Lincoln Electric ARC TRACKER IM10090 Manuel utilisateur

Marque: Lincoln Electric

Modèle: ARC TRACKER IM10090

Catégorie: Système de soudage

Taper: Manuel utilisateur

Operator’s Manual

ARC TRACKER ™

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

IM10090 | Issue D ate Sep-11

For use with machines having Code Numbers:

11724

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

FOR ENGINE

powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.

____________________________________________________

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 vaporiz-

ing on contact 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.

SAFETY

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.

WARNING

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.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is

hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

are known to the State of California to cause can-

cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

SAFETY

ARC RAYS can burn.

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.

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.

ELECTRIC SHOCK can

kill.

3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.

Do not touch these “hot” parts with your bare

skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

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 with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) 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. In confined spaces or in some circum-

stances, outdoors, a respirator may 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 spe-

cific 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

form phosgene, a highly toxic gas, and other irritating prod-

ucts.

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

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

iii

SAFETY

iii

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.

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

1235 Jefferson Davis Highway, Arlington, VA 22202.

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 cir-

cuits. 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.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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 suiv-

antes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent 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 nʼimporte quelle partie

du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray-

onnement de lʼarc et des projections quand on soude ou

quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de

soudage. Se protéger avec des vêtements de protection libres

de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque dʼincendie 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 dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible

de la zone de travail quʼil est pratique de le faire. Si on place

la masse sur la charpente de la construction ou dʼautres

endroits éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques dʼincendie ou dʼechauffement des chaines et des

câbles jusquʼà ce quʼils 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

dʼopérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de lʼarc 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

lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch-

er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

place.

SAFETY

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 compe-

tent 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 prob-

lems 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.

SAFETY

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 recommenda-

tions. 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 equip-

ment, 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 equip-

ment 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 connec-

tion 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 prob-

lems of interference. Screening of the entire welding installation may be considered for special

applications1.

_________________________

1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-

uct standard for arc welding equipment.”

viivii

Thank You for selecting a QUALITY product by Lincoln Electric. We want you

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.

The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

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.

Please record your equipment identification information below for future reference. This information can be

found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you

have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet

accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register

Your Product”. Please complete the form and submit your registration.

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-

ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln

Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-

sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-

mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,

with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or

correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any

warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control

of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in

applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com

for any updated information.

viii viii

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1

Safety Precautions ..........................................................................................A-2

Select Suitable Location..................................................................................A-2

Lifting...............................................................................................................A-2

Stacking ..........................................................................................................A-2

Environmental Limitations ...............................................................................A-2

Input and Grounding Connections ..................................................................A-2

High Frequency Protection ....................................................................................A-2

Recommended Electrode and Work Cable for arc Welding ..................................A-2

Electrical Connection ......................................................................................A-3

Work Connection.............................................................................................A-3

Remote Sense Lead Specification ..................................................................A-3

Product Specific Instructions...........................................................................A-3

Software Tools ................................................................................................A-3

Power Wave Manager.....................................................................................A-3

Connection Diagram-Electrode Positive................................................................A-4

________________________________________________________________________

Operation .........................................................................................................Section B

Safety Precautions.................................................................................................B-1

Graphic Symbols............................................................................................B-1, B-2

Product Description ...............................................................................................B-2

Design Features ....................................................................................................B-2

Recommended Processes and Equipment ...........................................................B-3

Common Equipment Packages .............................................................................B-3

Case Front Description..........................................................................................B-4

Case Back Controls...............................................................................................B-5

Power-Up Sequence..............................................................................................B-5

Duty Cycle .............................................................................................................B-5

Common Welding Procedures...............................................................................B-5

Set-Up Feature Menu ............................................................................................B-6

_______________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance.............................................................................................D-1

Periodic Maintenance............................................................................................D-1

Calibration Specification........................................................................................D-1

Calibration Procedure..............................................................................D-2 thru D-3

________________________________________________________________________

Section E ..............................................................................................Troubleshooting

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide ..........................................................................................E-2

