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Thermal Arc ULTRA FLEX 350, Owner'S Manual

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Thermal Arc ULTRA FLEX 350 Owner'S Manual Download Page 8

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ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001

2-4

May 8, 1996

Summary of Contents for ULTRA FLEX 350

Page 1: ...ollowing Specs 500237A 1 Pulse OWNER S MANUAL Number 430429 465 Rev 0 Issued February 28 2000 THERMAL ARC INC TROY OHIO 45373 1085 U S A IMPORTANT Read these instructions before installing operating o...

Page 2: ...on 4 1 Voltage Configuration 4 1 Connecting The Welding Machine To Line Voltage 4 1 Use Of Engine Generators For Input Power 4 2 Grounding 4 2 Welding Leads 4 2 OPERATION 5 General 5 1 Power Up Sequen...

Page 3: ...umber model and serial number usually appear on a nameplate attached to the control panel In some cases the nameplate may be at tached to the rear panel Equipment which does not have a control panel s...

Page 4: ...This page intentionally left blank 430429 465 INTRODUCTION 1 2 February 28 2000...

Page 5: ...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 c...

Page 6: ...ionary support or equipment cylinder rack to prevent falling or tipping 3 Keep cylinders away from any welding or other electrical circuits 4 Never allow a welding electrode to touch any cylinder 5 Us...

Page 7: ...troubleshooting as necessary 4 To prevent accidental starting during servicing disconnect nega tive battery cable from battery 5 Keep hands hair loose clothing and tools away from moving parts 6 Reins...

Page 8: ...This page intentionally left blank ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 2 4 May 8 1996...

Page 9: ...loquez le commutateur en circuit ouvert ou enlevez les fusibles de l alimen tation afin d viter une mise en marche accidentelle 5 Veuillez installer cet quipement et le mettre la terre selon le manuel...

Page 10: ...14 9 12 14 LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer 1 Eloignez la t te des fum es pour viter de les respirer 2 A l int...

Page 11: ...SER Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font nor malement partie du proc d de soudage traitez les avec s...

Page 12: ...rrecte et de l accumulateur LA VAPEUR ET LE LIQUIDE DE RE FROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous p...

Page 13: ...al protection features to assure continued reliable operation The features include AC input over and under voltage sensing and shutdown output overload shutdown overtemperature shut down short circuit...

Page 14: ...next five minutes at no load Figure 3 1 Overall Dimensions Output Data Output Range For SMAW Stick Output Range For GTAW TIG Output Range for GMAW MIG Overcurrent Shutdown Maximum Short Circuit Curren...

Page 15: ...Figure 3 2 Volt Ampere Curves 430429 465 DESCRIPTION OF EQUIPMENT February 28 2000 3 3...

Page 16: ...Receptacle This is the connection point for various remote controls and wire feeders It supplies 120 VAC power as well as the control signals The pinout is as follows Pin A Contactor Ckt 15 V Pin B Co...

Page 17: ...machine initially is powered up on three phase and later detects single phase the machine will shut off and turn on the RED fault light The digital meter will also display a fault code and the user i...

Page 18: ...of amps and volts for five seconds after the end of a weld The A V button can be used to toggle between the held values of amps and volts 10 AF IND Arc Force Inductance This but ton has two functions...

Page 19: ...itch For operation on either 200 or 230VAC slide the switch upwards to the 200 230V setting for operation on either 400 or 460VAC slide the switch down to the 400 460V setting CAUTION Make sure the ma...

Page 20: ...If this happens frequently then the generator output regu lation is not satisfactory to use as a power supply for this welding machine Grounding The frame of this welding machine should be grounded f...

Page 21: ...should not be used and all connec tions must be properly tightened To attach the plugs on the welding cables refer to Figure 4 2 Strip the insulation off of the welding cable for about 1 2 Insert the...

Page 22: ...This page intentionally left blank 430429 465 INSTALLATION 4 4 February 28 2000...

Page 23: ...lts while welding use the UP or DOWN buttons The display will automatically switch to showing the set amps or set volts The AF IND button is used to select arc force when Stick welding and inductance...

