Lincoln Electric Red-D-Arc EX350i Operator's Manual
RED-D-ARC
EX350i
IM764
March, 2002
Red-D-Arc Spec-Built Welding Equipment
This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.
Safety Depends on You
This welder 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.
For use with machines having Code Numbers:
10945
North America’s Largest Fleet of Welding Equipment
1-800-245-3660
OPERATOR’S MANUAL
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.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.
i
SAFETY
i
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The
Above For Diesel Engines
The Above For Gasoline Engines
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
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
iii
SAFETY
iii
Mar ‘95
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
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 L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode 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 s’isoler 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 l’eau 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 s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, 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 l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soud
e pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
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 d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils 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
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité 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, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
Thank You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
CAUTION
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
vv
vi
TABLE OF CONTENTS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Safety Precautions ..........................................................................................A-2
Select Suitable Location..................................................................................A-2
Stacking ..........................................................................................................A-2
Tilting...............................................................................................................A-2
Input and Grounding Connections ..................................................................A-2
Power Cord Connection ..................................................................................A-2
Connection of Wire Feeders to EX350i ..........................................................A-2
Remote Control of Invertec .............................................................................A-3
Undercarriage Mountings................................................................................A-3
Parallel Operations..........................................................................................A-4
________________________________________________________________________
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description ..............................................................................................B-1
Duty Cycle .............................................................................................................B-1
Operational Features and Controls........................................................................B-1
Upper Control Panel.......................................................................................B-1, B-2
Hidden Middle Control Panel ...................................................................B-2 thru B-7
Lower Case Panel .................................................................................................B-8
Remote Control of the Output Control and Weld Terminals ..................................B-8
Auxiliary Power......................................................................................................B-9
Limitations..............................................................................................................B-9
Recommended Processes ....................................................................................B-9
_______________________________________________________________________
Accessories.....................................................................................................Section C
Options / Accessories............................................................................................C-1
Field Installed Options...........................................................................................C-1
Quick Disconnect Plugs.........................................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
C
APACITOR DISCHARGE PROCEDURE..........................................................................D-1
V
ISUAL INSPECTION...................................................................................................D-1
R
OUTINE MAINTENANCE ............................................................................................D-1
PERIODIC MAINTENANCE ...........................................................................................D-1
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ...........................................................................E-2 Thru E-3
Fault Codes ...........................................................................................................E-4
Displays .................................................................................................................E-5
________________________________________________________________________
Connection , Wiring Diagrams and Dimension Prints .................................Section F
________________________________________________________________________
Parts List ......................................................................................................P439 Series
________________________________________________________________________
EX350i
A-1
INSTALLATION
A-1
TECHNICAL SPECIFICATIONS -
RED-D-ARC EX350i
INPUT AC VOLTAGE & DC OUTPUT
Product Ordering Input AC Rated DC Output Output Weight Dimensions Open
Name Information Voltage Amps/Volt Range with Cord HxWxD Circuit
/Duty Cycle
(continuous)
Voltage
200
208-230/ 14.8” x 13.3” x
380-400/ 350A / 34V / 60% (373 x 338 x
415-460/ AMPS (84.0 lbs) 27.8”*
EX350i K1728-2 575 5-425 (38.0 kg.) (373 x 338 x 80 VDC
1& 3 Phase 300A / 32V /100% 706*)mm
60/50 Hz
* Overall Length Including Handle, 27.8” (706mm)
Voltage
200
208
230
380
400
415
460
575
200
208
230
380
400
415
460
575
Phases
1
1
1
1
1
1
1
1
3
3
3
3
3
3
3
3
300Amps @
32Volts(100%)
Not
Recommended
76
69
Not
Recommended
Not
Recommended
41
36
31
41
39
36
23
22
22
19
16
350Amps @
34Volts(60%)
Not
Recommended
94
85
Not
Recommended
Not
Recommended
64
42
37
50
50
42
28
27
26
23
18
Line Cord
AWG
2
4
---
6
8
8
8
6
8
8
8
8
8
8
Fuse size
---
125A
125A
---
---
80A
70A
50A
80A
80A
70A
50A
50A
50A
50A
35A
EX350i INPUT CURRENT
OUTPUT CABLES, CONNECTIONS AND LIMITATIONS
Recommended Fuse Sizes Base On The U.S. National Electrical Code And Maximum Machine Outputs
Input 50/60 Hz Output Recommended
Note 1. Not rated is indicated by 4-x’s in the box on the rating plate.
Note 2. When operating on these inputs, the line cord should be changed to an input conductor of 6 AWG or larger.
Select The output cable size based upon the following chart.
Cable sizes for Combined Length of Electrode and Work Cable (Copper) 75C rated:
DUTY CYCLE
100%
60%
CURRENT
300
350
LENGTH UP TO 200FT.(61m)
1/0
1/0
200-250 FT. (61-76m)
1/0
2/0
Notes
Note 1
Note 2
Note 2
Note 1
Note 1
Note 2
Note 2
Note 2
A-2
INSTALLATION
A-2
SELECT SUITABLE LOCATION
The Invertec EX350i 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.