________________________________________________________________________

Wiring Diagram and Dimension Print ..............................................................Section F

________________________________________________________________________

Parts List ....................................................................................................P-675 Series

________________________________________________________________________

ARC TRACKER™

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS -

ARC TRACKER™

RATED OPERATING RANGE NEMA EW1

INPUT VOLTAGE AND CURRENT

Model

K3019-1

Volts at Rated Amperes

44 V DC

Amperes

1000 A DC

Duty Cycle

100%

Input Amperes

0.8-0.5 A

Input Voltage ± 10%

120-230 V AC, 50/60 Hz

* All attachment plugs must comply with the Standard for Attachment Plugs and Receptacles, UL498.

RATED OPERATING RANGE IEC60974-1

Volts at Rated Amperes

44 V DC

Amperes

1000 A DC

Duty Cycle

100%

VOLTAGE

50/60 Hz

120

230

Input

Amperes

0.8 A

0.5 A

PLUG

NEMA 5-15P (INCLUDED)

ANY NEMA 250 V TYPE*

CEE 7/7

INPUT CORD

3 CONDUCTOR, #18 AWG

TYPE S, SO, SOO, ST, STO, STOO OR

EQUIVALENT EXTRA HARD USAGE CORD

3 CONDUCTOR, 1.0 mm2HAR

REGION

NORTH

AMERICA

EUROPE

RECOMMENDED INPUT WIRE

PHYSICAL DIMENSIONS

TEMPERATURE RANGES

HEIGHT

12 in (305 mm)

MODEL

K3019-1

WIDTH

9 in (220 mm)

DEPTH

15 in (380 mm)

WEIGHT

20 lbs ( 9 kg)

OPERATING TEMPERATURE RANGE

STORAGE TEMPERATURE RANGE

14°F TO 104°F (-10°C TO 40°C)

-40°F TO 185°F (-40°C TO 85°C)

VOLTMETER

AMMETER

ENERGY

± 2% + 0.1**

± 2% + 2**

± 5%

METER ACCURACY (AS SHIPPED)

**Accuracy is expressed as +/- [Percentage of Reading + Digits].

For example: 10A = +/- 10A x 0.02 + 2 = 10A +/- 2.2, or 7.8A to 12.2A

A-2

INSTALLATION

A-2

SELECT SUITABLE LOCATION

UNIT IS IP23 RATED.

The ARC TRACKER™ will operate in harsh environ-

ments. Even so, it is important that simple preventative

measures are followed in order to assure long life and

reliable operation.

• Keep machine dry. Shelter from rain and snow. Do

not place on wet ground or in puddles.

TILTING

Place the ARC TRACKER™ on a secure, level sur-

face. The weight of the welding cables hanging from

the connection terminals may cause the ARC TRACK-

ER™ to topple. Secure the welding cables to an

appropriate structure to reduce the hanging weight to

stabilize the ARC TRACKER™

STACKING

The ARC TRACKER™ cannot be stacked.

GROUNDING AND INPUT CONNECTIONS

MACHINE GROUNDING

The frame of the ARC TRACKER™ must be

grounded. By using the power cord shipped

with the unit, or by using a cord per the speci-

fications described here, the unit will be properly

grounded if connected to a grounded receptacle. See

your local and national electrical codes for proper

receptacle grounding methods.

INPUT CONNECTIONS

Installation should be made in accordance with the

appropriate National Electrical Code, all local codes

and the information in this manual.

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• ONLY QUALIFIED PERSONNEL

SHOULD PERFORM THIS INSTAL-

LATION.

• TURN OFF INPUT POWER TO THE

POWER SOURCE AT THE DISCONNECT

SWITCH OR FUSE BOX BEFORE WORKING ON

THIS EQUIPMENT. TURN OFF THE INPUT

POWER TO ANY OTHER EQUIPMENT CON-

NECTED TO THE WELDING SYSTEM AT THE

DISCONNECT SWITCH OR FUSE BOX BEFORE

WORKING ON THE EQUIPMENT.

• DO NOT TOUCH ELECTRICALLY HOT PARTS.

