Lincoln Electric Control Box CB-WCS (For Automation) Operator Manual

Lincoln Electric Control Box CB-WCS (For Automation) Operator Manual
IM10070
Control Box CB-WCS
For use with machines having Code Numbers:
May, 2010
S-23271-1
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful 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
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.
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. And, most importantly,
think before you act and be careful.
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.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you develop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
Safety 01 of 04 - 5/16/2018
SAFETY
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
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 § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
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.
Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & 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.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
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.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
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.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. 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.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. 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.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.b. Operate engines in open, well-ventilated areas or vent the engine
exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact
Safety 02 of 04 - 5/16/2018
SAFETY
ELECTRIC SHOCK
CAN KILL.
ARC RAYS CAN BURN.
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.
4.a.
Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
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.
4.b.
Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c.
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.
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.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. 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.d. 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.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
Safety 03 of 04 - 5/16/2018
SAFETY
WELDING AND CUTTING
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. 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.
6.c. 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.
6.d. 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).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. 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 circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders 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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
Safety 04 of 04 - 5/16/2018
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. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
iv
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
SAFETY
v
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national codes.
Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel
welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
v
SAFETY
vi
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications.
1
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”
vi
TABLE OF CONTENTS
Page
PREFACE ................................................................................................................................................... 2
1
INTRODUCTION ................................................................................................................................. 2
1.1 Identification of the Product ....................................................................................................... 2
1.2 General Description .................................................................................................................. 2
1.3 Product Combinations ............................................................................................................... 2
1.4 Technical Specifications ........................................................................................................... 2
2
PRODUCT DESCRIPTION ................................................................................................................. 3
2.1 Components .............................................................................................................................. 3
2.2 Operation .................................................................................................................................. 3
3
SAFETY .............................................................................................................................................. 3
4
INSTALLATION .................................................................................................................................. 4
4.1 Unpacking ................................................................................................................................. 4
4.2 Installation ................................................................................................................................. 4
4.3 Electric connection ................................................................................................................... 4
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.4
Mains (“MAINS”) ............................................................................................................................. 4
Extraction fan (“FAN MOTOR”) ....................................................................................................... 4
Automatic start/stop device (WCS) (“WCS”) ................................................................................... 5
Work Lamp (WL) and/or Arc Sensor (AST) (“WCS”) ...................................................................... 5
Stationary welding fume extractor (Statiflex 400-MS) (“FILTER”) ................................................... 5
Adjustment ................................................................................................................................ 5
4.4.6 Start delay ....................................................................................................................................... 5
4.4.7 Stop delay ....................................................................................................................................... 5
5
OPERATION ....................................................................................................................................... 5
6
MAINTENANCE .................................................................................................................................. 5
7
TROUBLESHOOTING ........................................................................................................................ 6
8
SPARE PARTS ................................................................................................................................... 7
9
DISPOSAL .......................................................................................................................................... 7
10
ELECTRICAL DIAGRAM ................................................................................................................... 8
CONTROL BOX CB-WCS
1
•
•
•
•
PREFACE
Using this Instruction Manual
This instruction manual is intended to be used as a work of
reference for professional, well trained and authorized users
to be able to safely install, use, maintain and repair the
product mentioned on the cover of this document.
product name
serial number
supply voltage and frequency
power consumption
1.2 General Description
The CB-WCS is a control box to:
• connect the automatic start/stop device WCS to the
mains
• switch the connected extraction fan SF 2400 on and off
by the automatic start/stop device WCS
Always keep this manual with the product.
Pictograms and Symbols
The following pictograms and symbols are used in this
manual:
Suggestions and recommendations to simplify
carrying out tasks and actions.
The CB-WCS can also be used for connecting a stationary
welding fume extractor Statiflex 400-MS, an in the extraction
arm integrated Work Lamp (WL) and/or automatic start/stop
device (AST or WCS) and an extraction fan (SF 2400) to the
mains.
ATTENTION!
1.3 Product Combinations
TIP
Remark with additional information for the user. A
remark brings a possible problem to the user’s
attention.
The CB-WCS can be used with the following products:
• S23274-2 Welding cable sensor WCS
• K1656-1
Extraction fan SF 2400 (115V/1ph/60Hz)
CAUTION!
1.4 Technical Specifications
This statement appears where the instructions
must be followed to avoid minor personal injury
or damage to this equipment.
CB-WCS
WARNING!
This statement appears where the instructions
must be followed exactly to avoid serious
personal injury or loss of life.
CAUTION!
Denotes risk of electric shock.
