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5-1

SECTION 5:

MAINTENANCE AND TROUBLESHOOTING

5.1 Maintenance

The only routine maintenance required is a thorough cleaning and inspection,
with frequency being dependent upon the usage and the operating environment.

THIS PRODUCT CONTAINS EXREMELY DANGEROUS
VOLTAGES.

TURN OFF THE POWER SWITCH, UNPLUG

THE POWER CABLE FROM THE OUTLET, AND ALLOW
AT LEAST 2 MINUTES FOR THE PRIMARY CAPACITORS
TO DISCHARGE BEFORE PERFORMING MAINTENANCE
OR ATTEMPTING TO OPEN THE ENCLOSURE.

To clean the unit, open the enclosure and use a vacuum
cleaner or blow gun to remove any accumulated dirt and dust.
Avoid direct contact with electrical boards. Ensure that all fans
and exhaust vents are clean and clear.

The unit should also be wiped clean, if necessary; with solvents
that are recommended for cleaning electrical appliances.

MAINTENANCE SCHEDULE

Maintain more often if used under extremely dusty or severe conditions.

EACH USE:

Visual inspection of regulator, pressure, and consumable parts.

WEEKLY:

Visual inspection of torch body, consumables, cables, and leads.

Replace or repair as needed.

3 MONTHS:

Clean exterior of power supply. Clean and tighten weld terminals.

6 MONTHS:

Blow out or vacuum and accumulated dust/dirt from the interior.

5.2 Troubleshooting

If you are experiencing trouble with your unit, please refer to the following table
for assistance. If you are experiencing issues that are not addressed in the
following please contact Smarter Tools Customer Service for help in resolving
your issue.

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44
45
46
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Содержание ARC-100S

Страница 1: ...Don t work harder Work smarter ARC 100S ST INVERTER ARC WELDER with Stick and Lift TIG capability Revision AB Issue Date September 2010 Manual No 0 100S0910 Operating Features Operating Manual ...

Страница 2: ...MANUAL COULD RESULT IN PERSONAL INJURY PROPERTY DAMAGE AND OR VOIDING OF YOUR WARRANTY SMARTER TOOLS WILL NOT BE LIABLE FOR ANY DAMAGE BECAUSE OF FAILURE TO FOLLOW THESE INSTRUCTIONS Operating Manual Number 0 100S0910 Smarter Tools 100S System with Stick Kit and Case Part No ARC 100S Smarter Tools 100ST System Stick Tig Kit and Case Part No ARC 100ST Published by Smarter Tools Inc 12195 Harley Clu...

Страница 3: ...N AND SPECIFICATIONS 2 1 2 1 Equipment Identification 2 1 2 2 Description 2 1 2 3 Specifications 2 2 2 4 Duty Cycle 3 1 2 5 Transportation Methods 3 1 SECTION 3 INSTALLATION 3 1 3 1 Selecting a Location 3 1 3 2 Environment 3 2 3 3 Electrical Input Power 3 2 3 4 Electromagnetic Compatibility 3 3 3 5 Setup for Welding 3 5 3 6 STICK SMAW Setup 3 6 3 7 Lift TIG GTAW Setup 3 7 SECTION 4 OPERATION 4 1 4...

Страница 4: ...JURY OR DEATH IF INSTRUCTIONS ARE NOT FOLLOWED CAUTION CAUTIONS INDICATE A POSSIBILITY OF EQUIPMENT DAMAGE IF INSTRUCTIONS ARE NOT FOLLOWED PROPERLY Note Notes give helpful information 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 practi...

Страница 5: ...tion Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Disconnect input power or stop eng...

Страница 6: ... prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases B...

Страница 7: ...and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards 1 4 Wear approved safety glasses with side shields under your helm...

Страница 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 Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuff less trou...

Страница 9: ...art of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder...

Страница 10: ...ring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories Use equipment of adequate capacity to lift and support unit If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATI...

