Lincoln Electric IM10090 User Manual

Operator’s Manual

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ARC TRACKER

™

For use with machines having Code Numbers:

11724

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10090 | Issue D ate Sep-11

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

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SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

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.

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 Gasoline Engines

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 vaporizing 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.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

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

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

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure them with tape when possible.

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

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

___________________________________________________

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.

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.

SAFETY

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

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.

skin or wet clothing. Wear dry, hole-free

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.

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

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 circumstances, 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 specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon 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 products.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

ventilation and/or exhaust at the arc to keep

vapors

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

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

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 been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

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. Alway s 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. Re ad and fo llow 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.

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. Ins tall 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.

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 suivantes:

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.

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 levage, 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.

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 rayonnement 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, pantalons 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.

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 debrancher 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 competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being

used in the environment is compatible. This may require additional protection measures;

h) the time of day that welding or other activities are to be carried out.

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 recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special

applications

_________________________

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”

Thank You

viivii

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!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. 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 possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information 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.

CUSTOMER ASSISTANCE POLICY

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

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

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:

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

WARNING

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

CAUTION

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

viii viii

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

_______________________________________________________________________

TABLE OF CONTENTS

Page

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

________________________________________________________________________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS -

INPUT VOLTAGE AND CURRENT

Model

K3019-1

Duty Cycle

VOLTAGE

50/60 Hz

120

230

100%

Input

Amperes

0.8 A

0.5 A

Input Voltage ± 10%

120-230 V AC, 50/60 Hz

RATED OPERATING RANGE NEMA EW1

Volts at Rated Amperes

RATED OPERATING RANGE IEC60974-1

Volts at Rated Amperes

RECOMMENDED INPUT WIRE

REGION

NORTH

AMERICA

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

EQUIVALENT EXTRA HARD USAGE CORD

ARC TRACKER™

44 V DC

INPUT CORD

3 CONDUCTOR, #18 AWG

Input Amperes

0.8-0.5 A

Amperes

1000 A DC

Amperes

1000 A DC

PLUG

NEMA 5-15P (INCLUDED)

ANY NEMA 250 V TYPE*

230

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

0.5 A

EUROPE

3 CONDUCTOR, 1.0 mm

HAR

CEE 7/7

METER ACCURACY (AS SHIPPED)

VOLTMETER

AMMETER

ENERGY

± 2% + 0.1**

± 2% + 2**

± 5%

PHYSICAL DIMENSIONS

MODEL

K3019-1

HEIGHT

12 in (305 mm)

WIDTH

9 in (220 mm)

DEPTH

15 in (380 mm)

TEMPERATURE RANGES

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)

WEIGHT

20 lbs ( 9 kg)

**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

ARC TRACKER™

A-2

INSTALLATION

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS INSTALLATION.

• 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 CONNECTED TO THE WELDING SYSTEM AT THE DISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THE EQUIPMENT.

A-2

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 receptacle. 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

• DO NOT TOUCH ELECTRICALLY HOT PARTS.

• CONNECT THE ARC TRACKER™ TO AN OUTLET WITH PROPER SAFETY (EARTH) GROUND.

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SELECT SUITABLE LOCATION

UNIT IS IP23 RATED.

The ARC TRACKER™ will operate in harsh environments. 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 surface. The weight of the welding cables hanging from the connection terminals may cause the ARC TRACKER™ 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.

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 considered 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.

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 specifications 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.

ARC TRACKER™

Locate the ARC TRACKER™ away from radio controlled 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

• 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 welding 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 connection.

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.

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 connections.

SOFTWARE TOOLS

ARC TRACKER™ software tools and other documents 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™.

Total Cable Length ft (m)

Electrode and Work Combined

0 (0) to 250 (76.2)

Power Wave Manager

• Ethernet setup and verification

• Calibration

• Production Monitoring Configuration

• User Interface Lockout

TABLE A.1 Output Cable Guidelines

Current in Weld

Circuit

0-500 Amps

500-750 Amps

750-1000 Amps

Duty Cycle

(parallel if more than one)

100%

ARC TRACKER™

Number of Cables

1 2 3

Cable Size

(copper) AWG

4/0 (120 mm 4/0 (120 mm

3/0 (95 mm

) )

)

A-4

INSTALLATION

FIGURE A.1

CONNECTION DIAGRAM-ELECTRODE POSITIVE (0-500A)

CONNECTION DIAGRAM-ELECTRODE POSITIVE (500-750A)

A-4

CONNECTION DIAGRAM-ELECTRODE POSITIVE (750-1000A)

ARC TRACKER™

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

Read this entire section of operating instructions before operating the machine.

WARNING

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.

GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL

MACHINE STATUS

OFF

ELECTRODE

READ INSTRUCTION MANUAL

PROPER DISPOSAL

• 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.

IP23

CAL

RANGE

POSITIVE OUTPUT

NEGATIVE OUTPUT

ENCLOSURE RATING

INPUT POWER

CALIBRATION

WELD CURRENT

DUTY CYCLE

ARC TRACKER™

WORK CONNECTION

B-2

OPERATION

B-2

GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL

WELD AMPERAGE

INPUT VOLTAGE

WELD VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE GROUND

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 interface.

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 compatible 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.

WARNING or CAUTION

Explosion

Dangerous Voltage

Shock Hazard

SET UP MENU

ETHERNET CONNECTOR

DESIGN FEATURES

• Multiple process DC welding range: 10-1000 Amps, 100% duty cycle.

• Simple Plug-N-Play design – connect to welding circuit, attach voltage sense leads and the meter begins to function!

• Digital controls for highly accurate measurements.

ARC TRACKER™

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