Lincoln Electric IM987 User Manual
Safety Depends on You
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Harris Brazing, Soldering 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. And,
most importantly, think before you
act and be careful.
IM987
November, 2008
POWERBrazer
For use with machines having Code Numbers: 11535
IP21
OPERATING MANUAL
Copyright © Lincoln Global Inc.
a Division of Lincoln Electric
• World's Leader in Welding, Brazing, Soldering and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
4501 Quality Place, Mason, Ohio 45040 U.S.A. • Web Site: www.harrisproductsgroup.com
i
BRAZING, SOLDERING AND OTHER METAL JOINING ACTIVITIES CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS
FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.
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.
Both ANSI Standard Z49.1 and Arc Welding Safety Booklet E205 are available at (WWW.lincolnelectric.com/community 1 safety)
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY
QUALIFIED INDIVIDUALS.
AUG 08
SAFETY
i
POWERBrazer
ii
SAFETY
ii
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
flame when brazing or observing
brazing. 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 heat and flame.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to nor expose themselves to hot
spatterormetal.
FUMES AND GASES
can be dangerous.
5.a. Brazing may produce fumes and gases haz
ardous to health. Do not breathe these
fumes and gases. When brazing, keep your
head out of the fume. Use enough
tion and/or exhaust at the arc to keep
and gases away from the breathing zone.
When brazing with electrodes which
require special ventilation such as those containing
cadmium or fluorides (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 brazing
on galvanized steel.
ventila-
fumes
5. c. The operation of brazing 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.d. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
AUG 08
5. b. Additional precautions for materials containing Cadmium
and Fluorides:
BRAZING MATERIALS MAY CONTAIN CADMIUM.FUMES ARE POISONOUS AN CAN KILL.
• Do not breathe fumes. Even brief exposure to high concentrations should be avoided.
• Use enough ventilation, exhaust at the arc, or both, to
keep fumes and gases from your breathing zone and general area. If this cannot be done, use air supplied respirators.
First Aid: If chest pain, shortness of breath, cough, or fever
develop after use, obtain medical help immediately.
BRAZING MATERIALS MAY CONTAIN FLUORIDES.
FUMES AND GASES CAN BE HAZARDOUS TO YOUR
HEALTH. BURNS EYES AND SKIN ON CONTACT. CAN
BE FATAL IF SWALLOWED.
• Avoid contact of flux with eyes and skin.
• Do not take internally.
First Aid: If contact in eyes, flush immediately with water for
at least 15 minutes. If swallowed, induce vomiting. Never
give anything by mouth to an unconscious person. Call a
physician..
POWERBrazer
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SAFETY
iii
BRAZING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the brazing area.
If this is not possible, cover them to prevent
the sparks from starting a fire Remember
that brazing sparks and hot materials from
brazing and soldering can easily go through
small cracks and openings to adjacent
areas. Avoid working 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. Do not heat, cut or braze tanks, drums or containers until
proper steps have been taken to insure that such proce-
the
dures
will not cause flammable or toxic vapors from substances inside. They can cause an explosion even
they have been “cleaned”. For information, purchase
“Recommended Safe Practices for the
Welding and Cutting of Containers and Piping That Have
Held Hazardous Substances”, AWS F4.1 from the American
Welding Society
(see address above).
6.d. Vent hollow castings or containers before heating, cutting or
brazing. They may explode.
Preparation
though
for
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 manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
Aug, 08
When brazing Wear oil
6.e.
leather gloves, heavy shirt, cuffless trousers, high shoes and
a cap over your hair. Always wear safety glasses with side
shields.
6.f. 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.
free protective garments such as
POWERBrazer
iv
SAFETY
iv
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 l e s
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. Quandonnesoude 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.
POWERBrazer
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
montageoulapieceàsouderdoitêtrebranchéàunebonne
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.
Mar. ʻ93
v
Thank You
for selecting one of our QUALITY products. We want you to take
CUSTOMER ASSISTANCE POLICY
The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to
meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us 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. We are not in a position to warrant or guarantee such advice, and assume no
liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any
warranty of fitness for any customerʼs 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.
We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within the
control of, and remains the sole responsibility of the customer. Many variables beyond our control 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.
pride in operating this product ••• as much pride as we have in
bringing this product to you!
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.
v
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 (if available)______________________________________________________
Serial Number (if available)__________________________________________________________________
Date Received___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above.
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.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
vi
SAFETY ..............................................................................................................................................................i-iv
INSTALLATION ....................................................................................................................................SECTION A
Technical Specifications .................................................................................................................................A-1
Safety Precautions ..........................................................................................................................................A-2
Location.............................................................................................................................................................A-2
Procedures to Install Drive Rolls and Wire Guides ....................................................................................A-2
_____________________________________________________________________________________
OPERATION..........................................................................................................................................SECTION B
Safety Precautions ..........................................................................................................................................B-1
User Serviceability...........................................................................................................................................B-1
General Description.........................................................................................................................................B-1
Recommended Processes and Equipment..................................................................................................B-1
Case Front Controls ........................................................................................................................................B-2
Internal Controls ..............................................................................................................................................B-3
Rear Controls ...................................................................................................................................................B-4
_____________________________________________________________________________________
ACCESSORIES ....................................................................................................................................SECTION C
Drive Roll Kits, Steel Wire..............................................................................................................................C-1
_____________________________________________________________________________________
MAINTENANCE....................................................................................................................................SECTION D
Safety Precautions ..........................................................................................................................................D-1
Routine Maintenance ......................................................................................................................................D-1
Periodic Maintenance .....................................................................................................................................D-1
Calibration Specifications ...............................................................................................................................D-1
_____________________________________________________________________________________
TABLE OF CONTENTS
vi
TROUBLESHOOTING GUIDE............................................................................................................SECTION E
How to Use the Troubleshooting Guide .......................................................................................................E-1
Troubleshooting Guide....................................................................................................................................E-2
_____________________________________________________________________________________
WIRING DIAGRAM AND DIMENSIONS ...........................................................................................SECTION F
_____________________________________________________________________________________
PARTS PAGES ................................................................................................................................P-589 SERIES
_____________________________________________________________________________________
POWERBrazer
A-1
INSTALLATION
A-1
TECHNICAL SPECIFICATIONS –
INPUT VOLTAGE and CURRENT
INPUT VOLTAGE
1 phase 60 Hz 120 VAC
GEARING - WIRE FEED SPEED RANGE-WIRE SIZE
GEARING
Extra torque
K2772-1
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
14.8 in 8.7 in 23.2 in 30 lbs
(376 mm) (221 mm) (589 mm) (13.6 kg)
TEMPERATURE RANGE
OPERATION: -40°F to 104°F (-40°C to 40°C)
STORAGE: -40°F to 122°F (-40°C to 50°C)
POWERBrazer (K2772-1)
WFS RANGE
20-120 ipm
(0.51 – 3.1m/min)
INPUT AMPERES
1A
WIRE SIZES
1/16” – 3/32”
(0.6 – 1.6mm)
POWERBrazer
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