Страница 11: ... cause interference High frequency H F can interfere with radio navigation safety services computers and communications equipment Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation If notified by the FCC about interference stop u...

Страница 12: ...rdous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 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...

Страница 13: ...re to replace the gasket periodically if your helmet uses one Replace the clear retaining lens to protect your eyes from broken pieces Clean lenses periodically Discard pitted or damaged lenses The correct filter shade is selected according to the welding process wire diameter and operating current The table on the following page gives the correct shade numbers for different situations ALWAYS use ...

Страница 14: ... sparks spatter electric shock and radiation The use of PPE is a good safe practice and may be required by regulatory agencies Process Electrode Size in mm Arc Current Amperes Minimum Protective Shade Suggested Shade No Comfort Shielded Metal Are Welding SMAW Less than 3 32 2 4 3 32 5 32 2 4 4 0 5 32 1 4 4 0 6 4 More than 6 4 Less than 60 60 160 160 250 250 550 7 8 10 11 10 12 14 Gas Metal Arc Wel...

Страница 15: ...hing clean and free of oils greases and combustible contaminants Wear long sleeved shirts with buttoned cuffs and a collar to protect the neck Dark colors prevent light reflection Tape shirt pockets closed to avoid collecting sparks or hot metal or keep them covered with flaps Pant legs must not have cuffs and must cover the tops of the boots Cuffs can collect sparks Repair all frayed edges tears ...

Страница 16: ... from synthetic or synthetic blends The synthetic fabric can burn vigorously melt and produce bad skin burns Protect all areas of your body from injury during welding or cutting by wearing the proper protective clothing and equipment Do not weld or cut unless wearing the necessary PPE as specified in this manual and in ANSI Z49 1 1 7 EMF Information Considerations about Welding and the Effects of ...

Страница 17: ... clamp to work piece as close to the weld as possible About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended 1 8 General Precautionary Label Found on unit and packaging Do not attempt to remove destroy or cover label ...

Страница 18: ... si no sigue las instrucciones ATENCIÓN PRECAUCIONES INDICAN UNA POSIBILIDAD DE DAÑOS AL EQUIPO Si las instrucciones no se siguen correctamente Nota Toma nota de dar información útil Productos de soldadura y procesos de soldadura puede causar lesiones graves o la muerte o daños a otros equipos o la propiedad si el operador no tiene que observar estrictamente las normas de seguridad y tomar medidas...

Страница 19: ... aislamiento secos y sin huecos y protección del cuerpo Aislar a ti mismo del trabajo y la tierra usando alfombras o cubiertas o cubiertas suficientemente grande como para prevenir cualquier contacto físico con el trabajo o tierra No use la salida de corriente alterna en áreas húmedas si el movimiento se limita o si existe el peligro de caer Use la salida CA SOLAMENTE si lo requiere el proceso de ...

Страница 20: ... la pieza de trabajo o mesa de trabajo lo más cerca de la soldadura como sea posible Aísle la abrazadera cuando no están conectados a la pieza de trabajo para evitar el contacto con cualquier objeto de metal No conecte más de un electrodo o el cable de trabajo a cualquier terminal de salida de soldadura única IMPORTANTE DC VOLTAJE existe después de la eliminación de la potencia de entrada Apague e...

Страница 21: ...lquier metal que contiene estos elementos pueden emanar humos tóxicos cuando se sueldan Apague el protector cuando no suministro de gas en uso RAYOS DEL ARCO pueden quemar los ojos y la piel Los rayos del arco del proceso de soldadura producen intensa visible e invisible ultravioleta e infrarroja que los rayos pueden quemar los ojos y la piel Chispas se escapan de la soldadura Use una careta de so...

Страница 22: ...enos que estén debidamente preparados de acuerdo con AWS F4 1 véase normas de seguridad Conecte el cable de trabajo a la labor tan cerca de la zona de soldadura como sea posible para evitar que la corriente de soldadura de viajar rutas de largo posiblemente por partes desconocidas causando una descarga eléctrica y peligro de incendio No use una soldadora para descongelar tubos helados Retire elect...