• CONNECT THE ARC TRACKER™ TO AN OUT-

LET WITH PROPER SAFETY (EARTH)

GROUND.

----------------------------------------------------------------------

WARNING

ARC TRACKER™

The ARC TRACKER™ can be connected to 120 V AC

or 230 V AC, 50 or 60 Hz. The power supply inside

the unit can accept any single phase input voltage

from 120 V AC to 230 V AC. The unit is shipped from

the factory with a 6ft. (2m) detachable input cord with

a NEMA 5-15P plug and an IEC 60320 plug recepta-

cle. For the European market, it is suggested that an

input cord with a CEE 7/7 plug and IEC 60320 plug

receptacle be used. For all other regions, a cord

should be used with a plug which provides between

120 V AC and 230 V AC, 50 or 60Hz, and has the IEC

60320 plug receptacle. Cord must provide proper

ground per national electrical codes.

230 V INPUT

To change from 120 V to 230 V single phase input,

the NEMA 5-15P plug can be replaced by any NEMA

250 V type plug (for example – type 6-30P).

ATTACHMENT PLUG

In all cases, the green or green/yellow grounding wire

must be connected to the grounding pin of the plug,

usually identified by a green screw. All attachment

plugs must comply with the Standard for Attachment

Plugs and Receptacles, UL498. The product is con-

sidered acceptable for use only when an attachment

plug as specified is properly attached to the supply

cord. The ARC TRACKER™ will auto reconnect to

either 120 V or 230 V supplies.

HIGH FREQUENCY PROTECTION

The EMC classification of the ARC TRACKER™ is

Industrial, Scientific and Medical (ISM) group 2, class

A. The ARC TRACKER™ is for industrial use only.

(See Electromagnetic Compatibility EMC Safety

Section).

Harmonic Current Information:

Design complies with EN6100-3-2, -3.

Locate the ARC TRACKER™ away from radio con-

trolled machinery. The normal operation of the ARC

TRACKER™ may adversely affect the operation of RF

controlled equipment, which may result in bodily injury

or damage to the equipment.

RECOMMENDED ELECTRODE AND

WORK CABLE SIZES FOR ARC WELDING

General Guidelines

The following recommendations apply to all output

polarities and weld modes:

A-3

INSTALLATION

A-3

REMOTE SENSE LEAD SPECIFICATIONS

(See Figure A.1)

In order to get an accurate measurement of the true

energy going in to the weld, it is critical to get an

accurate measurement of the arc voltage. The arc

voltage sense leads are polarity specific – RED must

be connected to the positive side of the arc and

BLACK to the negative. The sense leads should be

connected as close as possible to the arc, e.g. at the

contact tip, wire feeder, etc and to the work.

PRODUCT SPECIFIC INSTRUCTIONS

Best Practices:

Place the ARC TRACKER™ in the work circuit. This

will keep the ARC TRACKER™ at the same potential

as the work piece.

The welding current MUST flow into the left side weld

terminals (when viewing the ARC TRACKER™ from

the rear) and out of the right side weld terminals. If the

welding current does not flow through the ARC

TRACKER™ in the right direction, the unit will not

properly sense the welding current and nothing will be

displayed on the unit during welding.

See the specific power source instruction manual for

additional general guidelines on output cable connec-

tions.

SOFTWARE TOOLS

ARC TRACKER™ software tools and other docu-

ments related to the integration, configuration, and

operation of the system are available at,

www.powerwavesoftware.com

An Ethernet connection gives the ARC TRACKER™

the ability to run Power Wave Manager and

Production Monitoring™.

Power Wave Manager

• Ethernet setup and verification

• Calibration

• Production Monitoring Configuration

• User Interface Lockout

ELECTRODE CONNECTIONS

Electrode Positive (See Figure A.1)

Connect cable(s) of sufficient size and length (Per

Table A.1) to the "ELECTRODE" terminals on the

power source. Connect the other end of the electrode

cable(s) to the contact tip, wire feeder, etc. Be sure

the connection makes tight metal-to-metal electrical

contact.

