Lincoln Electric DURAWELD 500, DURAWELD 350, K60096-1, K60107-1, 76187 Operator's Manual

...

IM7017-1

April, 2016

Rev. 07

DURAWELD

™

350/500

For use with machine Code

DURAWELD™ 500 K60096-1 / 76187 DURAWELD™ 350 K60107-1 / 76245

• W

orld’s Leader in Welding and Cutting•

THE SHANGHAI LINCOLN ELECTRIC COMPANY

No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907

www.lincolnelectric.com.cn

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. Most importantly, think before you act and be careful.

Thank you for selecting QUALITY Lincoln Electric products.

 Please examine the packaging and equipment for damage. Claims for material damaged in shipment must be

notified immediately to the authorized dealer from whom you purchased the machine.

 For future reference, please record your equipment identification information in the table below. Model Name,

Code & Serial Number can be found on the machine rating plate.

Model Name

□ DURAWELD™ 350 □ DURAWELD™ 500

Code & Serial number

Date & Where Purchased

Authorized dealer’s chop

Declaration of conformity

THE SHANGHAI LINCOLN ELECTRIC COMPANY

Designed in conformance with the following norm:

EN 60974-1

THE SHANGHAI LINCOLN ELECTRIC COMPANY

No. 195, Lane 5008, Hu Tai Rd.,(Gao Jing Industry Park), Shanghai, PRC 201907

SAFETY

URAWELD

350/500

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 EQUIPMENT.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

ELECTRIC AND MAGNETIC FIELDS may be dangerous.

1.a Electric cu

rrent flowing through any conductor causes localized Electric and Magnetic Field (EMF). Welding current creates EMF fields around welding cables and welding machines.

1.b EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physican before welding.

1.c All welders should use the following procedures in order to minize exposure to EMF fields from the welding circuit:

1.d.1 Route the electrode and work cables

together – Secure them with tape when possible.

1.d.2 Never coil the electrode lead around your

body.

1.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.

1.d.4 Connect the work cable to the workpiece

as close as possible to the area being welded.

ARC RAYS can burn.

2.a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc. Headshield and filter lens should conform to ANSI Z87. I standards.

2.b Use suitable clothing made from durable flameresistant material to protect your skin and that of your helpers from the arc rays.

2.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 Electrod

e 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, grating or scaffolds, when in cramped positions such as sitting, kneeling or lying down, 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 Man

ual (Stick) Welder.

 AC Welder with Reduced Open Circuit Voltage.

3.c In semiautomatic or auto

matic 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 holder to two welders because voltage between the two can be total of the open circuit voltage of both welders.

SAFETY

DURAWELD

350/500

FUMES AND GASES can be dangerous.

4.a Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the welding fumes. 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 below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

4.b 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.

4.c 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.

4.d 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.

FOR ELECTRONICALLY powered equipment.

5.a Turn off input power using the disconnect switch at the fuse box before working on the equipment.

5.b Install equipment in accordance with national standards, all local standards and the manufacturer’s recommendations.

5.c Ground the equipment in accordance with the national standards and the manufacturer’s recommendations.

WELDING 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 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.c 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”.

6.d Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirts, cuffless trousers, high shoes and a cap over your hair.

CYLINDER may explode if damaged.

7.a Use only compressed gas cylinders containing the correct shielding gas for the process 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.

A-1 INSTALLATION A-1

DURAWELD

350/500

TECHNICAL SPECIFICATIONS – DURAWELD

350/500

INPUT – THREE PHASE ONLY

DURAWELD

350/500

Standard Voltage/Phase/Frequency

380V ~ 415V(±10%)/3/50 Hz

Input Power @ 60% Duty Cycle

DURAWELD

350 18.1KVA/14.1KW

DURAWELD

500 30.6KVA/25.3KW

RATED OUTPUT – DC ONLY

DURAWELD

350

Duty Cycle

60%

100%

Amperes

350A 270A

Volts at Rated Amperes

31.5V

27.5V

DURAWELDTM 500

60%

100%

500A 390A

39V

33.5V

* OUTPUT RANGE

DURAWELD

350

Welding Current Range

50A ~ 350A

Rated Open Circuit Voltage

RMS/PEAK

53V/60V

Welding Voltage Range

16.5 V ~ 31.5V

DURAWELDTM 500 50A ~ 500A 60V/66V 16.5V ~ 39V

RECOMMENDED INPUT WIRE AND FUSE SIZES

DURAWELDTM 350

Input

Voltage/

Frequency

(Hz)