Страница 23: ...ILINDROS pueden explotar si están dañadas Cilindros de gas de protección contienen gas a alta presión Si están averiados los cilindros pueden estallar Como los cilindros son normalmente parte del proceso de soldadura asegúrese de tratarlos con cuidado Proteger los cilindros de gas comprimido del calor excesivo golpes mecánicos escoria llamas chispas y arcos Instale los cilindros en una posición ve...

Страница 24: ...d cerca de materiales inflamables No sobrecarga a los alambres edificio asegure que su sistema de alimentación es del tamaño adecuado capacidad y protegido para manejar esta unidad UNIDAD QUE CAE puede causar lesiones Utilizar los ojos de elevación para levantar la unidad NO con tren de rodaje cilindros de gas o cualquier otro accesorio Use equipo de capacidad adecuada para levantar y soporte de l...

Страница 25: ...MUEVEN pueden causar lesiones Manténgase alejado de las piezas móviles tales como ventiladores Mantenga todas las puertas paneles cubiertas y guardas cerrados y en su lugar H F puede causar interferencia Alta frecuencia HF puede interferir con la navegación de radio servicios de seguridad computadoras y equipos de comunicaciones Consiga que sólo personas calificadas familiarizadas con los equipos ...

Страница 26: ...uridad La seguridad en cortar y soldar estándar ANSI Z49 1 de la American Welding Society 550 NW LeJeune Rd Miami FL 33126 Normas de seguridad y salud OSHA 29 CFR 1910 del Superintendente de Documentos EE UU Government Printing Office Washington DC 20402 Prácticas Seguras Recomendadas para la Preparación de soldadura y corte de los envases que han contenido sustancias peligrosas la American Weldin...

Страница 27: ...nas o combinaciones de las anteriores Escoja un casco que cierre bien para ayudar a reducir el reflejo de luz en el casco a través del espacio entre el depósito y la cabeza Use el casco correctamente No lo utilice como un escudo a mano Proteja la lente de la sombra de los cambios de temperatura y repentino impacto que podría agrietarse Use una cubierta de lente para proteger los lentes oscuros Vue...

Страница 28: ...iar para adaptarse a las necesidades individuales Como regla general comience con un tono que es demasiado oscuro para ver la zona de soldadura Luego ir a un tono más claro que le dé suficiente vista de la zona de soldadura sin pasar por debajo del mínimo Process Electrode Size in mm Arc Current Amperes Minimum Protective Shade Suggested Shade No Comfort Shielded Metal Are Welding SMAW Less than 3...

Страница 29: ...ren en las botas Utilice protectores de arranque resistentes al fuego o polainas atadas alrededor de las piernas del pantalón y las botas para evitar que las chispas de rebote en la parte superior de las botas Eliminar todas las fuentes de ignición tales como fósforos y los encendedores de butano de los bolsillos Soldadura en caliente chispas pueden encender los fósforos o encendedor encender fuga...

Страница 30: ... de baja frecuencia Campos Eléctricos y Magnéticos Corriente de soldadura a medida que fluye a través de cables de soldadura hará que los campos electromagnéticos No ha sido y sigue siendo cierta preocupación acerca de estos campos Sin embargo después de examinar más de 500 estudios sobre el transcurso de 17 años de investigación un comité especial de la cinta azul de la Nacional Consejo de Invest...

Страница 31: ... lo más juntos posible torcer o cinta adhesiva 2 Los cables a un lado y lejos del operador 3 No envuelva o cuelgue cables alrededor de su cuerpo 4 Mantenga la fuente de poder de soldadura y los cables lo más lejos del operador como sea posible 5 Conecte la pinza de trabajo a la pieza de trabajo lo más cerca posible de la soldadura como sea posible Sobre los Marcapasos Portadores de marcapasos cons...

