électrode ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre
de la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
de courant alternatif, à moins qu’il soit muni d’un réducteur de
tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
2.
3.
4.
5.
pour vous protéger le visage et les yeux lorsque vous soudez ou
que vous observez l’exécution d’une soudure.
Portez des lunettes de sécurité approuvées. Des écrans latéraux
sont recommandés.
Entourez l’aire de soudage de rideaux ou de cloisons pour
protéger les autres des coups d’arc ou de l’éblouissement;
avertissez les observateurs de ne pas regarder l’arc.
Portez des vêtements en matériaux ignifuges et durables (laine
et cuir) et des chaussures de sécurité.
Portez un casque antibruit ou des bouchons d’oreille approuvés
lorsque le niveau de bruit est élevé.
2-1
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE
( selon AWS A 8.2-73 )
Opération
de
Coupage ou soudage
Brasage tendre au chalumeau
Brasage fort au chalumeau
Oxycoupage
mince
moyen
épais
Soudage aux gaz
mince
moyen
épais
Soudage à l’arc avec
electrode enrobées (SMAW)
Soudage à l’arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux
métaux ferreux
Soudage à l’arc sous gaz
avec électrode de tungstène (GTAW)
Soudage à l’hydrogène
atomique (AHW)
Soudage à l’arc avec
électrode de carbone (CAW)
Soudage à l’arc Plasma (PAW)
Gougeage Air-Arc avec
électrode de carbone
mince
épais
Coupage à l’arc Plasma (PAC)
mince
moyen
épais
Dimension d’électrode ou
Epaisseur de métal ou
Intensité de courant
toutes conditions
toutes conditions
Nuance de
de filtre
oculaire
2
3 ou 4
moins de 1 po. (25 mm)
de 1 à 6 po. (25 à 150 mm)
plus de 6 po. (150 mm)
2 ou 3
4 ou 5
5 ou 6
moins de 1/8 po. (3 mm)
de 1/8 à 1/2 po. (3 à 12 mm)
plus de 1/2 po. (12 mm)
moins de 5/32 po. (4 mm)
de 5/32 à 1/4 po. (4 à 6.4 mm)
plus de 1/4 po. (6.4 mm)
4 ou 5
5 ou 6
6 ou 8
10
12
14
toutes conditions
toutes conditions
11
12
toutes conditions
12
toutes conditions
12
toutes conditions
toutes dimensions
12
12
12
14
moins de 300 ampères
de 300 à 400 ampères
plus de 400 ampères
LES VAPEURS ET LES FUMEES SONT
DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant
relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.
2-2
9
12
14
5. Ne travaillez dans un espace confiné que s’il est bien ventilé;
sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi
causer des malaises ou la mort. Assurez-vous que l’air est
propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que
si l’espace est bien ventilé; si nécessaire portez un respirateur
à adduction d’air. Car ces revêtements et tout métal qui contient
ces éléments peuvent dégager des fumées toxiques au moment
du soudage.
8-V-96
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION
L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections
de soudure et l’équipement surchauffé peuvent
causer un incendie et des brûlures. Le contact
accidentel de l’électrode ou du fil-électrode avec un
objet métallique peut provoquer des étincelles, un échauffement
ou un incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou
des projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
LES ETINCELLES ET LES PROJECTIO N S BRU LA NTES PEU V EN T
CAUSER DES BLESSURES.
LES BOUTEILLES ENDOMMAGEES
PEUVENT EXPLOSER
Les bouteilles contiennent des gaz protecteurs
sous haute pression. Des bouteilles endommagées
peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitezles avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un
cadre fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout
soudage.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par de petites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portée de
la main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un
plancher, une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et
d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants
en cuir, une chemise épaisse, un pantalon revers, des bottines
de sécurité et un casque.
Le piquage et le meulage produisent des particules métalliques
volantes. En refroidissant, la soudure peut projeter du éclats de
laitier.
1. Portez un écran facial ou des lunettes protectrices approuvées.
Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent
être maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la
bouteille lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation
ou lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents
ci-dessous.
LES MOTEURS PEUVENT ETRE DANGEREUX
LES GAZ D’ECHAPPEMENT DES
MOTEURS PEUVENT ETRE MORTELS.
Les moteurs produisent des gaz d’échappement
nocifs.
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
8-V-96
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et
bien ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
2. Ne faites pas le plein en fumant ou proche d’une source
d’étincelles ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le
plein de carburant ou d’en vérifier le niveau au début du
soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de
l’espace pour son expansion.
5. Faites attention de ne pas renverser de carburant. Nettoyez tout
carburant renversé avant de faire démarrer le moteur.
2-3
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.