Service and Technical Support
For information about specific adjustments, maintenance or
repair jobs which are not dealt with in this manual, please
contact the supplier of the product. Make sure you have the
following data on hand:
- product name
- serial number
- purchase order (number + date) for warranty verification
Product part #
S-23271-1
Dimensions
refer to Fig. 1.1
Weight
3.9 kg (8.6 lbs)
Isolation class
IP 55
Operating temperature:
- minimum
- nominal
- maximum
- 5°C (41°F)
- 20°C (68°F)
- 45°C (113°F)
Max. relative humidity
80%
The product name and serial number can be found on the
identification label located at the cover of the control box.
1
INTRODUCTION
1.1 Identification of the Product
Fig. 1.1: Dimensions
The identification label contains the following data:
CONTROL BOX CB-WCS
2
2
maintenance and repair of the product mentioned on the
cover of this document and any corresponding accessories.
Specific working conditions or used accessories may
require additional safety instructions. Immediately contact
your supplier if you detect a potential hazard when using the
product.
PRODUCT DESCRIPTION
2.1 Components
The CB-WCS consists of the following components (Fig.
2.1):
A Cover
B Housing
C Timer PC board
D Fuse 2A
E Connecting block
F Transformer
G Thermal relay
H Relay
I Fuse holder
J Main fuse
K Cap nut
L Cable gland
User Manual
•
•
•
Everyone working on or with the product must be familiar
with the contents of this manual and must strictly observe
the instructions herein. Management should instruct and
train the operators in accordance with the manual and
observe all instructions and directions given.
Never change the order of steps-to-be-performed.
Always keep the manual with the product.
Users
The use of this product is exclusively reserved to authorized,
trained and qualified users. Temporary personnel and
personnel in training can only use the product under
supervision and responsibility of management and trained
personnel such as skilled engineers.
CAUTION!
The user of the product is always fully responsible
for observing the local safety instructions and
regulations.
Intended Use1
The product has been designed exclusively to switch the
connected extraction fan on and off by the automatic start/
stop device WCS and to connect the WCS to the mains.
Using the product for other purposes is considered contrary
to its intended use. The manufacturer accepts no liability for
any damage or injury resulting from such use. The product
has been built in accordance with state-of-the-art standards
and recognized safety regulations. Only use the product in
mechanically sound condition in accordance with its
intended use and the instructions set forth in the user
manual.
Fig. 2.1: Main components
2.2 Operation
The CB-WCS is a control box which supplies power to the
connected welding cable sensor WCS and extraction fan SF
2400. The CB-WCS arranges the extraction fan to switch on
and off automatically. To realise this, the WCS is to be
connected to the ground cable of a welding machine. When
the welding starts, the WCS sends a signal to the CB-WCS.
Subsequently, the extraction fan SF 2400 automatically
switches on. When the welding stops, the fan automatically
switches off. Depending on the specific circumstances and/
or the user’s wish, the start delay and the stop delay of the
fan can be adjusted.
3
Modifications
Modifications of this product, other than those specified in
this manual, are not allowed. Any unauthorized modification
will void the product warranty.
Use
If the product is used in combination with the in the
introduction of this manual mentioned products or machines
(see 1.3), the safety instruction in the documentation of
these products also apply.
SAFETY
General
The manufacturer does not accept any liability for damage
to the product or personal injury caused by non-observance
of the safety instructions in this manual, modifications made
to equipment or by negligence during installation, use,
1.
"Intended use" as laid down in EN-292-1 is the use for which the technical product
is suited as specified by the manufacturer, inclusive of his directions in the sales
brochure. In case of doubt it is the use which can be deducted from the
construction, the model and the function of the technical product which is
considered normal use. Operating the machine within the limits of its intended use
also involves observing the instructions in the user manual.
CONTROL BOX CB-WCS
3
•
•
•
•
•
Only use the product in technically perfect condition.
Inspect the product and check it for damage.
Protect the product against water and humidity.
Never use the product in an explosive environment.
Make sure that the facility contains sufficient approved
fire extinguishers.
Service, Maintenance and Repairs
CAUTION!
Service and repair should only be performed by
Lincoln Electric Factory Trained Personnel.
•
Always use tools, materials, lubricants and service
techniques which have been approved by the
manufacturer. Never use worn tools and do not leave any
tools in or on the product.
4
Fig. 4.1: Installation CB-WCS
4.3 Electric connection
INSTALLATION
CAUTION!
Electrical connection to be carried out in
accordance with the National Electrical Code
(NEC) and local requirements. This is strictly
reserved for skilled and authorised service
engineers.
WARNING!
The installer is responsible for following federal,
state and local safety codes and regulations.