Страница 32: ...only by the specification or part number printed on the shipping container Record these numbers for future reference 2 2 Description This compact inverter welding machine has infinitely adjustable welding current from 5 to 100 amps It uses standard general purpose SMAW 3 32 2 5mm electrodes for light gauge work generally less than 1 8 3 2mm thick The unit also has a Lift TIG GTAW welding mode that...

Страница 33: ... 0 x W 5 1 x D 9 0 H 330mm x W 130mm x D 230mm The recommended time delay fuse or circuit breaker size is 30 amp An individual branch circuit capable of carrying 30 amperes and protected by fuses or circuit breaker is recommended for this application Fuse size is based on not more than 200 percent of the rated input amperage of the welding power source Based on Article 630 National Electrical Code...

Страница 34: ...and allowed to cool Duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating Exceeding duty cycle can damage unit and void warranty GTAW TIG 20 Duty Cycle at 100 A AC DC SMAW Stick 20 Duty Cycle at 90 A DC or 100 A AC 2 5 Transportation Methods Electric Shock can kill DO NOT TOUCH live electric parts Disconnect input power conductors from de energized supply line...

Страница 35: ... or accidental contact by the operator C In wet or damp hot locations where humidity or perspiration considerably reduces the skin resistance of the human body and the insulation properties of accessories Environments with increased hazard of electric shock do not include places where electrically conductive parts in the near vicinity of the operator which can cause increased hazard have been insu...

Страница 36: ...proximately 5 seconds Damage to the PCA could occur if 133 VAC or higher is applied to the Primary Power Cable Primary Circuit Sizes to Achieve Maximum Current Model Primary Supply Lead Size Factory Fitted Minimum Primary Current Size Volt Amps Current and Duty Cycle TIG GTAW Stick SMAW ARC 100S ST 12 AWG 3 3mm 2 115V 30A 90A 23 6V 20 115V 21A 100A 14V 20 3 4 Electromagnetic Compatibility Extra pr...

Страница 37: ...munity 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 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 C Methods of...

Страница 38: ...piece is not bonded to earth for electrical safety nor connected to earth because of its size and position e g ship s hull or building steelwork a connection bonding the work piece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the work piece increasing the risk of injury to users or damage to other electrical equipment Where necessary t...

Страница 39: ...f electrode in use The operator should use the welding current range values as a guide then fine tune the welding current to suit the application 3 6 Stick SMAW Setup This set up is known as DC Electrode Positive or reverse polarity Please consult with the stick electrode manufacturer for specific polarity recommendations Set Process Selection Switch to Stick SMAW Negative Output Terminal Dinse 25...

Страница 40: ...nate 5 Set the Process Selection Switch to Stick 6 Set the weld current control knob to the desired amperage 7 Install a stick electrode in the electrode holder 8 You are now ready to begin Stick Welding 3 7 Lift TIG GTAW Setup This set up is known as Straight Polarity or DC Electrode Negative This is commonly used for DC TIG welding on most materials such as steel and stainless steel Set Welding ...

Страница 41: ...ectrode in the direction the grinding wheel is turning 12 Install the tungsten with approximately 1 8 to sticking out from the gas cup ensuring you have correct sized collet 13 Tighten the back cap 14 You are now ready to begin TIG Welding OPEN THE GAS VALVE ON TIG TORCH HANDLE AND ADJUST THE PRESSURE OF REGULATOR TO 15 25 CUBIC FEET PER HOUR THIS GAS FLOW SHOULD BE SUFFICIENT FOR MOST TIG WELDING...

Страница 42: ...rent control knob counterclockwise The welding current should be set according to the specific application Refer to the electrode manufacture s literature for further information C Over Heat Indicator The welding power source is protected by a self resetting thermostat The indicator will illuminate if the duty cycle of the power source has been exceeded If the Over Heat light illuminates wait for ...

Страница 43: ... 3 Back Panel Power Switch Familiarize yourself with the location of the Back Panel Power Switch before attempting to operate The Back Panel Power Switch controls the Mains Supply Voltage to the Power Source ...