Des pièces en mouvement, tels des ventilateurs, des
rotors et des courroies peuvent couper doigts et
mains, ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
DES ETINCELLES PEUVENT FAIRE EXP LOSER UN ACC UMU LATEUR;
L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET
LES YEUX.
Les accumulateurs contiennent de l’électrolyte
acide et dégagent des vapeurs explosives.
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS
PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur peut
être brûlant et sous pression.
3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage
nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples
et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes
après des travaux d’entretien et avant de faire démarrer le
moteur.
1. Portez toujours un écran facial en travaillant sur un accumulateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des
câbles d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger
un accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
PRINCIPALES NORMES DE SECURITE
Safety in Welding and Cutting, norme ANSI Z49.1, American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33128.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute,
1430 Broadway, New York, NY 10018.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Cutting and Welding Processes, norme 51B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
2-4
8-V-96
430429-255
DESCRIPTION OF EQUIPMENT
DESCRIPTION OF EQUIPMENT
General
The Advantage® HF High Frequency Arc Starter
has been designed to be used with Thermal Arc
welding systems for TIG welding. The need to minimize high-frequency radiation is needed. The
shorter the distance from the high frequency to the
electrode welding tungsten, the less chance of having High-Frequency radiation problems.
The High Frequency Arc Starter superimposes a
high voltage, very low current, high frequency signal
onto the pilot arc output. This creates an arc initiation between the tungsten electrode inside the torch
and the welding surface. This high frequency signal
is generated by a spark gap oscillator powered by
a small transformer. Each breakover of the two-series spark gaps creates a burst of 1 to 4 MHz energy
at a very rapid repetitive rate, until the arc is established. The circuitry automatically disables the high
frequency operation whenever the pilot arc, or the
transferred arc, is present when DC welding. It
operates continuously when AC welding. For proper
operation, each spark gap should be set for .006
inch. The inside and insulating surfaces should be
kept clean and dry. The torch must be properly
connected, and the proper type and amount of gas
must be supplied.
WARNING: High frequency
waves can damage electronic
components. Check with equipment manufacturer before using
equipment with or near this unit.
Model and
Input Volts
Rated
Welding
Amps. 60%
Duty Cycle
115 V
250
230 V
(Opt.)
250
NOTE: When using with engine-driven
equipment, automatic idling systems will
not operate with the high frequency arc
starter attached. Switch the auto idle to the
“OFF” or “HIGH IDLE” positions.
Controls, Instruments, Features
1. Power Switch — This toggle switch must be in
the ON position to place the unit in a ready mode
for operation. A light indicates when power is on.
2. High Frequency Switch — This switch is a
3-position type switch which controls the operation
of the high frequency circuitry.
The START position is for welding with DC current.
When in the START position, the high frequency will
only be available until the arc is established. It will
stay off until the arc is broken.
The CONTINUOUS position is for welding with AC
current. When in the CONTINUOUS position, the
high frequency will be available at all times.
The OFF position disconnects the high frequency
circuitry and places the unit back into a ready mode.
3. Control Remote/Local Switch — Place this
switch in the LOCAL position and high frequency
will be available without the need for a remote or
torch-mounted switch.
If placed in the REMOTE position, an external
switch is required (attached to the remote control
receptacle) to turn on the high frequency.
4. Remote Control Receptacle — For connection
of a remote hand switch.
Dimensions
Width
9-3/4 in.
(248 mm)
9-3/4 in.
(248 mm)
Height
19-1/8 in.
(486 mm)
19-1/8 in.
(486 mm)
Weight
Depth
16 in.
(406 mm)
16 in.
(406 mm)
Net
42 lbs.
(19 kg)
48 lbs.
(22 kg.)
Ship
50 lbs.
(23 kg.)
55 lbs.
(25 kg.)
Table 3-1 Specifications
December 1, 1997 Revised
3-1
430429-255
DESCRIPTION OF EQUIPMENT
Figure 3-1
5. Fuse — 3 amp fast blow for control circuits.
6. Gas inlet connection.
7. Gas outlet for connection to TIG torch.
8. Storage drawer.
9. Electrode In Terminal — Connect the electrode
cable from the welder to this terminal.
10. Electrode Out Terminal — Connect the TIG
torch to this terminal.
11. Work Terminal — Connect the work cables
from the welder and the ground cable from the
workpiece to this terminal.
3-2
12. Secondary Contactor (Option) — A field-installed secondary contactor kit option is available
for remote control of the open circuit voltage.
13. Input Power Connections — This unit comes
standard as a 115-volt AC powered unit equipped
with a 3-prong parallel plug. Never connect this to
a DC power source.