4.1 Unpacking
Connection Steps:
1) Connect the CB-WCS electrically to:
- mains (“MAINS”)
- extraction fan SF 2400 (“FAN MOTOR”)
- automatic start/stop device (WCS) (“WCS”)
or:
- working lamp (WL) and/or Arc Sensor (AST) (“WCS”)
- stationary welding fume extractor (Statiflex 400-MS)
(“FILTER”)
Check that the product package is complete. The package
should contain:
•
•
•
(1) fully premounted and wired CB-WCS (transformer,
relay, timer PC board with fuse and connection block)
(1) instruction manual
(1) instruction manual
If parts are missing or damaged, contact your supplier.
CAUTION!
Make sure that the system is suitable for
connection to the local mains. Information about
the connection voltage and frequency can be found
on the identification plate. The cables must be
connected in conformance with the local rules and
regulations and can only be carried out by well
qualified and authorised technicians.
4.2 Installation
ATTENTION!
Do not position the CB-WCS where it is exposed to
vibrations or heat radiation from heat sources.
Oberse the earlier described ambient conditions.
ATTENTION!
4.3.1 Mains (“MAINS”)
Before drilling, verify locations of existing gas,
water or electrical conduits.
2)
Installation Steps:
Feed the mains cord through the cable gland (“MAINS”)
and connect it in accordance with the also supplied
electric diagram.
Interconnect the black wire.
Tighten the cap nut.
Use Fig. 4.1 for steps 1-2
3)
4)
2)
4.3.2 Extraction fan (“FAN MOTOR”)
1)
Loosen the mounting screws (C) and remove the cover
(D).
The housing (A) is provided with mounting holes (B).
Use these to attach the housing to the wall by means of
four bolts.
5)
Feed the supply cable of the extraction fan through the
cable gland (“FAN MOTOR”) and connect the cable in
accordance with the also supplied electric diagram.
CONTROL BOX CB-WCS
4
5)
Tighten the cap nut.
4.3.3 Automatic start/stop device (WCS) (“WCS”)
7)
8)
Feed the supply cable of the WCS through the cable
gland (“WCS”) and connect the cable in accordance
with the also supplied electric diagram.
Tighten the cap nut.
4.3.4 Work Lamp (WL) and/or Arc Sensor (AST)
(“WCS”)
9)
Feed the supply cable (NCW 11) through the cable
gland (“WCS”) and connect the cable to the timer PC
board in accordance with the also supplied electric
diagram.
10) Tighten the cap nut.
Fig. 4.2: Timer PC board
If applicable:
4.4.1 Start delay
4.3.5 Stationary welding fume extractor (Statiflex 400MS) (“FILTER”)
The start delay can be set from 0 to 5 seconds (standard 0
seconds). To adjust the start delay, proceed as follows.
• Adjust Potmeter 1 (Fig. 4.2A) to the desired number of
seconds.
11) Feed the suply cable through the cable gland
(“FILTER”) and connect the cable as described in the
corresponding manual.
12) Tighten the cap nut.
4.4.2 Stop delay
The stop delay can be set from 0 to 300 seconds (standard
0 seconds). To adjust the stop delay, proceed as follows.
• Adjust Potmeter 2 (Fig. 4.2B) to the desired number of
seconds.
Use Fig. 4.1 for steps 13
13) Apply the cover (D) and fix it by the mounting screws
(C).
4.4 Adjustment
The standard start delay and the standard stop delay of the
extraction fan(s) are 0 seconds. This means that the
connected fan will immediately start running when the
welding starts and will stop immediately after the (last)
welder is finished. If desired, these pre-set times can be
adjusted by changing the settings of the timer PC board (Fig.
4.2). The timer PC board consists of the following
components:
A
B
C
D
E
F
G
In most cases, a stop delay of 20 seconds will be
sufficient.
When setting the installation, the functioning of the timer PC
board can be checked by the status leds Power, Input and
Output (Fig. 4.2C) on the timer PC board.
5
OPERATION
By applying the weldling cable sensor WCS to the ground
cable of a welding machine, the CB-WCS functions fully
automatically.
Potmeter 1 (start delay)
Potmeter 2 (stop delay)
Status leds
Fuse 2A
Connection WCS, AST, Filter
Connection 24 VAC
Relay contact
6
MAINTENANCE
The CB-WCS does not require any specific maintenance.
CONTROL BOX CB-WCS
5
7
Step 1: Symptom
TROUBLESHOOTING
The first column labeled “Symptom” describes possible
symptoms that the machine may exhibit. Find the listing that
best describes the symptoms that the machine is exhibiting.
Observe all safety guidelines detailed throughout this
instruction manual.
Step 2: Locate Problem
A number problems in the checklist below can also
be caused by defects in the connected equipment.