WORK CONNECTIONS

Electrode Positive (See Figure A.1)

Connect cable(s) of sufficient size and length (Per

Table A.1) between the "WORK" terminals on the

power source and the ARC TRACKER™ right side

weld terminals (when viewed from the rear). Connect

cable(s) of sufficient size and length from the ARC

TRACKER™ left weld terminals to the work. Be sure

the connection to the work makes tight metal-to-metal

electrical contact.

ARC TRACKER™

Total Cable Length ft (m)

Electrode and Work Combined

0 (0) to 250 (76.2)

Number of Cables

(parallel if more than one)

Current in Weld

Circuit

0-500 Amps

500-750 Amps

750-1000 Amps

Cable Size

(copper) AWG

4/0 (120 mm2)

3/0 (95 mm2)

Duty Cycle

100%

TABLE A.1 Output Cable Guidelines

• Select the appropriate size cables per the "Output

Cable Guidelines" Table A.1. Excessive voltage

drops caused by undersized welding cables and

poor connections often result in unsatisfactory weld-

ing performance. Always use the largest welding

cables (electrode and work) that are practical, and

be sure all connections are clean and tight.

Note: Excessive heat in the weld circuit indicates

undersized cables and/or bad connections.

• Route all cables directly to the work and electrode,

avoid excessive lengths and do not coil excess

cable. Route the electrode and work cables in close

proximity to one another to minimize the loop area

and therefore the inductance of the weld circuit.

• Always weld in a direction away from the work con-

nection.

A-4

INSTALLATION

A-4

ARC TRACKER™

FIGURE A.1

CONNECTION DIAGRAM-ELECTRODE POSITIVE (750-1000A)

CONNECTION DIAGRAM-ELECTRODE POSITIVE (0-500A)

CONNECTION DIAGRAM-ELECTRODE POSITIVE (500-750A)

B-1

OPERATION

ARC TRACKER™

B-1

SAFETY PRECAUTIONS

Read this entire section of operating instructions

before operating the machine.

ELECTRIC SHOCK can kill.

• Unless using cold feed feature, when

feeding with gun trigger, the

electrode and drive mechanism are

always electrically energized and

could remain energized several

seconds after the welding ceases.

• Do not touch electrically live parts or electrodes

with your skin or wet clothing.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be

dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

WELDING SPARKS can cause

fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have

held combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in the

beginning of this manual.

WARNING

MACHINE STATUS

WORK CONNECTION

OFF

ELECTRODE

READ INSTRUCTION

MANUAL

PROPER DISPOSAL

POSITIVE OUTPUT

NEGATIVE OUTPUT

ENCLOSURE RATING

INPUT POWER

CALIBRATION

WELD CURRENT

GRAPHIC SYMBOLS THAT

APPEAR ON THIS MACHINE

OR IN THIS MANUAL

RANGE

DUTY CYCLE

CAL

IP23

B-2

OPERATION

B-2

ARC TRACKER™

PRODUCT DESCRIPTION

General Functional Description

The ARC TRACKER™ is a high-performance,

portable product designed to accurately measure the

True Energy delivered into a weld from any welding

machine (DC process only). The ARC TRACKER™

will accurately measure the welding parameters (arc

voltage, arc current, and weld time) and provide a

real-time calculation of the True Energy into the weld.

While welding, the True Energy [in joules (J)] for the

weld will be accurately displayed on the user inter-

face.

The ARC TRACKER™ utilizes high-intensity LEDs

and alpha-numeric displays that can easily be seen

from a distance. The design uses advanced digital

controls to sample the welding parameters at a very

high rate of speed. The ARC TRACKER™ is compat-

ible with any DC welding process.

The ARC TRACKER™ has an Ethernet connector to

easily connect the product into a local network which

enables the use of Lincolnʼs additional software tools.

DESIGN FEATURES

• Multiple process DC welding range: 10-1000 Amps,

100% duty cycle.

• Simple Plug-N-Play design – connect to welding cir-

cuit, attach voltage sense leads and the meter

begins to function!

• Digital controls for highly accurate measurements.