A 230-volt AC option is available which can be field
installed at any time to any unit. However, a plug is
not supplied due to the number of different receptacles available.
December 1, 1997 Revised
430429-255
INSTALLATION
INSTALLATION
Location
For best operating characteristics and longest unit
life, take care in selecting an installation site. When
installing the equipment, avoid locations exposed to
high humidity, dust, high ambient temperature or
corrosive fumes. Moisture condenses on machine
parts and electrical controls, causing corrosion
which can seriously affect operation and efficiency.
Dust and dirt cause extra wear on all moving parts.
Therefore, use care to locate the equipment so that
excess moisture, dust, or corrosive fumes will not
be drawn into the unit.
Adequate air circulation is needed at all times in
order to assure proper operation. Provide a minimum of 12 inches (305 mm) of free air space at both
the sides and rear of the unit. Make sure that the
ventilator openings are not obstructed. Air enters
through the front panels and rear of machine.
Because high frequency stabilized arc welding
machines inherently radiate power at frequencies
which may interfere with radio communication, including commercial, police, and aviation broadcasts, their operation is subject to control by the
Federal Communications Commission.
Some general information on radio frequency radiation from high frequency stabilized arc welding
machines is given below:
Direct Radiation From Welding
Machine
The manufacturer controls direct radiation from the
welding machine by proper design of the unit. If the
user complies with the installation and operation
instructions furnished by the manufacturer, direct
radiation from the machine will be relatively low.
Direct Radiation From Welding
Leads
The initial radiation, due almost entirely to the
welding leads acting as an antenna, decreases
rapidly with the distance from the leads. This radiation can be kept to a minimum by making the welding leads as short as possible. The frequency
spectrum emitted by a particular unit can be altered
substantially by changing the length or position of
the welding leads and by differences in loading
December 1, 1997 Revised
caused by operation with the electrode arcing to the
work.
Radiation From Power Lines
High frequency voltage which is conducted from
the welding machine to the power line may cause
radiation from the line itself. This radiation can be
kept to a minimum by careful design of the unit and,
in some cases, by the use of line filters.
In a welding machine that has been certified by the
manufacturer, the radiation from the power line is
generally small when compared to the direct radiation from the welding leads.
Wiring In The Welding Area
The term “welding area” refers to the area in which
the welding machine, the welding leads, and the
welding work are located.
Re-Radiation
Ungrounded metallic objects in close proximity to
the welding area can act as antenna which will pick
up, conduct and re-radiate the high frequency generated by the welding machine. Unshielded wires in
the immediate vicinity may conduct radiation, and
re-radiate it. Therefore, no unshielded conductors
shall be located within 50 feet (15,240 mm) of the
welding area.
This means that all electrical power or lighting
wiring within 50 feet (15,240 mm) of the welding
area shall be enclosed in grounded rigid metallic
conduit, copper braid, or some other material having an equivalent shielding efficiency, or shall consist of lead-covered cable. (Ordinary flexible
helically wrapped metallic conduit is generally not
suitable.) The shielding or cable covering shall be
grounded at 50-foot (15,240 mm) intervals. Good
electrical bonding shall be maintained between conduit sections.
Wiring, other than electrical power and lighting
wiring within 50 feet (15,240 mm) of the welding
area, shall be shielded and the shields shall be
grounded. [This includes wiring located within 50
feet (15,240 mm) of the welding machine in a vertical or vertical-diagonal direction.]
4-1
430429-255
INSTALLATION
The foregoing procedure shall apply even if:
1. The welding area is not a fixed location.
2. There are exposed wires off the premises but
within 50 feet (15,240 mm) of the welding area.
Wiring Changes
All changes in power and lighting wiring shall be
made by a qualified electrician. Any shielding or
relocation of telephone or signal wires must be done
by the service company concerned or with their
specific permission.
This type of radiation can be kept to a minimum by
installing the welding machine in accordance with
the installation procedures outlined in this instruction manual.
Use In Metal Buildings
Where the welding area is enclosed within a metal
building, proper precautions must be taken to insure
that the building is properly grounded. This can be
accomplished by placing several good electrical
grounds around the periphery of the building. Refer
to following grounding procedure.
The installation procedures described in this publication shall be observed even if the welding machine is operated within a shielded structure.
Welding Leads
The TORCH lead and the WORK lead must each
be 25 feet (7620 mm) or less in length and run
together at floor level whenever possible except the
last 7 feet (2134 mm) at the torch or “whip” end.
Remote Control Cables
(When used)
The remote control cables for gun trigger or foot
control switch must also be 25 feet (7620 mm) in
length, or less, and must be brought out close to and
parallel to the welding leads.