This manual mainly deals with problems and
solutions directly related to the product itself.
The second column “Problem” describes the possible
consequences of the found symptom.
Step 3: Possible Cause
The third column labeled “Possible cause” lists the obvious
external possibilities that may contribute to the machine
symptom.
WARNING!
Service and repair should only be performed by
Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment
may result in danger to the technician and machine
operator and will invalidate your factory warranty.
For your safety and to avoid electrical shock,
please observe all safety notes and precautions
detailed throughout this instruction manual.
Step 4: Solution
The fourth column labeled “Solution” provides a course of
action for the possible cause. Generally it states to contact
your local Lincoln Authorized Field Service Facility.
CAUTION!
If for any reason you do not understand the test
procedures or are unable to safely perform the
tests and repairs, contact your Local Lincoln
Authorized Field Service Facility for technical
troubleshooting assitance before you proceed.
This troubleshooting guide is provided to help you locate
and repair possible machine malfunctions. Simply follow the
four-step procedure listed below.
Table 1: Troubleshooting guide
Symptom
Problem
Possible Cause
Solution
No extraction when
welding starts.
Fan motor does not
start.
Thermal breaker activated.
Reset thermal breaker.
Sensor of WCS not
activated.
Sensor defective.
Check sensor function with a small
magnet. Red LED should lit on the
sensor.
Sensor not connected to the ground
cable of the welding machine.
Connect sensor to the ground cable
of the welding machine.
Sensor
malfunctioning.
Sensor broken.
Check sensor input on circuit board.
Input LED should be lit when the
sensor LED is activated
Power supply failing.
Fuse in CB-WCS broken.
Check fuse and try to determine why
the fuse blew (e.g. short circuit) and
repair.
Delay timer.
Start delay timer activated.
Please see if you want the start delay
timer to be active.
Sensor.
Sensor defective.
Check sensor function with a small
magnet. Red LED should lit on the
sensor.
Delay timer.
Stop delay timer activated (0-5
minutes).
Please see if you want the stop delay
timer to be active.
Arc sensor in use.
AST has its own delay time with a
minimum of 12 seconds stop delay
and a maximum of 2 minutes.
See if you need to change the delay
time in the AST sensor.
Fan keeps running
without welding
activities.
No power connected to the CB-WCS. Check power supply.
CONTROL BOX CB-WCS
6
8
SPARE PARTS
The available spare parts for the control box are indicated on
the exploded views.
Address your order to your supplier and always state the
data below:
- product name and serial number (see the identification
label)
- article number of the particular part
- description
- quantity
Table 2: Spare parts
Item/Description
Part #
A Timer print
0326730020 1
B Fuse 2A
Qty
1
C Connection block + wire beam
0308400620 1
D Transformer 45VA
0334200170 1
E Relay
0328410120 1
F Themal relay
0328400170 1
G Fuse holder
0340520040 1
H Main fuse
0340010100 1
Fig. 8.1: Exploded view
9
DISPOSAL
After life of the product, dispose it of in accordance with
federal, state or local regulations.
CONTROL BOX CB-WCS
7
10 ELECTRICAL DIAGRAM
CONTROL BOX CB-WCS
8
NOTES
• 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.
• Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
• Isolez-vous du travail et de la terre.
• Berühren Sie keine stromführenden
fuera del área de trabajo.
• Gardez à l’écart de tout matériel
inflammable.
• Entfernen Sie brennbarres Material!
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
• Isolieren Sie sich von den
Elektroden und dem Erdboden!
• Não toque partes elétricas e electro-
dos com a pele ou roupa molhada.
• Isole-se da peça e terra.
cuerpo.
• Protégez vos yeux, vos oreilles et
votre corps.
• Tragen Sie Augen-, Ohren- und Kör-
perschutz!
• Mantenha inflamáveis bem guarda-
dos.
• Use proteção para a vista, ouvido e
corpo.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE
CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE
ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE
SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT
ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE
EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.
• 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.
• Débranchez le courant avant l’entre-
tien.
teur pour ôter les fumées des zones
de travail.
• Vermeiden Sie das Einatmen von
Schweibrauch!
• Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
• Mantenha seu rosto da fumaça.
• Use ventilação e exhaustão para
remover fumo da zona respiratória.
• Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen;
Maschine anhalten!)
• Não opere com as tampas removidas.
• Desligue a corrente antes de fazer
serviço.
• Não toque as partes elétricas nuas.
• No operar con panel abierto o
guardas quitadas.
• N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
• Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
• Mantenha-se afastado das partes
moventes.
• Não opere com os paineis abertos
ou guardas removidas.
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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