Страница 44: ...adura gama de guía a continuación ajustar la corriente de soldadura para adaptarse a la aplicación específica Refiérase a la literatura a la fabricación de electrodos para más información 4 2 del panel frontal controles Familiarícese con la ubicación y finalidad de los controles en esta unidad antes de intentar operar A Process Selection Switch Cambia entre STICK MMA SMAW y Lift TIG GTAW los modos...

Страница 45: ... extinguir antes de volver a soldar D Power On Indicator El Indicador de encendido se ilumina cuando el interruptor ON OFF está en la posición ON y la tensión de red nominal está presente 4 3 Panel trasero interruptor de alimentación Familiarícese con la ubicación de la Panel trasero interruptor de alimentación antes de intentar operar El panel posterior interruptor de encendido controla la tensió...

Страница 46: ...all fans and exhaust vents are clean and clear The unit should also be wiped clean if necessary with solvents that are recommended for cleaning electrical appliances MAINTENANCE SCHEDULE Maintain more often if used under extremely dusty or severe conditions EACH USE Visual inspection of regulator pressure and consumable parts WEEKLY Visual inspection of torch body consumables cables and leads Repl...

Страница 47: ...ow unit to cool see Section 1 3 Loose cable connections Check cable setup see Section 3 6 3 7 Fan not operating weld output available Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor Welding current reduces when welding Pour work lead connection Ensure that the work lead has a secure unobstructed connection to the work piece Circuit breaker ...

Страница 48: ...5 3 5 3 System Schematic ...

Страница 49: ...5 4 5 4 Parts List ...

Страница 50: ...0 11 Diode Radiator 22 WS 01 ARC 100 10 Control Transformer AC110V 23 WS 01 ARC 100 08 2PC IGBT Radiator Bracket 24 WS 01 ARC 100 07 IGBT Radiator 25 GB 823 88 M4x20 11PC Screw 26 WS 01 ARC 100 13 Rectifier Bridge Radiator 27 WX12038 Fan 28 KCD 25 Seesaw Switch 29 Fan Cover 30 WS 01 ARC 100 09 IGBT Teeterboard 31 KSD302 2PC Thermostat 85 C 32 GB T 818 2000 M3x10 4PC Screw 33 GB T 93 1987 3x1 1 4PC...

Страница 51: ...a y clara La unidad también se debe limpiar si es necesario con los solventes que se recomiendan para la limpieza de los aparatos eléctricos PROGRAMA DE MANTENIMIENTO Mantener con más frecuencia si se utiliza bajo condiciones de mucho polvo o grave CADA USO La inspección visual del regulador la presión y piezas de desgaste SEMANA La inspección visual del cuerpo de la antorcha consumibles cables y ...

Страница 52: ...low unit to cool see Section 1 3 Loose cable connections Check cable setup see Section 3 6 3 7 Fan not operating weld output available Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor Welding current reduces when welding Pour work lead connection Ensure that the work lead has a secure unobstructed connection to the work piece Circuit breaker...

Страница 53: ...5 3A 5 3 Esquema del sistema ...

Страница 54: ...5 4A 5 4 Lista de piezas ...

Страница 55: ...diator 22 WS 01 ARC 100 10 Control Transformer AC110V 23 WS 01 ARC 100 08 2PC IGBT Radiator Bracket 24 WS 01 ARC 100 07 IGBT Radiator 25 GB 823 88 M4x20 11PC Screw 26 WS 01 ARC 100 13 Rectifier Bridge Radiator 27 WX12038 Fan 28 KCD 25 Seesaw Switch 29 Fan Cover 30 WS 01 ARC 100 09 IGBT Teeterboard 31 KSD302 2PC Thermostat 85 C 32 GB T 818 2000 M3x10 4PC Screw 33 GB T 93 1987 3x1 1 4PC Elastic Wash...

Страница 56: ......

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