Certification Notice
In order to comply with F.C.C. regulations after the
unit has been installed in accordance with the preceding instructions, the user must post the certification notice at the location of the welding machine. A
convenient form is enclosed which may be used for
this purpose after it has been properly filled out.
4-2
Individual Installation
Certification
1. The user may waive any of the requirements
outlined in these special installation requirements if
he desires to exercise the option of having an
installation test survey made. This survey shall be
made by a competent engineer in accordance with
the test procedure requirements set forth in Part 18
of the Federal Communications’ Rules and Regulations.
2. Certification may cover a unit installation or may
be included in the certification of a complete plant.
Responsibility For Interference
In the event this equipment causes interference, it
is the user’s responsibility to take steps in eliminating the interference.
Grounding
The frame of this welding machine should be
grounded for personnel safety. Where grounding is
mandatory under state or local codes, it is the
responsibility of the user to comply with all applicable rules and regulations. Where no state or local
codes exist, it is recommended that the National
Electrical Code be followed.
The work or work table must also be grounded by
using a conductor attached to a driven ground or
water pipe as described below. See Figures 4-1 and
4-2.
The requirements and recommendations for
grounding apply to rubber tire mounted equipment.
In addition to the usual function of protecting personnel against the hazard of electrical shock due to
fault in the equipment, grounding serves to discharge the static electrical charges which tend to
build up on the surfaces of tire mounted equipment.
These static charges sometimes cause painful
shock to personnel, and in some instances, lead to
the erroneous conclusion that an electrical fault
exists in the equipment.
Use an input-power cable assembly which includes a grounding conductor to connect this equipment to the input power supply. When included in
the cable assembly, the grounding conductor will be
green or green with a yellow stripe, or bare. Connect
the grounding conductor to the equipment grounding terminal, if provided, and if not, to the equipment
frame, taking care to see that good electrical contact
is made between conductor and frame. Connect the
other end of the grounding conductor to the system
ground.
December 1, 1997 Revised
430429-255
INSTALLATION
If, for any reason, an input cable which does not
include a grounding conductor is used, the equipment may be grounded with a separate conductor if
permitted under applicable code, or by special permission of the jurisdictional body responsible for
enforcement of the code. Minimum size and color
coding requirements must be in accordance with
any applicable state or local code, or the National
Electrical Code.
If metallic armored cable or conduit is used, the
metal sheathing or conduit must be effectively
grounded as required by state or local code, or the
National Electrical Code.
If a system ground is not available, the welding
machine must be connected to a driven ground rod
(see Figures 4-1 and 4-2) or to a water pipe that
enters the ground not more than 10 feet (3,048 mm)
from the machine.
Figure 4-1
Outside Ground
December 1, 1997 Revised
NOTE: The grounding conductor must be
as short as possible in order to produce the
most efficient installation.
Treating An Outside Ground — The soil treating
materials are placed in a circular trench around the
rod, but not in direct contact. The crystals are gradually dissolved by surface waters and the solution is
carried into the most useful area of earth surrounding the electrode (rod). Flood the trench several
times when making original installation. See Figure
4-1.
Treating An Inside Ground — Reduce the diameter of the hole to 6 inches (152 mm), pour soil
treating material in and around the rod. Add enough
water to dissolve 8 pounds (4.0 kg) of soil treating
material. Flood the hole every 6 months and replace
the soil treating material when it is all dissolved. See
Figure 4-2.
Figure 4-2 Inside Ground
4-3
430429-255
INSTALLATION
Connection To Line Voltage
The power supply wires serving the welding machine shall be completely enclosed for a distance of
at least 50 feet (15,240 mm) (in any direction) from
the machine in solid metallic conduit or closely
braided copper sheathing. This shielding shall be
connected to the ground at the extreme end of the
shielding. The shielding shall be solidly connected
to the case so as to make good electrical contact
and there shall be no gaps in the shielding run.
(Ordinary flexible helically wrapped metal conduit is
generally not suitable.)
CAUTION: Conductor size shall be selected to meet NEC, CE Code, and local
codes and shall be modified as required
for line voltage drop and ambient temperature.
This welding machine operates on a single-phase,
AC input. See nameplate of the machine to determine required input voltage and frequency. Make
certain that the welding machine is connected for
the power supply voltage available. The input power
cables should be connected to the power supply
through a fused disconnect switch (furnished by the
customer). Refer to the identification nameplate to
determine the rating of the machine, then consult
the local power company for wire and fuse size
code.
The proper operation of the welding machine depends to a great extent on the use of output cables
that are insulated copper, adequately sized, in good
condition and properly connected to the machine. It
is recommended that the output cables be kept
shorter than 25 ft. (this is particularly important for
TIG applications using ACHF), and be of adequate
current carrying capacity.