Page 24: ...int the machine is ready to weld SMAW Operation See Figure 5 1 1 Connect the welding leads to the power source with the correct polarity Figure 5 1 shows typical connections for DCEP welding Make sure...

Page 25: ...back to showing either actual amps or actual volts LIFT GTAW Operation See Figure 5 2 The purpose of Lift GTAW is to allow for striking the arc by momentarily touching the torch to the workpiece The...

Page 26: ...rc starter will connect to the 19 pin amphenol receptacle on the rear of the power source The foot pedal or remote control will then connect to the arc starter If an optional pulser control is also us...

Page 27: ...acitor discharge arc starter is being used hold the torch in close proximity to the workpiece while pressing the foot pedal The high voltage will jump the gap to the workpiece and the arc will follow...

Page 28: ...h switch while holding the torch in place at the end of the weld This will allow the wire conditioning circuit in the power source to condition the end of the wire for the next weld The wire condition...

Page 29: ...tor to fit the application In order to change them an optional Programming Pendant 204180A 1 is required The programming pendant plugs into the PRO GRAMMING PENDANT connector located on the front of t...

Page 30: ...ower source is now ready to weld To initiate the weld activate the torch switch on the MIG torch 10 To end the weld release the torch switch As with conventional MIG welding a wire conditioning sequen...

Page 31: ...in increments of 0 01 seconds Longer times will give more of a burnback effect 25 25 2XXX 3 MAXIMUM SELECTABLE AMPERAGE Maximum selectable amperage is the largest amperage value that the user is capab...

Page 32: ...te by using a feeder with voltage setting capability Minimum selectable reference can have a range of values between 0 and 440 in increments of 1 The minimum selectable reference is never permitted to...

Page 33: ...re spond to the parameter values These digits will flash Changes to the displayed parameter value can be made by pressing the UP or DOWN arrow buttons To gain access to the next option number press th...

Page 34: ...This page intentionally left blank 430429 465 OPERATION 5 12 February 28 2000...

Page 35: ...rom this welding machine it is necessary to keep the ma chine clean dry and well ventilated At least every three months or more often as necessary wipe and blow out all dirt from the machine s interio...

Page 36: ...This page intentionally left blank 430429 465 MAINTENANCE 6 2 February 28 2000...

Page 37: ...an and free of oxidation or debris Do not pull on leads or cables to disassemble connections Firmly grasp each lug or connector Use appropriate tools to enhance leverage if needed Pulling on leads and...

Page 38: ...ter mining what is working correctly A few typical questions whose answers might be of benefit in troubleshooting are Is the input voltage correct Are fuses blown Does the machine have the proper inpu...

Page 39: ...line Check AC line voltage If line voltage is ok reset the machine by turning the main power switch off and back on If voltage is ok and machine will not reset service will be required E015 Over under...

Page 40: ...This page intentionally left blank 430429 465 TROUBLESHOOTING 7 4 February 28 2000...

Page 41: ...red riveted or welded to another part The part descriptions may be indented to show part relationships To determine the part number description quan tity or application of an item simply locate the it...

Page 42: ...Figure 8 1 Ultra Flex Welder Assembly 430429 465 PARTS LIST 8 2 February 28 2000...

Page 43: ...1 Bushing Strain Relief 1 21 205123 Cable Power Input 1 22 203163 3 Switch Rotary Power 1 23 205089 Board PC Assy Auto Link Relay 1 24 204826 Board PC Amphenol Interface 1 25 171370 2 Cable 16 Pin Ri...

Page 44: ...Figure 8 2 430429 465 PARTS LIST 8 4 February 28 2000...

Page 45: ...Bar Current Sensor 1 15 205018 1 Current Sensor 1 16 205074 Board PC Assy Power IGBT 2 17 404915 2 Stand Off 12 18 405362 1 Bushing Snap 2 19 830116 Label Frame Ground 1 20 205048 Bracket Right Side...

Page 46: ...This page intentionally left blank 430429 465 PARTS LIST 8 6 February 28 2000...

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Page 50: ...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 pro...

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