WELD AMPERAGE

INPUT VOLTAGE

WELD VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE

GROUND

WARNING or CAUTION

Explosion

Dangerous Voltage

Shock Hazard

GRAPHIC SYMBOLS THAT

APPEAR ON THIS MACHINE

OR IN THIS MANUAL

SET UP MENU

ETHERNET

CONNECTOR

B-3

OPERATION

B-3

RECOMMENDED PROCESSES AND

EQUIPMENT

RECOMMENDED PROCESSES

• DC arc welding circuits only

• Any welding process

• Any welding equipment

PROCESS LIMITATIONS

• Cannot be used with AC arc welding circuits

• 1000 A, 120 V, (maximums)

EQUIPMENT LIMITATIONS

• The weld terminals on the back of the ARC TRACK-

ER™ have a maximum threshold of welding current

which can flow through them. The correct number

and size of welding conductors must be used for

proper cooling. See the installation section for prop-

er connectivity.

• The ARC TRACKER™ has been calibrated before

being shipped from the factory. The Lincoln Electric

Company recommends that end-users of its welding

equipment evaluate the suitability of utilizing this

product in their quality system, determine if periodic

calibration is required and the calibration interval

based upon the criticality of the welding application,

the environment in which the equipment is located,

the level of preventive maintenance and the actual

conditions of use.

• The Ethernet connection gives the ARC TRACK-

ER™ the ability to run Production Monitoring™ with

certain function limitations, such as, no support for

wire feed speed, deposition rate, consumable pack-

age tracking and weldscore.

ARC TRACKER™

B-4

OPERATION

B-4

CASE FRONT CONTROL DESCRIPTIONS

(See Figure B.1)

1. Amps Display

2. Volts Display

3. Amps Calibration Knob

4. Volts Calibration Knob

5. Message Display

6. Setup Mode LED

7. Left Push Button

ARC TRACKER™

FIGURE B.1

8. Right Push button

9. Center Knob

10. ON/OFF Switch

11. Status LED

12. Ethernet Connector

13. Voltage Sense Lead Connector

B-5

OPERATION

B-5

ARC TRACKER™

POWER-UP SEQUENCE

When power is applied to the ARC TRACKER™, the

status light will flash green for up to 60 seconds.

During this time the unit is performing a self test. The

status light will also flash green as a result of a system

reset or configuration change during operation. When

the status light becomes steady green the system is

ready for use.

If the status light does not become steady green con-

sult the troubleshooting section of this manual for fur-

ther instruction.

DUTY CYCLE

The

ARC TRACKER™

is rated for 1000 A, 44 V DC,

100% duty cycle.

• Note: The correct number and size of welding con-

ductors must be used for proper cooling. See

the installation section for proper connectivity.

COMMON WELDING PROCEDURES

The ARC TRACKER™ can be used with any DC

welding process.

CASE BACK

(TERMINAL COVERS NOT SHOWN)

Case Back Descriptions (See Figure B.2)

1. Left weld terminals (weld current IN)

2. Right weld terminals (weld current OUT)

3. Input cord receptacle

FIGURE B.2

SETUP MENU FEATURES

The Setup Menu gives access to the Setup

Configuration. Stored in the setup configuration are

user parameters that generally only need to be set at

installation. The parameters are grouped as shown in

the following table.

SET-UP FEATURES MENU

(See Figure B.1)

1. To access the set-up menu, press the Right and

Left buttons of the Main Display panel simultane-

ously. Note that the set-up menu cannot be

accessed if there is a fault (The status LED is not

solid green).

Change the value of the blinking parameter by rotat-

ing the Center knob.

2. After changing a parameter it is necessary to press

the Right hand button to save the new setting.

Pressing the Left button will cancel the change.

3. To exit the set-up menu at any time, press the

Right and Left buttons of the Main Display panel

simultaneously. Alternately, 1 minute of inactivity

will also exit the set-up menu.