The resistance of the output cables and connections cause a voltage drop which is added to the
voltage of the arc. Excessive cable resistance may
result in overloading as well as reducing the maximum current output of which the power supply is
capable. The welding output terminals are located
on the front panel.
Welding Adjustments
Keep spark gaps set at .006 inch.
CAUTION: When the machine is in operation, make sure that the top is in
place, and all access holes covered in
the cabinet. Proper flow of cooling air
must be directed through the unit to
avoid overheating. Make no changes or
adjustments not covered in this manual,
as modification might affect radiation
and void the manufacturer’s certification.
External Power/Control/Hose
Installation
WARNING: Before making any
connections to the power supply’s output terminals, make
sure that all primary input power
to the machine is deenergized
(off) at the customer’s disconnect switch.
4-4
December 1, 1997 Revised
430429-255
OPERATION
OPERATION
TIG Welding Procedure
1. Check installation to be certain all connections
are tight and proper controls, gas, and torches are
installed.
2. Preset all controls as practical.
3. Turn on gas supply at gas cylinder.
4. Adjust the gas supply to the desired flow rate.
5. Place the welding torch in proximity of the work.
6. Switch control switch to “LOCAL” (if using a
remote hand switch, leave control switch in REMOTE and switch hand switch to “ON”). Open circuit
voltage will appear, and high frequency will immediately initiate the welding arc.
NOTE: On DC TIG welding, the high frequency will shut off after the arc is established. On AC TIG, the high frequency will
run continuously to stabilize the AC welding
current.
7. Readjust any controls as necessary
CAUTION: Once a welding arc is established, power should not be removed
from the welding machine, and the
POWER ON/OFF SWITCH should not be
turned OFF until after postflow is completed. The work or the torch may be
damaged if water and/or gas ceases to
flow too soon.
8. To terminate welding, proceed in the following
manner:
December 1, 1997 Revised
a. Switch control switch to “REMOTE” (hand
switch to “OFF”). Gas will continue to flow, until
postflow times out (a maximum of 25 seconds).
b. Leave torch in position over the work to
provide shielding gas until the end of the postflow cycle.
c. After the flow of gas stops, that is, on completion of postflow, turn off the gas at source.
d. Place the fused disconnect switch in the
OFF position.
Welding Currents For The TIG
Process
Welding currents for the TIG process depend upon
the size of the tungsten electrode used, the material
being welded, welding speed, size and shape of the
material, and other factors. Table 5-1 is a rough
guide for usable current ranges for various tungsten
electrode sizes.
Regulation Of Inert Gas
The inert gas flow should be controlled accurately
with a regulator and flowmeter. No specific recommendations for rates of flow can be given as this
depends entirely on the welding conditions and the
torch and nozzle used. Correct argon flow is usually
between 8 and 35 cubic feet (226 to 990 liters) of
gas per hour; and helium flow is between 18 and 85
cubic feet (510 to 2410 liters) per hour.
More specific information concerning the torch
configurations available and the gas flows for each
can be obtained from the manufacturer of the torch
equipment.
5-1
430429-255
OPERATION
Welding Current, Amps
ACHF
DCEN
DCEP
Electrode
Diameter
Inches
Using pure
tungsten
electrodes
Using
thoriated
electrodes
.020
5-15
5-20
5-20
————
.040
10-60
15-80
15-80
————
1/16
50-100
70-150
70-150
10-20
3/32
100-160
140-235
150-250
15-30
1/8
150-210
225-325
250-400
25-40
5/32
200-275
300-400
————
40-55
3/16
250-350
————
————
55-80
1/4
————
————
————
80-125
Using pure or thoriated
tungsten electrodes
Table 5-1 Typical Current Ranges for
Tungsten Electrodes
5-2
December 1, 1997 Revised
430429-255
MAINTENANCE
MAINTENANCE
If this equipment does not operate properly, stop
work immediately and investigate the cause of the
malfunction. Maintenance work must be performed
by an experienced person, and electrical work by a
trained electrician. Do not permit untrained persons
to inspect, clean, or repair this equipment. Use only
recommended replacement parts.
WARNING: The welding arc is
extremely bright and penetrating. Do not weld without the
proper protective lenses, and
clothing. Make sure workpiece is
separated from combustible or
dangerous materials, and an
adequate fire watch has been established.
Refer also to:
ANSI Z87.1 Practice for Occupational and Educational Eye and Face Protection.
ANSI Z49.1 Safety in Welding and Cutting.
OSHA 29 CFR 1910 Occupational Safety and
Health Standards.
Inspection And Cleaning
Every Day — Every day that the system is used,
first check closely for any gas leaks, evidence of
plugged lines or valves, and a proper supply of inert
gas.
