Lincoln Electric IM987 User Manual

Page 1
Safety Depends on You
RETURN TO MAIN MENU
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
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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
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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
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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
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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.
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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
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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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A-2
INSTALLATION
A-2
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
• Only qualified personnel should perform this installation.
• Only personnel that have read and
understood the POWERBrazer Operating Manual should install and operate this equipment.
• The POWERBrazer must be plugged into a recep­tacle which is grounded per any national, local or other applicable electrical codes.
• The POWERBrazer power switch is to be in the OFF (“O”) position when connecting the power cord to the input power.
------------------------------------------------------------------------
LOCATION
For best wire feeding performance, place the POWERBrazer on a stable and dry surface. Keep the wire feeder in a vertical position. Do not operate the wire feeder on an angled surface of more than 15 degrees.
PROCEDURE TO INSTALL DRIVE ROLLS AND WIRE GUIDES
WARNING
ELECTRIC SHOCK CAN KILL.
• Turn the input power OFF at the POWERBrazer before installation or changing drive rolls and/or guides.
• Do not operate with covers, panels or guards removed or open.
• Only qualified personnel should perform mainte­nance work.
------------------------------------------------------------------------
1. Turn power off at the POWERBrazer.
2. Release the idle roll pressure arm.
3. Remove the outer wire guide by turning the knurled
thumbscrews counter-clockwise to unscrew them from the feedplate.
4. Rotate the triangular lock and remove the drive
rolls.
Do not submerge the POWERBrazer.
The POWERBrazer is rated IP21 and is suitable for indoor use.
The handle of the POWERBrazer is intended for moving the wire feeder about the workplace only.
5. Remove the inner wire guide.
6. Insert the new inner wire guide, groove side out,
over the two locating pins in the feed plate.
7. Install a drive roll on each hub assembly secure
with the triangular lock.
8. Install the outer wire guide by aligning it with the
pins and tightening the knurled thumbscrews.
9. Close the idle arm and engage the idle roll pressure
arm. Adjust the pressure appropriately.
POWERBrazer
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B-1
OPERATION
B-1
SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION BEFORE OPERATING MACHINE
WARNING
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove fumes from breathing zone.
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, exhuast 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.
----------------------------------------------------------------------------------------
• Do not wear gloves when threading or changing wire spool.
• Keep hands, hair, clothing and tool away from rotating equipment.
----------------------------------------------------------------------------------------
FLAME and BRAZING SPARKS can cause fire or explosion.
• Keep flammable material away.
GENERAL DESCRIPTION
The POWERBrazer is a specially engineered wire feeder for brazing materials. As part of a patent pending process, the POWERBrazer brings productivity and efficiency gains to brazing customers. A simple press of a button on the gun feeds brazing wire at a controlled speed.
The heart of the POWERBrazer is the 2 roll MAXTRAC™ drive. The patented features on the wire drive offer tool-less changing of the drive rolls and wire guides for quick spool changes. A tachometer controlled motor powers the patent pending drive rolls for smooth, steady feeding without slippage.
With only one printed circuit board, the POWERBrazer is designed to be simple, reliable and easy to service.
RECOMMENDED PROCESSES AND EQUIPMENT
K1500-1 Gun Bushing Installed
RECOMMENDED PROCESSES
Semi-Automatic Brazing
PROCESS LIMITATIONS
The POWERBrazer is intended for brazing only.
It cannot be used for arc welding.
EQUIPMENT LIMITATIONS
------------------------------------------------------------------------------
USER SERVICEABILITY
The serviceability of a product or structure utilizing the POWERBrazer is and must be the sole responsibility of the builder/user. Many variables beyond the control of the Harris Products Group affect the results obtained in using the POWERBrazer. These variables include, but are not limited to, brazing procedure, plate chemistry and temperature, joint design, fabrica­tion methods and service requirements. The available range of the POWERBrazer may not be suitable for all applications, and the builder/user is and must be sole­ly responsible for welding settings.
POWERBrazer
• The maximum spool size is 45lbs.(20.4Kg.), 12”(305mm) diameter.
• Maximum gun length is 15 ft.(4.6m).