• The machine must be located where there is free circulation of clean air such that air movement in the
back, out the sides and bottom will not be restricted.
• Dirt and dust that can be drawn into the machine
should be kept to a minimum. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown.
• Keep machine dry. Shelter from rain and snow. Do
not place on wet ground or in puddles.
• DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly under
stationary or fixed electrical equipment, that surface
shall be covered with a steel plate at least
.06”(1.6mm) thick, which shall extend not less than
5.90”(150mm) beyond the equipment on all sides.
STACKING
EX350i cannot
be stacked.
TILTING
Place the machine directly on a secure, level surface
or on a recommended undercarriage. The machine
may topple over if this procedure is not followed.
INPUT AND GROUNDING CONNECTIONS
• Only a qualified electrician should connect the
Invertec EX350i. Installation should be made in
accordance with the appropriate National Electrical
Code, all local codes and the information detailed
below.
• When received directly from the factory, multiple
voltage machines are internally connected for
460VAC. If 460VAC is the desired input, then the
machine may be connected to the power system
without any setup required inside the machine.
• Initial 200VAC - 415VAC and 575VAC operation will require an Input voltage panel setup.
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• TURN THE INPUT POWER OFF AT
THE DISCONNECT SWITCH BEFORE
ATTEMPTING TO CONNECT OR DIS-
CONNECT INPUT POWER LINES, OUTPUT
CABLES, OR CONTROL CABLES.
• Only qualified personnel should perform this
installation.
• Connect the green/yellow lead of the power
cord to ground per U.S.National Electrical
Code.
----------------------------------------------------------------------
WARNING
• Open the access panel on the rear of the machine.
• For 200 or 230: Position the large switch to 200-
230.
For higher voltages: Position the large switch to
380-575.
• Move the "A" lead to the appropriate terminal.
POWER CORD CONNECTION
A 25 ft. power cord is provided and wired into the
machine. Follow the power cord connection instructions.
• Incorrect connection may result in equipment
damage.
-----------------------------------------------------------------------
Single Phase Input
Connect green lead to ground per National Electrical
Code.
Connect black and white or brown leads to power.
Wrap red lead with tape to provide 600V insulation.
Three Phase Input
Connect green lead to ground per National Electric
Code.
Connect black, red and white leads to power.
CONNECTIONS OF WIRE FEEDERS TO EX350I
LN-25 Connection Instructions
-Not recommended for Pulse Welding with the
Advanced Process Kit ).
• Turn the EX350i power switch "off".
• Connect the electrode cable to the output terminal of
polarity required by electrode. Connect the work lead
to the other terminal.
• LN-25 with Remote Control options can be used with
the EX350i. The 14 pin (K444-2) remote can be connected directly to the 14 pin amphenol. The 42 Volt
Remote Voltage and Output Control (K624-1) Kit can
be connected to the EX350i 24/42 VAC amphenol
using Remote Control Cable assembly K627- [ ]. LN25s with a K431-1 remote kit can be connected to
the 24/42 VAC amphenol using a K432 cable and a
K876 adapter. (See connection diagram S19899) to
connect it to one of the 14-pin amphenols. Or the
K432 cable could be modified with a K867 Universal
Adapter Plug (See connection diagram S19405) to
connect it to the 24/42 VAC 14-pin amphenol.
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GREEN
RED
BLACK
WHITE or BROWN
EX350i
CAUTION
CAUTION
A-3
INSTALLATION
A-3
LN-7 Connection Instructions
• Turn the EX350i power switch “off”.
• Connect the K480 control cable from the LN-7 to
the EX350i 115 VAC control cable connector.The
control cable connector is located at the front of the
EX350i.
• Connect the electrode cable to the output terminal
of polarity required by electrode. Connect the work
lead to the other terminal
• Set the meter polarity switch on the front of the
EX350i to coincide with wire feeder polarity used.
The wire feeder will now display the welding voltage.
• If K480 is not available, see connection diagram
S19404 for modification of K291 or K404 LN-7 input
cable with K867 universal adapter plug.
LN-10 Connection Instructions
• Turn the EX350i power switch "off"
• Connect the K1505 control cable from the LN-10 to the
EX350i 24/42VAC 14-pin amphenol connector on the
front of the EX350i.
• Connect the electrode cable to the output terminal of
polarity required by the electrode. Connect the work lead
to the other terminal.
• Set the meter polarity switch on the front of the EX350i to
coincide with wire feeder polarity used.
• See the LN-10 manual for details on accessing Control
DIP Switch
LN-742 Connection Instructions
• Turn the
EX350i
power switch "off"
• Either a K591 or a K593 Input cable assembly is
required to connect the LN-742 to the
EX350i
.
• Connect the control cable from the LN-742 to the
24/42 VAC 14-pin wire feeder amphenol on the
front of the
EX350i
.
• Connect the electrode cable to the output terminal
of the polarity required by electrode. Connect the
work lead to the other terminal.
• Set the meter polarity switch on the front of the
EX350i
to coincide with wire feeder polarity used.
The wire feeder will now display the welding voltage.
• If a remote control is to be used with the LN-742,
use a K864 adapter to connect the feeder and a
K857 remote to the 14-pin wire feeder connector on
the front of the
EX350i
.