Every Thirty Days — Remove the cover.
1. Inspect the interior for evidence of leaking,
corrosion, overheated components, arcing, damaged insulation, defective components, or loose
hardware.
2. Check the high frequency spark gaps for proper
spacing. Resurface the gas “faces” as necessary to
permit accurate gap spacing of .006 inch.
3. Clean the interior and the vents in the cover with
a vacuum cleaner or with dry, compressed air of not
over 25 psi (172 kPa) pressure. Oily residue may
require cleaning with a cloth and a non-volatile
solvent.
4. Replace cover and all securing screws.
5. Inspect all the connections, especially on the
front panel, the electrode in terminal, for tightness,
arcing, etc. Recondition and tighten if arcing has
occurred.
AWS A6.0-65 Safe Practices For Welding and
Cutting Containers That Have Held Combustibles.
High Frequency Arc Starter
WARNING: High voltage can
KILL. Before service, inspection,
or cleaning is performed on the
High Frequency Arc Starter
module, disconnect the four cables between the Advantage®
HF and the power source. The
power source (welding machine)
should be turned OFF also.
December 1, 1997 Revised
Figure 6-1 Spark Gap Assembly
6-1
430429-255
MAINTENANCE
Frequent inspection and cleaning of the power
source is recommended. Some suggestions for inspecting and cleaning are as follows:
3. With all input power disconnected, and wearing
proper eye and face protection, blow out the inside
of the power source using low pressure dry compressed air.
WARNING: Make sure the power
is shut off.
1. Make sure cable and hoses are not damaged or
kinked.
WARNING: Water occasionally
accumulates in compressed air
lines. Be sure to direct the first
blast of air away from the equipment to avoid damage.
2. Make sure all plugs, fittings, and ground connections are tight.
4. Drain the water from the air regulator. See the
instruction label on the regulator.
6-2
December 1, 1997 Revised
430429-255
TROUBLESHOOTING
TROUBLESHOOTING
WARNING: Be sure that all primary power to the machine has been externally
disconnected. Open the wall disconnect switch or circuit breaker before
attempting inspection or work inside of the power supply.
Check the problem against the symptoms in the following troubleshooting guide. The remedy may be
quite simple. If the cause cannot be quickly located, shut off the input power, open up the unit, and perform a simple visual inspection of all components and wiring. Check for secure terminal connections,
loose or burned wiring or components, bulged or leaking capacitors, or any other sign of damage or discoloration.
The following chart contains information which can be used to diagnose and correct unsatisfactory operation or failure of the various components of the welding machine. Each symptom of trouble is followed by
a list of probable causes and procedures to correct them.
Troubleshooting Guide
No high frequency
No AC voltage at plug
Check to make sure that cable is plugged into power source.
Check HIGH-FREQUENCY Switch is in the correct mode. Start for DC, Continuous
for AC.
No power supply to transformer
Check primary power supply to transformer.
No secondary power from transformer
Check secondary of transformer using extreme caution with the high voltage (3500
volts). Only use meter leads which have heavy duty insulation for very high voltages.
Weak high frequency
Incorrect gap on Spark Gaps
Adjust gaps to .006" (.1524 mm). Also check that the gaps are not deteriorated.
Failed component in the HF feedback circuit
Check components R1, R2, C1, and C4. Also check for good electrical connections
throughout the entire circuit.
Increase in high frequency interference in other equipment
Unit not properly grounded
Make good ground connection.
Capacitors C2, C3 failed
Replace failed capacitors.
December 1, 1997 Revised
7-1
430429-255
TROUBLESHOOTING
This page intentionally left blank.
7-2
December 1, 1997 Revised
460429-255
PARTS LIST
PARTS LIST
Equipment Identification
All identification numbers as described in the Introduction chapter must be furnished when ordering
parts or making inquiries. This information is usually
found on the nameplate attached to the equipment.
Be sure to include any dash numbers following the
Specification or Assembly numbers.
How To Use This Parts List
The Parts List is a combination of an illustration
(Figure Number) and a corresponding list of parts
which contains a breakdown of the equipment into
assemblies, subassemblies, and detail parts. All
parts of the equipment are listed except for commercially available hardware, bulk items such as wire,
cable, sleeving, tubing, etc., and permanently attached items which are soldered, riveted, or welded
to another part. The part descriptions may be
indented to show part relationships.
To determine the part number, description, quantity, or application of an item, simply locate the item
in question from the illustration and refer to that
item number in the corresponding Parts List.
An “Application Code” is used to distinguish parts
that are applicable only to certain Specifications
and/or Assemblies. This code is found in the rightmost column of the Parts List. If an item in the Parts
List applies to all Specifications or Assemblies, the
word “ALL” will be in the Application Code column.