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B-2
OPERATION
CASE FRONT CONTROLS
B-2
ITEM
1
2
3
DESCRIPTION
Wire Feed Speed Knob
5-pin gun trigger connector
Triggers on pins A and C
Power Switch
POWERBrazer
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B-3
OPERATION
INTERNAL CONTROLS
B-3
2
1
3
ITEM
1
2
3
4 5 6 7
4
Pressure Adjustment Knob
Spool Retainer
Spindle Brake
Socket Head Cap Screw for Gun Bushing Drive Hubs Inlet Bushing Cold Feed Pushbutton
5
DESCRIPTION
6
7
POWERBrazer
PURPOSE
The pressure arm controls the amount of force the drive rolls exert on the wire. Too much pressure will distort the brazing wire. Too little pressure allows the drive rolls to slip. Most brazing wires feed best with the pressure arm set between 2 and 4. Holds the spool in place. Remove by squeezing the steel piece. Used to set moderate friction to keep the spool from unwinding. Holds the gun in place. Hold the drive hubs. Guides the wire into the wire drive. Used to jog the wire.
Page 13
B-4
OPERATION
REAR CONTROLS
B-4
1
ITEM
1
2
2
DESCRIPTION
Circuit Breaker
Power Cord
POWERBrazer
Page 14
C-1
ACCESSORIES
KITS AVAILABLE
C-1
PBKT-062
PBKT-094 PBGN-062 PBGN-094
1/16” gun, Drive Rolls and wire guides 3/32” gun, Drive Rolls and wire guides
1/16” gun 3/32” gun
POWERBrazer
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D-1
MAINTENANCE
D-1
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform this installa­tion.
• Only personnel that have read and under­stood the POWERBrazer Operating Manual should install and operate this equipment.
• The POWERBrazer must be plugged into a receptacle which is grounded per any nation­al, local or other applicable electrical codes.
• The POWERBrazer power switch is to be in the OFF (“O”) position when connecting the power cord to the input power.
--------------------------------------------------------------------
ROUTINE MAINTENANCE
• Check cords and the brazing gun for cuts and damage.
• Clean and tighten all weld terminals.
To change the wire feed speed calibration:
(See Figure D.1)
Tools required:
• 5/16" nut driver
• RPM meter
• Shorting plug. The shorting plug shorts pins 4 and 8 of
connector J3 on the printed circuit board. J3 is an 8 pin molex connector.
1. Unplug the POWERBrazer.
2. Remove the (4) screws holding the rear cover inside the feeder and remove the cover.
3. Open the idle arm.
4. Set the wire feed speed to 100 in/min.
5. Disconnect the fan connector from J3.
6. Plug in the POWERBrazer and turn power ON.
7. Insert the shorting plug into connector J3 on the print­ed circuit board.
8. Remove the shorting plug.
9. Turn power OFF.
10. Reconnect the fan connector into J3.
11. Replace the cover and secure with the screws.
FIGURE D.1
PERIODIC MAINTENANCE
• Clean the drive rolls and inner wire guide and replace if worn.
• Blow out or vacuum the inside of the feeder.
CALIBRATION SPECIFICATION
Wire Feed Speed Validation:
Calibration of the POWERBrazer may be required when the printed circuit board, wire feed speed potentiometer or motor is replaced or serviced. Calibration matches the scale on the name plate to the actual wire feed speed.
Tools required:
• RPM meter
• 7/16” open end wrench.
To verify if calibration is necessary:
1. Turn power OFF.
2. Set the wire feed speed to 100 in/min.
3. Remove the plastic cover from the lower portion
of the wire drive with a 7/16” wrench.
4. Turn power ON.
5. Measure the motor rpm when the COLD FEED
button is pressed.
6. Verify the rpm is within 16 – 19 rpm.
POWERBrazer
Page 16
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
Observe all Safety Guidelines detailed throughout this manual
WARNING
Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
E-1
This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the Possible Cause, generally it states to contact your local Authorized Field Service Facility.
If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWERBrazer
Page 17
E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
The feeder does not power up: no cold feed.
TROUBLESHOOTING
POSSIBLE
CAUSE
Output Problems
1. The PowerBrazer is unplugged.
2. The power switch is turned off.
3. The circuit breaker tripped.
4. The motor is not receiving power.
E-2
RECOMMENDED
COURSE OF ACTION
1. Plug in the PowerBrazer.
2. Turn on the power switch.
3. Check cords for damage. Verify the brazing wire easily feeds through the gun. Consult a trained repair person if the circuit breaker repeatedly trips.