342V ~

456.5V/ 50Hz or

60Hz

Maximum

Input

Ampere

30A

Maximum

Effective

Supply

Current

22A

60°C Copper

Wire in

Conduct

Sizes

10 mm

Fuse or

Breaker Size

(Super Lag)

50A

Grounding Conductor

Size

6mm2

DURAWELDTM 500 48A 38A 16 mm2 80A 10mm2

PHYSICAL DIMENSIONS

DURAWELD

350

Height

755mm

Width

500mm

Depth

590mm

Weight

116Kg

DURAWELDTM 500 755mm 500mm 590mm 154Kg

Temperature Range

Operating Temperature Range

-10°C ~ +40°C

Storage Temperature Range

-25°C ~ +55°C

*Note: The output range is measured under conventional welding condition per IEC 60974-1:2000 standard.

For any maintenance or repair operation it is recommended to contact the nearest technical service center or directly consult the machine division of the Shanghai Lincoln Electric Co. Ltd.. Maintenance or repairs performed by unauthorized service centers or personnel will void the manufacturer’s warranty.

A-2

INSTALLATION

A-2

DURAWELD

350/500

SAFETY PRECAUTIONS

Read the entire installation section before starting installation.

ELECTRIC SHOCK can kill.  Only qualified personnel should perform this installation.  Turn the input power OFF at the main switch or fuse box

before working on this equipment. Turn off the input power to any other equipment connected to the welding system at the main switch or fuse box before working on the equipment.

 Do not touch electrically “Hot” parts.  Always connect the DURAWELDTM grounding lug

(located at the rear of the case) to a proper safety (Earth) ground.

 DURAWELDTM must only be used on three-

phase, MEN input power.

SELECT SUITABLE LOCATION

This power source should not be subjected to rain, nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area.

The bottom of machine must always be placed on a firm, secure, level surface. There is a danger of the machine toppling over if this precaution is not taken.

Place the welder where clean cool air can freely circulate in through the side and back louvers and out through the case bottom. Water dust or any foreign material that can be drawn into the welder should be kept a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdowns.

Locate the DURAWELD

machine away from radio controlled machinery. Normal operation of the welder may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

INPUT POWER AND GROUNDING CONNECTION

Only a qualified electrician should connect the input leads to the DURAWELD

. Connections should be made in accordance with the connection diagram. Failure to do so may result in bodily injury or death.

Open the input box on the rear of the case. Use a three-phase supply line, the three live wires should go through the three holes of the input wire holder and be securely clamped and fixed. Connect L1, L2, L3 and ground according to the Input Supply Connection Diagram decal, refer to Figure A.1 on this page.

FIGURE A.1 – Input Supply Connection Diagram

The DURAWELDTM is supplied connected for 50Hz input. In regions where the frequency of electricity is 60HZ, the DURAWELDTM machine can identify the 60 HZ frequency automatically and work in terms of this frequency.

Make sure the amount of power available from the input connection is adequate for normal operation of the machine. Refer to the Technical Specifications at the beginning of this Installation section for recommended fuse and wire sizes. Fuse the input circuit with the recommended super lag fuse or delay type breakers. Using fuses or circuit breakers smaller than recommended may result in “nuisance” shut-offs from welder inrush currents, even if the machine is not being used at high currents.

OUTPUT AND WIRE FEEDER CONNECTIONS

Connect a work lead of sufficient size and length (Per Table A.1) between the Negative Output terminal on the power source and the work. Be sure the connection to the work makes tight metal-to-metal electrical contact. To avoid interference problems with other equipment and to achieve the best possible operation, route all cables directly to the work and wire feeder. Avoid excessive lengths and do not coil excess cable.

Minimum work and electrode cable sizes are as follows:

TABLE A.1

Current (60% Duty Cycle) Minimum Copper

Work Cable Size

200A 300A 400A 500A

Up To 30m Length

30 mm

50 mm

70 mm

95 mm

Note: Recommended cable sizes may vary due to different cable quality. The overall voltage pressure of grounding and welding cables is no more than 4V under rated current.

WARNING

CAUTION

WARNING

A-3

INSTALLATION

A-3

DURAWELD

350/500

PWF wire feeder connection instructions (See Figure A. 2)  Turn the DURAWELD

power switch “OFF”.