Refer to the following list to determine the appropriate Application Codes for the Specifications or
Assemblies covered by this manual. If only the
assembly or specification number is listed, the use
of an Application Code does not apply to this
manual.
SPEC NUMBER
APPLICATION NUMBER
7027
A
7027A
B
December 1, 1997 Revised
8-1
460429-255
PARTS LIST
Figure 8-1
8-2
December 1, 1997 Revised
460429-255
PARTS LIST
Parts List for Figure 8-1
Item
No
1
2
3
4
5
6
7
8
9
10
11
Part
Number
493894
493894-1
493795
493791
493791-1
493792
493792-1
493844
493844-1
493802
493812
493812-1
Deleted
170653
493831
204036
493807-1
493807-2
12
493810
493810-1
Description
Qty Application
per
Code
Assy
Starter - Arc, Hi-Freq. Assembly
Starter - Arc, Hi-Freq. Assembly
. Handle - Grab
. Panel - Wrapper
. Panel - Wrapper
. Panel - Side
. Panel - Side
. Base - Assembly
. Base - Assembly
. Mount - Shock
. Support - Bottom
. Support - Bottom
1
1
1
1
1
1
1
1
1
4
2
2
A
B
All
A
B
A
B
A
B
All
A
B
. Label - Danger
. Latch - Draw
. Label - Precautionary
. Panel - Front, Rear, & Bottom Assembly
(For Details See Fig. 8-2)
. Panel - Front, Rear, & Bottom Assembly
(For Details See Fig. 8-2)
. Panel - Interior, Assembly
(For Details See Fig. 8-2)
. Panel - Interior, Assembly
(For Details See Fig. 8-2)
1
1
1
All
All
All
1
A
1
B
1
A
1
B
(Breakdown continued on Figure 8-2)
December 1, 1997 Revised
8-3
460429-255
PARTS LIST
Figure 8-2
8-4
December 1, 1997 Revised
460429-255
PARTS LIST
Parts List for Figure 8-2
Item
No
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
December 1, 1997 Revised
Part
Number
493809
493809-1
493807-1
493807-2
493793
493793-1
376388-2
404162-3
W-10892-1
400400
407016
402421-3
16DA-4107
370447
402658
W-11166-10
494091
493838
W-10080-2
375432-9
No Number
No Number
No Number
No Number
5CW-976A
5CW-975-1
5CW-974-1
No Number
No Number
402119-4
No Number
493805
493810
493810-1
493794
493794-1
409996
367703-7
Description
. Cover - Hole
. Cover - Hole
. Panel - Front, Rear, & Bottom Assembly
. Panel - Front, Rear, & Bottom Assembly
. . Panel - Front, Bottom, & Rear
. . Panel - Front, Bottom, & Rear
. . Transformer
. . Valve - Solenoid (120 V, 60 PSI)
. . Elbow - Street, 90° Brs.
. . Switch - Toggle (Quick Connect)
. . Switch - Toggle, D.P.D.T. (Center Off)
. . Light - Indicator
. . Receptacle - Box, Solid Shell (5 Pin)
. . Adapter - Gas, Right Hand
. . Holder - Fuse
. . Fuse - Fast Blow (3 Amp, 250 V)
. . Label - Ident.
. . Capacitor - Mica
. . Connector - Straight
. . Cable - W/Plug, Assembly
. . Screw - 1/2-13 x 1-3/4, HHC, ST.
. . Screw - 1/2-13 x 1-1/2, HHC, ST.
. . Washer - LK, Std. 1/2
. . Washer - Flat, ST. 1/2
. . Washer - Insulator
. . Bushing - Insulator, Cable Stud
. . Bus - Cable Stud
. . Washer - Flat, ST. 1/4
. . Washer - LK. Std. 1/4
. . Screw - 1/4-20 x 3/4, HHC. ST.
. . Nut - 1/2-13, Hex, Flg., ST.
. . Board - Terminal
. Panel - Interior, Assembly
. Panel - Interior, Assembly
. . Panel - Interior
. . Panel - Interior
. . Timer - Delay
. . Resistor - W/Lugs Assembly
Qty Application
per
Code
Assy
1
1
Ref.
Ref.
1
1
1
1
2
2
1
1
1
2
1
1
1
1
1
1
2
1
3
3
4
2
3
5
3
3
3
1
Ref.
Ref.