4. Consult a trained repair person.
Inconsistent wire feeding or wire not feeding but drive rolls turning.
The wire feed speed is fast (maxi­mum) and there is no change when the wire feed speed knob is adjust­ed.
1. The gun cable is kinked and/or twisted.
2. The wire is jammed in the gun and cable.
3. The gun liner is dirty or worn.
4. The filler wire is corroded or dirty.
5. Improper gun liner, tip, drive rolls and/or inner wire guide.
6. Incorrect tension arm pressure on the drive rolls.
7. The spindle brake is too tight.
8. Worn drive roll.
1. The tachometer is connected improperly.
2. The tachometer has failed.
1. Keep the gun cable as straight as possible. Avoid sharp corners or bends in the cable.
2. Remove the gun from the wire feeder and pull the jammed wire out of the gun and cable.
3. Blow dirt out of the liner with low pressure (40psi or less). Replace the liner if worn.
4. Use only clean electrode. Use quality electrode from the Harris Products Group.
5. Verify the proper parts are installed.
6. Most filler wires feed well with the pressure arm set between “2” and “4”.
7. Verify the spool of wire moves with minimal effort.
8. Replace the drive rolls if worn or filled with dirt.
1. Verify all of the tachometer leads are properly connected.
2. Replace the motor and tachome­ter assembly.
The POWERBrazer stops feeding after a few seconds. After a while, it will begin to feed again when it has been retriggered.
1. The motor has gone into thermal overload.
1. Verify that the filler wire can be easily pulled through the gun when the pressure arm is open.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWERBrazer
Page 18
F-1
WIRING DIAGRAM
F-1
POWERBrazer
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on
one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
Page 19
F-2
DIMENSIONS
23.17
F-2
14.81
8.6 5
12” x 18” ELLIP SE
16” CIRCLE
17.19
POWERBrazer
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NOTES
POWERBrazer
Page 21
NOTES
POWERBrazer
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WARNING
Spanish
AVISO DE
PRECAUCION
Do not touch electrically live parts or
electrode with skin or wet clothing.
Insulate yourself from work and
ground.
No toque las partes o los electrodos
bajo carga con la piel o ropa moja­da.
Aislese del trabajo y de la tierra.
Keep flammable materials away.
Mantenga el material combustible
fuera del área de trabajo.
Wear eye, ear and body protection.
Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact avec des pièces sous tension.
Isolez-vous du travail et de la terre.
Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!
Isolieren Sie sich von den
Elektroden und dem Erdboden!
Não toque partes elétricas e elec-
trodos com a pele ou roupa molha­da.
Isole-se da peça e terra.
Gardez à l’écart de tout matériel
inflammable.
Entfernen Sie brennbarres Material!
Mantenha inflamáveis bem guarda-
dos.
Protégez vos yeux, vos oreilles et
votre corps.
Tragen Sie Augen-, Ohren- und Kör-
perschutz!
Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Page 23
Keep your head out of fumes.
Use ventilation or exhaust to
remove fumes from breathing zone.
Turn power off before servicing.
Do not operate with panel open or
guards off.
WARNING
Los humos fuera de la zona de res-
piración.
Mantenga la cabeza fuera de los
humos. Utilice ventilación o aspiración para gases.
Gardez la tête à l’écart des fumées.
Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones de travail.
Vermeiden Sie das Einatmen von
Schweibrauch!
Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Mantenha seu rosto da fumaça.
Use ventilação e exhaustão para
remover fumo da zona respiratória.
Desconectar el cable de ali-
mentación de poder de la máquina antes de iniciar cualquier servicio.
Débranchez le courant avant l’entre-
tien.
Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)
Não opere com as tampas removidas.
Desligue a corrente antes de fazer
serviço.
Não toque as partes elétricas nuas.
No operar con panel abierto o
guardas quitadas.
N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de protection enlevés.
Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in Betrieb setzen!
Mantenha-se afastado das partes
moventes.
Não opere com os paineis abertos
ou guardas removidas.
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
Page 24
a Division of Lincoln Electric
• World's Leader in Welding 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
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