PARAMETER DEFINITION

P.1 through P.99 Unsecured Parameters

(always adjustable)

P.101 through P.199 Diagnostic Parameters

(always read only)

P.501 through P.599

Secured Parameters

(only accessible through a p.c.

application)

B-6

OPERATION

B-6

ARC TRACKER™

USER DEFINED PARAMETERS

Parameter Definition

Exit Setup Menu

P.0 This option is used to exit the setup menu. When P.0 is displayed, press the Left Button to exit

the setup menu.

P.83 Calibration

See Calibration Specification section for further details.

P.106 View Ethernet IP Address

Used for viewing the IP address of Ethernet compatible equipment. Press the Right Button to

read the IP Address. Press the Left Button to back out and exit this option. The IP address

cannot be changed using this option.

P.505 Setup Menu Lock

Determines if the setup parameters can be modified by the operator without entering a pass-

code.

No = The operator can change any set menu parameter without first entering the passcode

even if the passcode is non-zero (default).

Yes = The operator must enter the passcode (if the passcode is non-zero) in order to change

any setup menu parameters.

This parameter can only be accessed using Power Wave Manager software.

P.506 Set User Interface Passcode

Prevents unauthorized changes to the equipment. The default passcode is zero which allows

full access. A nonzero passcode will prevent unauthorized changes to setup parameters (if

P.505 = Yes).

This parameter can only be accessed using Power Wave Manager software.

P.509 UI Master Lockout

Locks all user interface controls, preventing the operator from making any changes. This para-

meter can only be accessed using Power Wave Manager software.

D-1

MAINTENANCE

D-1

Required equipment:

• Power source to provide welding current and volt-

age. The power source should be capable of pro-

ducing the same level of welding current and volt-

age as the ARC TRACKER™ application. It is rec-

ommended to use the same power source used in

the welding application for this calibration proce-

dure.

• Calibrated reference volt meter, shunt and amme-

ter as in Figure D.1. The recommended accuracy

must be at least four times the desired accuracy of

the digital meters on the ARC TRACKER™ being

calibrated. Example, to obtain +/-2% accuracy, the

shunt accuracy and ammeter accuracy combina-

tion must be +/-0.5% accurate. The meters listed

below have been verified to produce accurate

results with inverter power sources. If other

meters are used, the compatibility and accuracy

with inverter power sources must be determined

by the user.

Volt meter: Keithley 2701 Digital Multimeter

Ammeter: Keithley 2701 Digital Multimeter

Shunt: GE 1000A/100mV Master Shunt

• Resistive Load, such as Lincoln Electric Master

Load 750 (750 A max).

• ARC TRACKER™ being calibrated.

• 4/0 welding cables

Test Setup:

Connect equipment as shown in Figure D.1.

ARC TRACKER™

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Only Qualified personnel should

perform this maintenance.

• Turn the input power OFF at the

disconnect switch or fuse box before

working on this equipment.

• Do not touch electrically hot parts.

------------------------------------------------------------------------

See additional warning information

throughout this Operatorʼs Manual

------------------------------------------------------------

WARNING

CALIBRATION SPECIFICATION

The ARC TRACKER™ as shipped from the factory

has +/-2% accuracy on the digital volts display and

amps display. Due to the heat input calculation being

a function of measured volts, amps, and arc on-time,

the displayed energy value has an accuracy of +/-5%.

The Lincoln Electric Company recommends that end-

users of its welding equipment evaluate the suitability

of utilizing the ARC TRACKER™ in their quality sys-

tem.

Determine if periodic calibration is required and the

calibration interval based upon the criticality of the

welding application, the environment in which the

equipment is located, the level of preventive mainte-

nance and the actual conditions of use.

FIGURE D.1

La page charge ...

Lincoln Electric ARC TRACKER IM10090 Manuel utilisateur

Marque: Lincoln Electric

Modèle: ARC TRACKER IM10090

Catégorie: Système de soudage

Taper: Manuel utilisateur

Télécharger le PDF

rapport

dans d''autres langues

English: Lincoln Electric ARC TRACKER IM10090 User manual

Lincoln Electric ARC TRACKER IM10090 Manuel utilisateur

Lincoln Electric ARC TRACKER IM10090 Manuel utilisateur

dans d''autres langues

Documents connexes