1
1
1
1
A
B
A
B
A
B
All
All
All
All
All
All
All
All
All
All
A
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
A
B
A
B
All
All
8-5
460429-255
PARTS LIST
Parts List for Figure 8-2
Item
No
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
—
64
65
—
8-6
Part
Number
405182-1
362909
403056-11
404065-2
401937-1
403056-7
403765-5
400078
493811-1
369286-1
396971-8
202258-1
398646-3
396971-9
202258-2
490597-4
396971-10
493834
200116
490597-4
490597-3
493848
of Item 18)
405548
494040
—
493855
—
Not Illustrated
Description
Qty Application
per
Code
Assy
. . Capacitor - 330 V. A.C.
. . Resistor - 10,000 Ohm
. . Relay - Enclosed
. . Rectifier
. . Terminal - Block, 5 Station
. . Relay - Enclosed
. . Resistor - 100 W.
. . Bracket - Mtg. Resistor
. . Transformer - High Freq.
. . Spark Gap - Assembly
. . Capacitor - Assembly
. . Suppressor - Assembly
. . Resistor - Discharge, Assembly
. . Capacitor - Assembly
. . Suppressor - Assembly
. . Diode - Assembly
. . Capacitor - Assembly
. . Coil - High Freq. (Mounts on Item 41)
. . Capacitor - Assembly
. . Diode - Assembly
. . Diode - Assembly
. Capacitor - Assembly (Mounts on rear
1
. Label - Ground
Kit - Diode (Replaces Item 59 in 60 Volt
OCV machines)
Kit - Suppression
1
1
2
1
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
All
1
All
1
1
All
All
December 1, 1997 Revised
CERTIFICATION NOTICE
HIGH FREQUENCY STABILIZER
Serial No.
Model No.
This equipment may be reasonably expected to meet radiation limits of ten microvolts per
meter at one mile, provided installation, operation, and maintenance is in accordance with
the instructions of the manufacturer.
Thermal Arc Inc.
Troy, Ohio 45373
USER CERTIFICATE
The above equipment has been installed in accordance with manufacturer’s instructions,
and is being operated and maintained as outlined in these instructions.
USER:
Date:
THIS CERTIFICATION NOTICE MUST BE POSTED NEAR THE WELDING
MACHINE.
December 1, 1997 Revised
830006
430429-255
DIAGRAMS
DIAGRAMS
•
Note the model and specification number shown on the equipment nameplate.
•
Locate these numbers in the model and specification number columns below.
•
Use only those diagrams and instructions that are applicable.
MODEL
ADVANTAGE HF®
December 1, 1997 Revised
SPECIFICATION
NUMBER
7027
7027A
CONNECTION &
SCHEMATIC
DIAGRAM
493823
STATEMENT OF WARRANTY
®
LIMITED WARRANTY: Thermal Arc , Inc., A Thermadyne Company, warrants that its products will be free of defects in workmanship
or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated
below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal
Arc’s sole option, of any components or parts of the product determined by Thermal Arc to be defective.
THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF
ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal Arc shall not under any circumstances be liable for special or consequential damages, such as,
but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”)
for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strike tort, or under
any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is
based. No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other
warranty.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH
IN THERMAL ARC’S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY
NON-AUTHORIZED PERSONS.
Except with regards to the products listed below, this warranty shall remain effective three (3) years from the date Thermal Arc’s
authorized distributor delivers the product to Purchaser, but in no event more than (4) years from the date Thermal Arc delivers the
product to the authorized distributor.
Shorter warranty periods apply to the products listed below. On these products, the warranty is effective for the time stated below
beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event
shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the
authorized distributor.
ALL OTHER
P-WEE, PRO-LITE
POWER SUPPLIES
POWER SUPPLIES
PRO-PLUS, PRO-WAVE
LABOR
MAIN POWER MAGNETICS (STATIC & ROTATING)
3 YEARS
2 YEARS
1 YEAR
ORIGINAL MAIN POWER RECTIFIER
3 YEARS
2 YEARS
1 YEAR
CONTROL PC BOARD
3 YEARS
2 YEARS
1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS INCLUDING
1 YEAR
1 YEAR
1 YEAR
BUT NOT LIMITED TO, CONTACTORS, RELAYS,
SOLENOID, PUMPS, POWER SWITCHING SEMI-CONDUCTORS
ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE ENGINE
MANUFACTURER. SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS.
CONSOLES, CONTROL EQUIPMENT, HEAT
1 YEAR
1 YEAR
1 YEAR
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS
180 DAYS
180 DAYS
180 DAYS
REPAIR/REPLACEMENT PARTS
90 DAYS
90 DAYS
90 DAYS
®
Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to
send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s
risk and expense. This warranty supersedes all previous Thermal Arc warranties.
®
Thermal Arc is a Registered Trademark of Thermadyne Industries Inc.
Thermal Arc Inc.
Troy, Ohio 45373
Effective January 4, 1999
830538