 Connect the control cable from the PWF/LWF feeder

to the 6-pin connector. 2 wire feeder models are: LWF-2/LWF-4Plus

 Connect the electrode cable to the Positive Output

terminal.

For secure electrical connections, the Nuts connecting the output terminals and cables must be tightened. Damage to output studs and poor performance may occur, if this instruction is not followed.

GUN AND CABLE INSTALLATION

Optional guns with various cable length can be used with the DURAWELD

Turn the welder power switch off before installing gun and cable.

Gun and cable assembly installation instruction

 Unscrew the hexagon head screw in front of the wire

drive unit (inside wire feed compartment) until tip of screw no longer protrudes into gun opening as seen from front of wire feeder.

 Insert the male end of gun cable into the female

casting. Make sure connector is fully inserted and tighten the hexagon head screw.

 Connect the two-pin gun trigger connector from the

gun and cable to the mating receptacle, then tighten the retaining ring.

 Connect the gas connector to the mating receptacle

at front of wire feeder, and tighten the copper retaining ring.

CONNECTING SHIELDING GAS

DURAWELD

supports MIG/MAG, FCAW-GS/SS

Welding Process.

User must provide gas cylinder of appropriate type shielding gas for the process being used with the DURAWELD™.

CYLINDER may explode if damaged.  Gas under pressure is explosive. Always keep

gas cylinders in an upright position and always keep chained to undercarriage or stationary support.

Install shielding gas supply as follows:

 Remove the cylinder cap. Inspect the cylinder valve

and regulator for damaged threads, dirt, dust, oil or grease. Remove dust and dirt with a clean cloth. DO

NOT ATTACH THE REGULATOR IF OIL, GREASE OR DAMAGE IS PRESENT! Inform your gas

supplier of this condition. Oil or grease in the presence of high pressure oxygen is explosive.

 Stand to one side away from the outlet and open the

cylinder valve for an instant. This blows away any dust or dirt which may have accumulated in the valve

outlet.  Attach the flow regulator to the cylinder valve and tighten the union nut(s) securely with a wrench. NOTE: When connecting to a CO

cylinder, please select a CO

Regulator Heater for the prevention of ice build up. Failure to do so, may result in poor welding performance. The power cord of the gas heater must be plugged into the receptacle on the rear of the DURAWELD

case.

 Attach the end of the inlet gas hose, from the wire

feeder, to the outlet fitting of the flow regulator, and tighten the union nuts securely with a wrench.

 Before opening the cylinder valve, turn the regulator

adjusting knob counterclockwise until the adjusting spring pressure is released.

 Standing to one side, open the cylinder valve slowly

a fraction of a turn. When the cylinder pressure gauge pointer stops moving, open the valve fully.

Never stand directly in front of or behind the flow regulator when opening the cylinder valve. Always stand to the side.



The flow meter is adjustable. Adjust it to the flow rate recommended for the weld procedure.

CAUTION

WARNING

FIGURE A. 2 – OUTPUT AND WIRE FEEDER CONNECTIONS

B-1

OPERATION

B-1

DURAWELD

350/500

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.  Do not touch electrically live parts or electrode with skin or wet clothing.  Insulate yourself from 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 closed containers.

ARC RAYS can burn eyes and skin.  Wear eyes, ear and body protection.

PLEASE SEE ADDITIONAL WARNING INFORMATION AT THE FRONT OF THIS OPERATOR’S MANUAL.

GENERAL DESCRIPTION

The DURAWELDTM is a semiautomatic DC arc welding machine offering CV DC welding. It is rated as follows: DURAWELD

350: 350amps, 31.5volts at 60% duty

cycle.

DURAWELD

500: 500amps, 39volts at 60% duty

cycle.

DUTY CYCLE

The duty cycle of a welding machine is the percentage of time in a 10 minute cycle at which the welder can operate the machine at rated welding current.

60% duty cycle:

Weld for 6 minutes Break for 4 minutes

Excessive extension of the duty cycle will cause the thermal protection circuits to activate.

The DURAWELD

machine is equipped with a

thermostat overheating protection device. When the machine detects overheating, the output will turn off, and the Thermal Indicator Light will turn “ON“. When the machine has cooled to a safe temperature, the Thermal Indicator Light will go out and the machine will resume normal operation. Note: For safety reasons the machine will not come out of thermal shutdown if the trigger on the welding gun has not been released.