Cobramatic Connection Instructions
• Turn the
EX350i
power switch "off"
• Connect the control cable from the Cobramatic to
the 24/42 VAC 14-pin wire feeder amphenol on the
front of the
EX350i
.
• Connect the electrode cable to the output terminal
of the polarity required by electrode. Connect the
work lead to the other terminal.
• Set the meter polarity switch on the front of the
EX350i
to coincide with wire feeder polarity used.
• If a remote control is to be used with the
Cobramatic, or use a K864 adapter to connect the
cobramatic and a K857 remote to the 24/42VAC
14-pin wire feeder amphenol connector on the front
of the EX350i.
TIG Module K930-2
The TIG Module connects to the EX350i with a K9361 (9-14 pin) control cable. Connect the K936-1 to the
115VAC wire feeder amphenol on the front of the
EX350i.
General Instructions for Connection of Wire
Feeders to EX350i
Wire feeders other than LN-7 and LN-25 may be used
provided that the auxiliary power supply capacity of
the EX350i is not exceeded. K867 universal adapter
plug is required. See connection diagram S24985 on
page F-4.
REMOTE CONTROL OF INVERTEC
Remote Control K857, Hand Amptrol K963 and Foot
Amptrol K870.
UNDERCARRIAGE MOUNTINGS
EX350i
NOTE: MOUNTING SCREWS CANNOT PROTRUDE MORE THAN 0.5 INCHES I NSIDE THE MACHINE.
MOUNTING HOLE LOCATIONS
1/4-20 NUT (4 PLACES)
11.84
3.50
5.50
10.00
A-4
INSTALLATION
A-4
EX350i
PARALLEL OPERATION
The EX350i are operable in parallel in CC mode. For
best results, the currents of each machine should be
reasonably well shared. As an example, with two
machines set up in parallel for a 400 amp procedure,
each machine should be set to deliver approximately
200 amps, not 300 amps from one and 100 amps
from the other. This will minimize nuisance shutdown
conditions. In general, more than two machines in
parallel will not be effective due to the voltage requirements of procedures in that power range.
To set machine outputs, start with output control pots
and arc control pots in identical positions. Use the
output control pots to balance the currents and maintain the desired voltage or current. The arc control
pots should be kept identical on the two machines.
B-1
OPERATION
EX350i
B-1
SAFETY PRECAUTIONS
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
------------------------------------------------------------------------
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
• Do not weld on closed containers.
------------------------------------------------------------------------
ARC RAYS can burn eyes and skin.
• Wear eye, ear and body
protection.
------------------------------------------------------------
See additional warning information at
front of this operator’s manual.
-----------------------------------------------------------
WARNING
GENERAL DESCRIPTION
The Invertec EX350i offers multi-process CV, CC, and
DC welding and is rated 350 amps, 34 volts at a 60%
duty cycle.
DUTY CYCLE
The EX350i is rated at 350 amps, 60% duty cycle
(based on a 10 minute cycle). It is also rated at 300
amps, 100% duty cycle.
OPERATIONAL FEATURES and CONTROLS:
UPPER CONTROL PANEL
1. AMPS Meter
• Prior to STICK or TIG operation (current flow), the
meter displays preset current value (either 2 amps
or +/- 3% (e.g. 3 amps on 100), whichever is
greater).
• Prior to CV operation, the meter displays four dashes indicating non-presettable AMPS.
• During welding, this meter displays actual average
amps.
• After welding, the meter holds the actual current
value for 5 seconds. Output adjustment while in the
"hold" period results in the "prior to operation" characteristics stated above. The displays blink indicating that the machine is in the "Hold" period.
2. VOLT METER
• Prior to CV operation (current flow), the meter displays desired preset voltage value (+/- .5V).
• Prior to STICK or TIG operation, the meter displays
the Open Circuit Voltage of the Power Source or
four dashes if the output has not been turned on.
• During welding, this meter displays actual average
volts.
• After welding, the meter holds the actual voltage
value for 5 seconds. The displays blink indicating
that the machine is in the "Hold" period.
• Output adjustment while in the "hold" period results
in the "prior to operation" characteristics stated
above.
3. OUTPUT CONTROL
• Output control is conducted via a single turn potentiometer.
• Adjustment is indicated by the meters as stated
above.
• When in TIG modes, this control sets the maximum
welding current. Full depression of a foot or hand
Amptrol results in the preset level of current.
4. WELD TERMINALS-REMOTE / ON
• Two status lights indicate the location of trigger control as determined by the "WELD TERMINALS"
push button.
• If trigger control is local "weld terminals on", the ON
display will be lit.
• If trigger control is remote "weld terminals remotely
controlled", the REMOTE display will be lit.
• The unit will power up in "pre-determined preferred"
trigger modes.
STICK = ON
CV = REMOTE
TIG = REMOTE if remote output controls are
attached to the machine.
TIG = 0N if remote output controls are not attached to
the machine.
For all versions, these trigger modes can be over-ridden
(switched) with the WELD TERMINALS push button. When
changed, the unit will power up in the configuration it was in
when it was last powered down.
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