Wait for machine

to cool down

Or decrease duty cycle

OPERATIONAL FEATURES AND CONTROLS

Front Panel (Please see figure B.1)

123456

1. ON/OFF POWER SWITCH

After input power is connected and the power switch is turned on, the digit meters are active. Voltage meter will show pre-set value.

2. Wire selection

Solid and Flux-cored

3.GAS SELECTION

There is a selection switch on CO2 and mix gas according to actual welding condition.

WARNING

B-3

OPERATION

B-3

DURAWELD

350/500

4. VOLTAGE METER

Actual welding voltage will be shown in welding state; pre-set value will be shown if no welding operation. Crater pre-set value will be shown when any crater parameter is adjusted.

5. SYNERGIC STATE INDICAITOR

The indicator will be lighted when this function is turned on to indicate synergic function. Otherwise, it will be in the independent adjustment state.

6. CRATER ADJUSTMENT INDICATOR The indicator will be lighted when adjusting crator voltage or current to indicate pre-set value of crater voltage and current.

7. AMPERAGE METER

During the welding process, this meter displays the welding current value. This meter displays pre-set value if there is no welding operation; Crator current pre-set value will be shown when crator parameter is adjusted.

8. Crater Current Potentiometer

This knob adjusts the output current (wire feed speed), when the Dura Weld

machine is in crater mode.

9. Crater Voltage & spot weld time Potentiometer

This knob adjusts the value of output voltage, when the Dura Weld

weld mode switch is selected to 4-step.

This Knob adjust the persistence time of spot weld, when the weld mode switch is selected to spot weld.(Only for Duraweld 350)

10. Weld Mode SWITCH

This switch enables the selection of 2-step or 4-step mode(Enable or disable the crater mode) by this switch. And also can use this switch enable the spot weld mode on Duraweld 350. NOTE: The DURAWELD

machine also features a Crater mode. During 2-step mode, there is no crater output. During the 4-step mode, after the welder activates the trigger, the DURAWELD shifts to crater mode. Please see FIGURE B.4 for an understanding of the detailed working process for 2 and 4 step modes.

11. WIRE DIAMETER SELECTION

There are three diameter selection switch; For Duraweld 500,1.0, 1.2, 1.6 can be select with this switch. For Duraweld 350,1.2,1.0, 0.8 can be select with this switch. It can be set according to actual welding request. Preset current is more accurate when the wire diameter above is selected. Otherwise, it will stray from pre-set value.

12. PROTECTION DOOR

This door is used to protect the output terminal and wire feeder connector. Only after turning off the power, Open protection door to connect the welding cables and LWF feeder.

Do NOT operate the DURAWELD

machine with

this door open.

Output Stud

(Fig B.2)

1 Negtive Stud. 2 The connector of Wire feeder. 3 Positive Stud.

REAR PANEL (FIGURE B.3)

2 3

1. INPUT POWER PROTECTIVE BOX Insulation box is used to cover the input connections, offering insulating protection to the operator.

WARNING

Insulation box must be installed before turning on the main power supply.

2. INPUT CABLE HOLDING BRACKET

This bracket holds the three phase power cables securely.

3. GROUND CABLE CONNECTION

Connect the input earth cable to the rear of the case. A earth Hex. Screw is located on the lower rear of the case. Secure the earth cable lug-end with the screw into the case hole.

4. WIRE FEEDER 8A FUSE AND FUSE HOLDER

250V 8A fuse is used to protect wire feeder control circuit from short circuit so that control board is not damaged.

WARNING

B-3

OPERATION

B-3

DURAWELD

350/500

5. GAS HEATING 2A FUSE AND FUSE HOLDER

This machine is equipped with AC220V(200W) heating power. This fuse is used to protect heating circuit.

6. GAS HEATING SOCKET This is output socket of Max Aux 220v power, used to connect with gas heater.

WARNING

Only 220V gas heater could be connected at the plug of low voltage, do not connect other electrical device, otherwise, the machine could be damaged.

7. 2 A FUSE FOR CONTROL BOARD An 2-amp slow blow fuse on the machine’s rear

panel protects the control board and contactor from excessive overloads or short circuits.

Function and schedule See B.4

FIGURE B.4

FOUR STEP

TWO STEP

+ 23 hidden pages

Lincoln Electric DURAWELD 500, DURAWELD 350, K60096-1, K60107-1, 76187 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual